SL-PS-I-O Rev B
Solar Pump Station
Installation and Operation
Manual
SPS0250, SPS0500 & SPS1000
This manual must only be used
by a qualified heating installer/
ƽ WARNING:
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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SL-PS Installation & Operation Manual
1 General Information
Before starting work, the Installer must read, understand and note these installation and operating
instructions.
ƽ WARNING
ƽ WARNING
ƽ WARNING
The solar pump station may only be installed and maintained by trained professionals. Trainees may
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
station. No other form of use is intended.The manufacturer is not liable for any damage resulting from
misuse of the solar station. For safety reasons, modifications or changes are not permitted.
■
The solar station must be installed as far away from the collectors as possible. Extremely high
temperatures may occur in the pipes near the collectors. If installing in attic space, ensure that
the instruments do not overheat.
ƽ WARNING
■
■
The pressure / temperature operating parameters must be within the prescribed limits. Excess
operating temperatures should be avoided for continuous operation.
The provisions stated in DIN EN 12976-1 should be observed when installing solar systems.
■ The expansion tank should be regularly checked according to DIN 4807.
■
■
Solar systems should be grounded to protect against lightning.
The system’s electrical connection for sensors and voltage supply should only be established by a
trained professional. The relevant specifications (VDE 0100, VDE 0185, VDE 0190 etc.) should
be observed as well as special local (construction) requirements. (Grey cable = tank, black cable
= collector)
■
■
The solar pump station’s componentry varies depending on type and equipment.
The diagrams used are examples.
■ Subject to technical changes and further developments.
A properly sized expansion tank must be used to avoid damage to the solar thermal system.
ƽ WARNING
Thermal expansion tanks should be sized to account for 1.5 times the solar system circuit volume.
The expansion tank may be hot, ensure that scalding does not occur.
ƽ WARNING
ƽ WARNING
ƽ WARNING
Failure to heed these instructions, especially the safety instructions, can result in the destruction of and
defects on the expansion tank, endanger persons, and impair the operation.
3
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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 collector and 2 tank sensors Pt 1000
Technical documentation:
■ Operation and installation instructions (with appendix) for
pump and solar control unit.
Figure 1-1 SPS0250/ SPS0500
4
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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
bracket and rear insulation shell. Secure both components
as a complete unit at the intended location, working the
front and using anchors and screws suitable for the wall
construction type.
the right of the solar station.
■ Ensure that the corrugated stainless steel hose is long
enough for the connection between the pump station and
the expansion tank, not forgetting the expansion coupling.
Installing the relief valve
Installation, connection lines to tank and
collector
■ The solar station is equipped with a solar safety relief valve
which meets the relevant requirements.
A) Piping
■ Fit the enclosed relief valve to the outlet of the return
instruments above the pump using the 3/4" union nuts. A
gasket is enclosed with the solar station for use when
installing the relief valve.
■ Connect the lines between the solar pump station and tank.
■ Connect supply and return lines to the collectors.
B) Clamp ring screw connections
■ The enclosed discharge connection bracket should be fitted
to the safety valve so that there is no risk of scalding should
liquid escape. Follow local codes for drainage piping.
■RefertoSection3: Technology,installationandcommissioning,
on page 6.
The following information should be noted:
■ The safety valve must be easily accessible.
■ No valves should be placed between relief valve and pump
station. The relief valve should be piped to a suitable drain
as close as possible to the pump station with no reducing
couplings or other restrictions. The piping must be sloping
away from the pump station at all times.
■ Dirt traps or other constrictions are not permitted between
the collectors (field) and safety valve.
5
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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,
FILLING, FLUSHING, DRAINING
FLOW CHECK CLOSED
DRAINING
SERVICE
BALL VALVE
CLOSED
FLOW CHECK OPEN
BALL VALVE 1/2 OPEN
■ Tighten clamp ring nut by hand.
BALL VALVE OPEN
■ Use open-ended wrench to tighten clamp ring screw
connection (approx. 33 Ft lb), re-tighten if necessary.
Figure 4-2 Return multi-functioning instruments
■ When tightening the clamp ring screw connection, use two
wrenches–using one wrench to prevent the pumping station
from turning.
Flat seal screw connections
■ All pre-fitted solar station screw connections are firmly
tightened in the factory so that they do not need to be
retightened.
SETTING FOR OPERATIONS
DRAINING
SERVICE, FILLING FLUSHING
FLOW CHECK CLOSED
BALL VALVE OPEN
BALL VALVE CLOSED
FLOW CHECK OPEN
BALL VALVE 1/2 OPEN
Torque levels when tightening flat seal screw connections
using AFM 34 flat seals, s = 2mm.
– 3/4" screw connection 26 Ft. lb
– 1" screw connection 40 Ft. lb
– 1 1/4" screw connection 66 Ft. lb
– 1 1/2" screw connection 96 Ft. lb
Operation, multi-function ball valve and
check valve
■ The forward flow ball valve must be open for filling, flushing
and bleeding solar systems with a filling and flushing pump.
The return ball valve should be closed.
■ Both flow checks should be opened in order to drain the
solar system (thermometer handles in 45° position).
■ The two mult-function ball valves must be fully open in
order to operate the solar system (turn the red and blue
thermometer handles counter-clockwise until the stop is
reached).
6
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SL-PS Installation & Operation Manual
4 Commissioning the solar system
General
■ Fill the solar system via the filling and flushing pump and
then flush the solar circuit for at least 15 min. to purge all of
the air out of the circuit.
■ Before commissioning, all piping, connections and saftey
equipment should be checked to ensure that they are
correctly installed.
■ Close the fill/flush valve (return) with the filling and
flushing pump running and increase the system pressure to
60 psi. The system pressure can be read at the
pressure gauge.
■ All pre-fitted solar station screw connections are firmly
tightened in the factory so that they do not usually need
retightening.
■ Seal integrity must be tested when commissioning and a
■ Close the fill/flush valve (forward flow) and switch off the
pressure test must be completed.
filling and flushing pump.
■ Fill the complete solar system with Lochinvar/TiSUN solar
liquid only. The mixing ratio should be adapted to local
conditions.
■ Open return ball valve (by turning the blue thermometer
handle 90° counter-clockwise until it stops).
■ The solar system features an air separator. Open the bleeder
■ Never flush or pressure test the complete solar system with
just water. Flushing the system with water only can cause a
freezing hazard.
valve until the solar liquid exits free of air bubbles.
■ Only if collector bleeder is installed: Bleed the system on the
collector until the solar liquid exits free of bubbles.
Filling, flushing and bleeding
■ If necessary, increase the test pressure again to 60
psi and check the system for leaks. If the pressure gauge
shows the pressure dropping substantially, you have a leak
in the system.
■ There is one fill valve with hose connection for filling,
flushing and draining the solar system on both the safety
group and sensor measurement section.
■ Connect the pressure hose (forward flow) to the safety
group’s filling connection under the pressure gauge and
open fill/flush valve.
■ Set the operating pressure to 60 psi as prescribed by the
system manufacturer
■ Start up the circulation pump at maximum speed and allow
■ Connect the flushing hose (return) to the flushing
connection on the sensor measuring section and open
fill/flush valve.
liquid to circulate for at least 15 min.
■ Remove the filling station hoses and screw the caps on the
flushing and filling valves.
■ Refer to “Technology, installation and commissioning:
Operation, multi-function ball valve and check valve” on
page 6.
■ Check the system again for leaks. Use the red and blue
thermometer handles to fully open the forward flow and
return ball valves.
■ Open the supply ball valve (by turning the red thermometer
handle counter-clockwise until it stops).
■ Activate speed control on solar control unit. The highest
speed level should be set on the pump (phase control).
■ Close return ball valve (by turning the blue thermometer
handle clockwise, until it stops).
Note: The minimum speed set on the solar control unit must
not fall below the pump’s minimum nominal speed.
Note instructions for pump and solar control unit.
■ If necessary, the supply and return check valve can be
opened by moving the thermometer handles to the 45°
position.
■ Once the installation settings have been completed and
checked, fit the solar station’s front insulation shell.
■ Put sufficient solar liquid in the tank of a filling and flushing
pump (not supplied). The mixing ratio should be adapted
to local conditions in terms of freeze protection.
■ Refer to the collector manufacturer’s recommendations for
minimum flow requirements.
7
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SL-PS Installation & Operation Manual
5 Pressure loss and residual delivery height
Max. residual delivery height
pressure drop of components
Solar group with Grundfos UPS 25-58U pump
(and GF sensor 0.5-3 GPM) residual delivery height
Figure 5-1
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
pressure drop of components
Figure 5-2
SPS0500
Solar group with Grundfos UPS 25-99U pump
(and GF-Sensor 0.5-10.5 GPM) residual delivery height
35
30
25
20
15
10
5
0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
8,0
Volumetric flow rate [GPM]
Max. residual delivery height
pressure drop of components
Figure 5-3
SPS1000
Solar group with Grundfos UP 25-120U pump
(and GF-Sensor 0.5 - 10.5 GPM) residual delivery height
40
35
30
25
20
15
10
5
0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
8,0
8,5
9,0
9,5 10,0
Volumetric flow rate [GPM]
8
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SL-PS Installation & Operation Manual
6 VFS flow sensor
■ Vortex flow sensor for liquid media.
■ Measures flow rate and temperature for BTU metering
(energy balance, etc.)
Figure 6-4 VFS 2-40 temperature output signal
VFS 2-40 output signal temperature
■ Zero wear (no moving parts).
Assignment of measurement range: 32-212°F is equal to0.5-3.5V
Temperature rate calculation: T =32°F + [(U-0.5)V/3V]*180°F
Figure 6-1 VFS 1-12 flow ouput signal
VFS 1-12 output signal flow
Assignment of measurement range: 0.26-3.17 gpm is equal to 0.5-3.5V
Flow rate calculation: Q = 0.26gpm +[(U-0.5)V/3V]*2.91gpm
Figure 6-5 VFS flow sensor
Figure 6-2 VFS 1-12 temperature output signal
VFS 1-12 output signal temperature
Assignment of measurement range: 32-212° F is equal to
Temperature rate calculation: T =32°F + [(U-0.5)V/3V]*180°
0.5-3.5V
F
Item
Pin Configuration
1
2
Temperature signal (0.5 to 3.5 relative to pin 3)
Flow pressure signal (0.5 to 3.5 relative to pin 3)
3
4
GND (UV)
Voltage Supply (+5 VDC) PELV
Figure 6-3 VFS 2-40 flow output signal
VFS 2-40 output signal flow
Assignment of measurement range: 0.53-10.6gpm is equal to 0.5-3.5V
Flow rate calculation: Q = 0.53gpm +[(U-0.5)V/3V]*10gpm
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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
SPS0500: Grundfos UPS 25 - 99 U
3/4" compression
SPS1000: Grundfos UP25 -120 U
PUMP
SOLAR AND TANK CONNECTIONS
EXPANSION TANK CONNECTION
INSTALLATION OPTIONS
1" compression
1/2" NPT
Wall mounting
HOLDING PLATE FOR WALL
MOUNTING
With 2 slot holes 5" apart for M6 screws
With 2 slot holes 5" apart for M6 screws
Plastic 8x40 mm anchors
MOUNTING MATERIAL FOR WALL
MOUNTING
6x50 mm clipboard screws
M6 8 zn DIN 912 washers
CENTER SPACING OF THE PIPING
Forward flow/return spacing: 5"
Forward flow/return spacing: 5"
Material: EPP
Thermal conductivity: 0.041 W/(mK)
Max temp: 250°F
INSULATION
Short-term max temp: 355 °F
Height: 14"
Height: 14"
Width: 9.75"
Depth: 7.5"
Width: 9.75"
Depth: 7.5"
SPS0250: VFS 1-12 sensor
SPS0500: VFS 2-40 sensor
VFS 2-40 sensor
Materials: Grivory, PPS
Seal material: EPDM
Nominal size: DN 15 / DN20
Nominal size: DN20
FlOW SENSOR AND MEASURING
SECTION
Measuring range: .26 –3.17 GPM/ .5 –10.5 GPM
Measuring range: .5 – 10.5 GPM
Output signal Q: 0.5 to 3.5 V (proportional to GPM)
Output signal T: 0.5 to 3.5 V (proportional to 32-212°F)
Max pressure: 145 psi
Power supply: 5 V DC
Temperature measuring range: 32°F to 212°F (145 psi)
Temp. min/max: -73°F / 248°F
Forward Flow/ G3/4" with seal cap and Solar 1/2" fill and flush valve
Return/ G3/4” with seal cap and Solar 1/2" fill and flush valve
Multi-function instruments fitted on right including ball valve, flow check and thermometer handles.
FILLING AND FLUSHING
CONNECTIONS
SAFETY GROUP
FORWARD FLOW BALL VALVE
RETURN BALL VALVE
Complete ball valve 1" /22 mm compression Complete ball valve 1 1/2" / 28 mm compression
Complete ball valve 1" /22 mm compression Complete ball valve 1 1/2" / 28 mm compression
0 – 145 psi, 2" diameter (EN 837-1, CL. 2.5)
SOLAR PRESSURE GAUGE
Designation: SVE/SOL 100 1/2" Solar
Designation: SVE/SOL 3/4" Solar
Standard /certificate: DIN EN 12164 CW 617N/
TÜV SV 07-2008
DIN EN 12164 CW 617N / TÜV SV 07-2008
SOLAR SAFETY VALVE
Nominal pressure 145 psi
Response pressure 145 psi
Max temp 320 °F
Glycol-water mixture max. 50%
10
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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
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
GRAVITY BRAKES
Scale: 32 - 288°F in 3.6 F increments
Diameter: 2"
SOLAR DIAL INDICATOR
THERMOMETER
Size: 30 x 22 x 2 - 1"
Size: 44.5 x 33 x 2 - 1 1/2"
Material: AFM 34 light grey
FLAT SEALS FOR PUMP
FLAT SEAL FOR SAFETY GROUP
BLEEDER PIPE
Long-term temperature: Liquid 482°F, water vapor 360°F
Peak temp. briefly: 720°F
Size: 17 x 24 x 2 - 3/4"
Material: AFM 34 light grey
Long-term temperature: Liquid 482°F, water vapor 392°F
Peak temp. briefly: 752°F
Type SER-RDT
Series: Solar 8010 compression 22 mm compres. Series: Solar 8010 compression 28 mm compres.
Connection: M28 x 1.5 / 22 mm / 3/8" female
Length: 9.25 ft
3/8" bleeder valve can be shut off manually
Connection: M36 x 1.5 / 28 mm / 3/8" female
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11
SL-PS Installation & Operation Manual
8 Component breakdown
SPS0250/ SPS0500
Name
SPS0250 - Pumpstation 250 sq-ft w/ flow sensor and CU
SPS0500 - Pumpstation 500 sq-ft w/ flow sensor and CU
Item
–
–
1
2
3
Solar return ball valve USA
Solar forw. flow ball valve USA
Solar bleeder block M28 x 1.5 L=283mm
1 1/2" x M28 x 1.5
M28 x 1.5M28
4
5
Nut M28 x 1.5mm
Clamp ring 22mm
6
7
Clamp ring 22.3 mm USA
Nut 1 1/2" x 16mm
8
Reducing socket 1 1/2" female x 1" male
9
10
Sealing kit 2x 1 1/2" ; 2x 1" ; 3x 3/4" ; 1x 1/2"
Solar cross piece cpl. USA 145 psi safety valve cpl.
Flow sensor housing 0.26-3.17 gpm cpl. w/ fill/ flush valve USA
Flow sensor housing 0.50-10.5 gpm cpl. w/ fill/flush valve USA
11
12
SPS0250- UPS 25/58U - 1 1/2" - 180-F12K03
115V60Hz
115V 60Hz
SPS0500- UPS 25/99U - 1 1/2" - 180-F12K09
13
14
Solar control unit LCD plus USA 115 Volt w/ SD-card
SPS0250-Sensor direct 0.26-3.17 gpm
SPS0500-Sensor direct 0.50-10.5 gpm
Power cord USA
w/ cable
w/ cable
w/ AC-plug XYTP
15
16
17
18
19
20
21
22
23
Control unit bracket
Red thermometer handle L=92mm RAL 3020
Blue thermometer handle L=92mm RAL 5010
Thermometer D51 L=100.5
Wall bracket for pumpstation
Retaining clamp cropped
0/160°C - 40/320°F
250/500 sq-ft
Spring wire 2mm
Sealing kit 2x 1 1/2" ; 2x 1" ; 3x 3/4" ; 1x 1/2"
Mounting kit S8x50/D10x50
anchors / screws
Insulation SPS0250 machined for pump and control unit
Insulation SPS0500 machined for pump and control unit
24
25
26
Additional insulation
Additional insulation
D=42mm/DN32
L=190mm machined
Cover white-alu RAL9006 Type C
27
Cover white-alu bottom RAL9006 Type B
Cover white-alu top RAL9006 Type B
28
Cover white-alu RAL9006 Type B w/ control unit cutout
Figure 9-1 SPS0250
4
6
17
19
1
10
20
2
18
7+9
21
4+5
3
12+15
25
8+9
22
14
11
24
23
26
16
13
30
27
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12
SL-PS Installation & Operation Manual
8 Component breakdown
(continued)
SPS1000
Name
Pumpstation 1000 sq-ft w/ flow sensor and CU
Item
–
1
2
Solar return ball valve
Solar forw. flow ball valve
1 1/2" Fl. x M36 x 1.5 incl. CV
M28 x 1.5 x M36 x 1.5 incl. CV
3
Solar bleeder block M36 x 1.5 L=283mm
4
5
Nut M28 x 1.5mm
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
Clamp ring 28.7 mm
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Reducing socket 1 1/2 female x 1" male
Reducing piece M36 x 1.5 male
Reducing piece M36 x 1.5 KVSR 28.7 x D28mm
Sealing kit 2x 1 1/2" ; 2x 1" ; 3x 3/4" ; 1x 1/2"
2x 1" AFM 34
Solar cross piece cpl. USA
w/ reducing pc. and cap
Flow sensor housing 0.50-10.5 gpm w/ fill/flush valve USA
Safety group KS0150 USA
Solar control unit LCD plus USA 115 Volt w/ SD-card
UP 25/120U - 1 1/2" - 180F12K9UL 115V 60Hz
Sensor direct 0.50- 10.5gpm
w/ cable
Power cord USA w/ AC-plug XYTP
Control unit bracket
Red thermometer handle L=92mm RAL 3020
Blue thermometer handle L=92mm RAL 5010
Thermometer D51 L= 100.5 0/160°C - 40/320°F
Wall bracket for pumpstation 1000 sq-ft
Retaining clamp cropped, spring wire 2mm
Mounting kit S8x50/D10x50 anchors / screws
Insulation SPS1000 machined for pump and control unit
Additional insulation D=42mm/DN32
Additional insulation L=190mm machined
Cover white-alu bottom RAL9006 Type B
Cover white-alu top RAL9006 Type B
Cover white-alu RAL9006 Type B w/ control unit cutout
Figure 9-2 SPS1000
8
25
26
20+22
10
24
1
18
16
28
33
27
2
4+5
3
34
35
19
30
31
11
6+7
13
9
13
21
29
4
23
32
12
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SL-PS Installation & Operation Manual
9 Service
De-energize and lock the solar control
Draining the system
ƽ WARNING
and pump to prevent them from
accidentally being switched back on
again by mistake before any maintenance
or repair work.
■
Fit corresponding drainage hoses on to the filling and
flushing connections and guide these into a collecting
vessel.
■ Open the check valves by placing the red and blue
Serviceisnotpermitteduntilcomponents
and solar liquid have cooled.
thermometer handles in their 45° position.
■ Open the fill/flush valve (return) under the pump.
Air separator
■ The solar station features an air separator. Open bleeder
■ Open the fill/flush vlave (forward flow) on the safety group.
valve until the solar liquid exits free of air bubbles.
■ Optional: Open the fill/flush valve at lowest point of
■ Check system pressure and top off solar liquid if required.
system, as close to the tank connection as possible.
■
Open bleeder equipment at highest point (above
collectors).
Flat seal screw connections
■ The screw connections may have to be retightened as the
seals settle. Note tightening torque requirements in the
“Technology: installation and commissioning” section of
this manual.
Clamp ring screw connections
■ Use an open-ended wrench to retighten clamp ring screw
connections if required (approx. 33 Ft lb).
■ When tightening the clamp ring screw connection, use two
wrenches–one wrench to prevent the pumping station from
turning.
Disassembling the solar station
(Wall bracket, for repairs and service only)
■ Use a screwdriver or similar tool to remove the retaining
springs to the front.
The solar station is now loose. Ensure
ƽ CAUTION
that it does not slide forward and out
of the wall bracket.
14
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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 of movement of
pump rotor by turning the slotted shaft end with a
screwdriver; use force to turn if necessary.
Pump Noise:
■ In the event of cavitation caused by insufficient inlet
pressure, increase primary system pressure within allowable
range.
■ Check speed setting.
If the fault cannot be rectified, please contact your nearest
Lochinvar/TiSUN customer service representative.
15
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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
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