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UniMaxx-Plus Pump Station

*48001070*

48001070

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

UniMaxx-Plus Pump Station


B
Manual
www.sunmaxxsolar.com

Mounting Installation Operation Commissioning

UniMaxx-Plus Pump Station


Contents:
Safety advice ...................................................................... Technical data and operation 1. 1.1 1.2 1.3 1.4 1.5 Wall mounting ........................................... Installation .............................................................. ....................................................... ............... Optional compression ring connection Mounting the expansion vessel (optional) Electrical connection ............................................. ....................................... Integration of the controller 2 3 4 4 5 6 6 .......... 5 2. 2.1 2.2 2.3 2.4 2.5 3. Commissioning ...................................................... Filling and ushing the system Emptying the system Non-return valves ............................. ............................................. 7 7 7 8 8 9 9 12

..................................................

Safety assembly ...................................................... Air-Stopp ................................................................ Accessory ...............................................................

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

IntelliMaxx-DHW Plus

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 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 and VDE. These instructions are exclusively addressed to authorized skilled personnel. - Only quali ed electricians should carry out electrical works. - Initial installation must be e ected by qualied personnel named by the manufacturer

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

Subject to technical changes. Errors excepted.

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UniMaxx-Plus Pump Station


Prepared for integration of the IntelliMaxx-DHW Plus controller Dial thermometer for ow and return Outstanding design Return line with ball valve and openable nonreturn valve Integrated owmeter Safety assembly with relief valve and pressure gauge Fill/drain valve for lling and ushing the system Wall mounting bracket with screws and dowels Insulated casing

315

520 mm 315 mm 63 mm IT, with cutting ring connections (optional) Connection for expansion vessel: ET pipe 3/4, at sealing Outlet safety valve: ET pipe 3/4 Max. admissible pressure: 8 bar Max. admissible temperature: 120C 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 ow 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

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

520

UniMaxx-Plus Pump Station


1. Installation
12 16 10 11 9 13 7 14 4

1 2 8

6 5

15

1 2 3 4 5 6 7 8 9 10 11

Wall mounting bracket of the pump station Insulation - rear Controller Insulation - front cover Flowmeter Drain valve pump ball valve in ow IT-IT, with integrated thermometer ball valve in return IT-IT, with integrated thermometer Safety head-piece, with ll valve Pressure gauge

12 13 14 15

Safety valve 6 bar Optional: expansion vessel set Optional: AirStopp Optional: Compression ring connection for copper pipe

1.1 Wall mounting


1. 2. 3. 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. order to connect the In pipes with the compression ring connections, pay attention to the following instructions!

4. 5.

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


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.

> 3 mm 5 2 3

1 -

Please note: In order to absorb the strain of the pipes, corresponding ttings (strain neutralizers) or expansion bends (consisting of at least two 90 - 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 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 atly 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 elds.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 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 and large washers.

- Attach the front part of the insulation to the pump station. Do not yet insert the thermometers (red in ow, on the left / blue in return, on the right), because the insulation has to be opened once again for commissioning. -

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, ushing and commissioning the pump station
Connect the pressure hose to the ll valve at the safety head-piece below the pressure gauge (11) and open the ll and drain valve. Connect the ushing hose to the ll and drain valve at the owmeter and open the ll and drain valve. The slot of the adjustment screw at the owmeter has to be in a horizontal position.Thus the integrated ball valve is closed (see owmeter 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 sufcient solar uid into the tank of a ushing and lling station (not supplied) and ll the solar thermal system. Flush the solar thermal system using the ushing and lling station for at least 15 minutes.To remove all air from the system, open the adjustment screw at the owmeter several times. The system may be ushed with water before commissioning but the nal installation must con tain antifreeze to protect against frost damage. Adjust the system to the manufacturers 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 ow rate at the owmeter according to the specications of the collector manufacturer. Remove the hoses of the ushing and lling station and screw the caps onto the valves of the ushing and lling valves. Check the system for leaks. Open both ball valves Die vordere Isolierschale der Solarstation anbringen, die Thermometer einstecken.

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 ll valve and switch-o the pump of the ushing and lling station; open the adjustment screw at the owmeter (vertical position). Bleed the system above the collector until the dis charged uid is free of bubbles. Increase the pressure to approx. 6 bar and check the system for leaks. In the case of a signicant decrease in pressure, there may be leakage in the system

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 ll 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 ow 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 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 efcien cy of the valve must not be inuenced or disabled by barriers! The strainer or other restriction devices must not be mounted between collector (-eld) 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 inadmiss able. 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 uid will be collected and can be relled 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 uid in the solar thermal system.The air precipitated from the solar uid 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 uid gathers in the up per area of the manual bleed valve (see gure).At rst 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 efciency.

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

3.Accessory
Sensors Our product range includes high temperature sensors, at screw 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 owmeter for measuring the ow rate in your system.

UniMaxx-Plus Pump Station


Notes

UniMaxx-Plus Pump Station


Notes

UniMaxx-Plus Pump Station

Distributed by: SunMaxx Solar SunMaxx Solar 56 Broome Corp.Road 15 Catherwood Pkwy Conklin NY 13748 Ithaca NY 14850 877.786.6299 877.786.0329 Fax 877.786.6299 877.786.0329 Fax 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 lms 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 o er 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 specications are to be changed without prior notice The illustrations may di er from the original product.
Important notice

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