Installation Manual- UniMaxx Plus Pump Station by SunMaxx Solar

48001070

*48001070*

Mounting Installation Operation Commissioning

UniMaxx-Plus Pump Station

B Manual

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

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UniMaxx-Plus Pump Station Contents: Safety advice ......................................................................

Commissioning ......................................................

Technical data and operation

2.1

Filling and flushing the system

Installation ..............................................................

2.2

Emptying the system

1.1

Wall mounting

2.3

Non-return valves

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1.2

Optional compression ring connection

2.4

Safety assembly ......................................................

1.3

Mounting the expansion vessel (optional)

2.5

Air-Stopp ................................................................

1.4

Electrical connection

Accessory ...............................................................

1.5

Integration of the controller

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IntelliMaxx-DHW Plus

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.......... 5

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Imprint .............................................................................

Safety advice Please pay attention to the following safety advice in order to avoid danger and damage to people and property. This product is to be used in accordance with its intended use 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 accidents, - 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 relevant safety regulations of DIN, EN, DVGW,TRGI,TRF and VDE. These instructions are exclusively addressed to authorized skilled personnel. - Only qualified electricians should carry out electrical works. - Initial installation must be effected by qualified personnel named by the manufacturer

Subject to technical changes. Errors excepted.

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Declaration of conformity We atSunMaxxSolar declare under our sole responsibility that our product , UniMaxx-Plus Pump Station, complies with the following standards: 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

UniMaxx-Plus Pump Station

• • • • • • • •

Prepared for integration of the IntelliMaxx-DHW Plus controller Dial thermometer for flow and return Outstanding design Return line with ball valve and openable nonreturn 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

520

•

315

Technical data Height (with insulation): Width (with insulation): Distance axis / wall: Pipe connections:

520 mm 315 mm 63 mm 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 bar Max. admissible temperature: 120°C continuous and 160 °C intermittent Safety 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, openable in 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 °C O-Ring sealings: VITON / EPDM - max. 180 °C Insulation: EPP, l = 0,041 W/(m*K) max. 120 °C continuous and 180 °C intermittent

UniMaxx-Plus Pump Station 1. Installation 12 16 10 11

7 4

6 5

1. Wall mounting bracket of the pump station Wall mounting 2.1Insulation - rear bracket of the pump station 2 Insulation - rear 3. Contoller 3 Controller 4. Insulation - front cover Insulation - front cover 5.4Flowmeter 5 Flowmeter 6. Drain valve 6 Drain valve 7.7Pumppump 8.8Ball Valve withincheck valve andintegrated temperature gauge ball valve flow IT-IT, with thermometer 9.9Ball Valve withincheck and temperature gauge ball valve returnvalve IT-IT, with integrated thermometer 10. headhead-piece, peice 10 Safety Safety with fill valve 11 Pressure Pressure gauge 11. Gauge 12. Pressure Relief Valve

13. Optional: Expansion vessel set

12 Safety valve 6 bar 14. Optional: AirStopp 13 Optional: expansion set 15. Optional: Compressionvessel Ring Connection 14 Optional: AirStopp 16. Fill Valve 15 Optional: Compression ring connection for copper pipe

1.1 Wall mounting 1. 2. 3.

4. 5.

Determine where to mount the pump station; consider the space for the (optional) expansion vessel! Take the complete station out of the packing. 6. Remove the front half of the insulation by pulling it.The thermometers loosen from the ball valves. Do not unsrew the pump station from the back part of the insulation! Mark the fastening holes (centres 70 mm) and drill holes (diameter 8 mm); insert the enclosed dowels (S 8). Fasten the complete pump station with the wall mounting bracket to the wall (depending on the pump version, upper or lower holes in the insulated casing)

and tighten the screws. For this purpose, use a positive cross-recessed screwdriver! Connect the connection line between the pump station and the store and the collectors repectively. Optionally, compression ring connections can be used for mounting copper pipes.In order to connect the pipes with the compression ring connections, pay attention to the following instructions!

UniMaxx-Plus Pump Station

Screws S6 x 60

All connections are pre-assembled by the manufacturer but have to be tightened by the installer. Check for leaks when commissioning the station (pressure test).

1.2 Optional compression ring connection -

> 3 mm 5

2 3

1 -

First push the union nut (2),then the brass compression ring (3) onto the copper pipe (1). In order to ensure secure load transmission and sealing, the pipe must extend 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 the compression ring connection (2). First screw on the union nut by hand.Then tighten it by at least one full rotation with a suitable open-ended spanner.

Please note: In order to absorb the strain of the pipes, corresponding fittings (strain neutralizers) or expansion bends (consisting of at least two 90Â° - bends) are required. For expansion bends, the distance between the bends must be larger than twice the pipe diameter in cm. [Example: pipe diameter = 18 mm Ă&#x17E; distance between the bends more than 36 cm].

1.3 Mounting the expansion vessel (optional) -

Attach the wall mounting bracket of the expansion vessel in a suitable position to the wall. Pay attention to the corrugated stainless steel hose (optional accessory).

Connect the optional hose flatly sealing using the enclosed sealings (optional) to the quick connector (optional) of the expansion vessel and to the expansion vessel connection at the safety head piece of the pump station.

UniMaxx-Plus Pump Station 1.4 Electrical connection The unit must only be located in dry interior locations. It Push the cover in front of the controller downwards in order is not suitable for installation in hazardous locations and to access the controller.Open the housing of the controller at should not be placed close to any electromagnetic fields.The the front.Follow the steps described in the controller manual. controller must additionally be supplied from a double pole switch with contact gap of at least 3 mm. Please pay atten tion to separate routing of sensor cables and mains cables.

1.5 Integrating the IntelliMaxx-DHW Plus controller

Front insluation front view

Front insluation rear view

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

- 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 insulation has to be opened once again for commissioning.

- Put the controller into the provided space in the insulation and attacht it with the fastening screws 3 x 30 and large washers.

For further information on the connection of the con troller, see IntelliMaxx-DHW Plus controller. - Electrical connections (plug, sensor and relay connections) must be carried out according to the steps described in the manual. - The cables - especially those of the pump - must be long enough so that the front part of the insulation can be removed without damaging the controller. Please ensure that the cables do not come into contact with hot water pipes!

UniMaxx-Plus Pump Station 2. Commissioning 2.1 Filling, flushing and commissioning the pump station ·

· ·

Connect the pressure hose to the fill valve at the safety head-piece below the pressure gauge (11) and open the fill and drain valve. Connect the flushing hose to the fill and drain valve at · the flowmeter and open the fill and drain valve. The slot of the adjustment screw at the flowmeter has to be in a horizontal position.Thus the integrated ball · valve is closed (see flowmeter manual). Open the non- · return valve above the pump; for this purpose turn the ball valve by means of an open-ended spanner (wrench · size 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 thermal · system. · Flush the solar thermal system using the flushing and filling station for at least 15 minutes.To remove all air from the system, open the adjustment screw at the flowmeter 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 and increase the system pressure to approx. 6 bar. The system pressure is indicated at the pressure gauge.

Close the fill valve and switch-off the pump of the flushing and filling station; open the adjustment screw at the flowmeter (vertical position).

Bleed the system above the collector until the discharged fluid is free of bubbles. Increase the pressure to approx. 6 bar and check the system for leaks. In the case of a significant decrease in pressure, there may be leakage in the system

Adjust the system to the manufacturer‘s recommended pressure (to approx. 1,8 to 2,3bar with a collector height of approx. 5 to 10 m). Put the circulation pump into operation at maximum speed (see pump manual) and let it circulate for at least 15 minutes. Afterwards, adjust the desired pump speed. Adjust the flow rate at the flowmeter according to the specifications of the collector manufacturer. Remove the hoses of the flushing and filling station and screw the caps onto the valves of the flushing and filling 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 (see following 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 the system, if possible close to the store connection (not supplied) or at the drain valve and the pump .

UniMaxx-Plus Pump Station 2.3 Non-return valves -

The non-return valves of the pump station are integrated into the ball valves above the circulation pump 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 45째 position. The ball in the ball valve then opens the non-return valve. For normal system operation, the ball valve has to be completely opened.

2.4 Safety assembly -

The pump station is equipped with a diaphragm safety valve which corresponds to the relavant directives and regulations. For installation and operation, please pay attention to the following advice: The safety valve has to be easily accessible.The efficiency of the valve must not be influenced or disabled by barriers! The strainer or other restriction devices must not be mounted between collector (-field) and safety valve! The diameter of the discharge pipe must correspond to the diameter of the valve outlet; the maximum length must not exceed 2 m; more than 2 bends are inadmissable. When these values are exceeded (2 bends, 2 m pipe length), you have to install a discharge pipe with larger dimensions. Do not use more than 3 bends and pipes 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 least twice as large as the valve inlet. The opening of the discharge pipe should be inclined downwards. It should be routed so that the opening can be seen but does not present any risk to a person standing or passing by It is useful to place a container under the discharge pipe.If the safety valve opens,the fluid will be collected and can be refilled in to the system when the pressure is too low.

UniMaxx-Plus Pump Station 2.5 AirStopp, manual bleed valve (optional) The AirStopp is for bleeding the solar fluid in the solar thermal 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. Mounting In order to make sure that the AirStopp operates faultlessly, it is to be mounted vertically and with the bleed valve upwards! Operation The air precipitated from the solar fluid gathers in the upper area of the manual bleed valve (see figure).At first you should bleed the solar thermal system daily and then weekly or monthly, depending on the volume of discharged air. Bleed the solar thermal system half-yearly with the manual bleed valve to achieve optimal efficiency.

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

3.Accessory Sensors Our product range includes high temperature sensors, flatscrew sensors, outdoor temperature sensors, indoor temperature sensors, cylindrical clip-on sensors and irradiation sensors, also as complete sensors with immersion sleeves. 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 .

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

UniMaxx-Plus Pump Station Notes

UniMaxx-Plus Pump Station

Distributed by: SunMaxx SunMaxx Solar Solar 56 Corp.Road Pkwy 15 Broome Catherwood Conklin NY 13748 Ithaca NY 14850 877.786.6299 FaxFax 877.786.6299 877.786.0329 877.786.0329 sunmaxxsolar.com sunmaxxsolar.com

Imprint This mounting- and operation manual including all parts is We took a lot of care with the text and drawings of this manualand to the best of our knowledge and consent. As copyrighted.Another use outside the copyright requires the approval of SunMaxx Solar.This especially applies for copies, faults can never be excluded, please note: translations, micro films and the storage in electronic systems. Your own calculations and plans, under consideration of the current standards and directives should only be basis for your projects.We do not offer a guarantee for the completeness of the drawings and texts of this manual - they only represent some examples They can only be used at your own risk. No liability is assumed for incorrect, incomplete or false information and / or the resulting damages. Please note The design and the specifications are to be changed without prior notice The illustrations may differ from the original product. Important notice