CitrinSolar DN 20 User manual

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 1
Installation and Operation Instructions
Separation system M
DN 20

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2 9960910CIT01-mub-en –V01 2017/04
Contents
1General Information ...........................................................................................................3
1.1 About these instructions ............................................................................................... 3
1.2 About this product ........................................................................................................ 4
1.3 Designated use ............................................................................................................ 5
2Safety instructions .............................................................................................................6
3Assembly and installation [specialist] ..................................................................................8
3.1 Controller connection ................................................................................................. 10
4Commissioning [specialist] ...............................................................................................11
4.1 Preparations before flushing and filling....................................................................... 12
4.2 Flushing and filling the storage tank circuit................................................................. 12
4.3 Flushing and filling the solar circuit............................................................................. 13
5Maintenance [specialist] ...................................................................................................18
5.1 Draining the solar system........................................................................................... 19
5.2 Deinstallation.............................................................................................................. 19
6Spare parts [specialist].....................................................................................................20
6.1 Primary circuit separation system M (198245)............................................................ 20
6.2 Secondary circuit separation system M (198245) ....................................................... 21
7Technical data .................................................................................................................22
7.1 Dimensional drawing.................................................................................................. 23
7.2 Pressure drop characteristic curve ............................................................................. 24
8Function of the check valves [Expert]................................................................................25
9Commissioning report ......................................................................................................27
Item no. 9960910CIT01-mub-en - Version V01 –Issued 2017/04
Translation of the original instructions
We reserve the right to make technical changes without notice!
Printed in Germany –Copyright by CintrinSolar GmbH
CitrinSolar GmbH
Energie- und Umwelttechnik
Böhmerwaldstraße 32
D-85368 Moosburg, Germany

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 3
1General Information
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1.1 About these instructions
These instructions describe the installation, commissioning, function and operation of the
separation system M DN 20. The chapters called [specialist] are intended for specialists only.
For other components of the solar installation, such as pumps, collectors, storage tanks or
expansion tanks, please observe the instructions of the corresponding manufacturer.
DN 20
Item number
Flow rate
(maximum)
Separation system M
198245
450 l/h

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
4 9960910CIT01-mub-en –V01 2017/04
1.2 About this product
The station is a premounted group of fittings checked for tightness and used to transfer
the heat from the primary or solar circuit to the secondary or storage tank circuit.
The station contains important valves, fittings and safety devices for the operation
of the installation:
Ball valves with integrated thermometers in the solar circuit (flow and return)
Ball valves in the storage tank circuit (flow and return)
Check valves to avoid undesired gravity circulation in the flow and
return of the primary circuit and in the flow of the secondary circuit
Pressure relief valves to prevent inadmissible overpressures
Pressure gauge to display the system pressure in the solar circuit
Vent valves for an easy venting of the solar circuit
Fill and drain valves with caps to flush, fill and drain the solar circuit
Two flow meters on the primary and secondary side for the balancing of the flow rates
The expansion tank required for operation must be adapted to the size and the requirements
of the installation and must be ordered separately.
The separately available cap valve and the tank connector allow an easy mounting
and separation of the expansion tank from the solar installation.
The wrapping materials are made of recyclable materials and can be disposed of
with recyclable materials.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 5
1.3 Designated use
The station may only be used as a separation system between the solar and the heating circuit
in solar thermal systems taking into consideration the technical limit values indicated in these
instructions. Due to its design, the station must only be mounted and operated as described
in these instructions!
Only use original accessories with the separation system.
Improper usage excludes any liability claims.
Under the influence of solar radiation, the collectors can get very hot.
The solar fluid in the solar circuit can heat up to more than 100 °C.
Only flush and fill the solar circuit if the collector temperatures are
below 70 °C.
Schematic structure
separation system M
Scope of delivery

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
6 9960910CIT01-mub-en –V01 2017/04
2Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable
level of knowledge [specialist].
The following must be observed during installation and commissioning:
relevant local and national regulations
accident prevention regulations of the professional association
instructions and safety instructions of this manual
WARNING
Danger of scalding due to vapour escape!
With pressure relief valves, there is a risk of scalding due to vapour escape.
During installation, check if the local conditions require the connection of a
discharge line to the safety group.
For this purpose, please observe the instructions regarding the
pressure relief valve.
The pressures calculated by the installation planner for the expansion
tank and the operating pressure of the installation must be set.
CAUTION
Risk of burns!
The valves, fittings and the pump may heat up to more than 100 °C
during operation.
The insulating shell must remain closed during operation.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 7
CAUTION
Personal injury and damage to property due to overpressure!
By closing the two ball valves in the primary circuit, the safety group is separated
from the heat exchanger. A rise in temperature in the storage tank will cause
high pressures which can result in personal injury or damage to property!
Only close the ball valves for service and maintenance.
NOTICE
Material damage due to mineral oils!
Mineral oil products cause lasting damage to seals made of EPDM, whereby the sealant
properties get lost. We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.
It is imperative to avoid that EPDM gets in contact with substances containing
mineral oils.
Use a lubricant based on silicone or polyalkylene and free from mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
8 9960910CIT01-mub-en –V01 2017/04
3Assembly and installation [specialist]
The location of installation must be dry, load-carrying, frost-proof and protected against
ultraviolet radiation. Furthermore, the access to the control and safety equipment must
be guaranteed at all time during operation!
The discharge lines of the pressure relief valves must be conducted into heat-resistant
collecting containers of corresponding size. An uncontrolled discharging into the environment
is thus avoided and the refilling of the circuits is facilitated.
NOTICE
Material damage due to high temperatures!
As the solar fluid can be very hot near the collector, the group of fittings must be installed
at a sufficient distance from the collector field.
It may be necessary to install an intermediate tank to protect the expansion tank.
1. Remove the station from the packaging.
2. Copy the measure for the mounting holes to the
mounting surface. You will find a corresponding
drilling template on the paper board under the station.
3. Drill the holes and insert appropriate wall plugs into
the holes.
4. Screw in the screws and let them stick about 3 cm
out of the wall.
5. Remove the insulating front shell. Hang the
station onto the screws and tighten the screws.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 9
6. Connect the station to the installation
by using the piping:
① Solar flow from the collector
② Solar return to the collector
③ Flow to the buffer tank
④ Return from the buffer tank
All thread connections have ¾" internal threads.
7. Mount the safety group, consisting of the pressure
relief valve [c], the fill valve [d] and the pressure
gauge [e] to the connection of the return ball valve [b].
8. Connect the pipe for the expansion tank below
the pressure gauge [e] and fix the bracket for
the expansion tank.
For service work on the expansion tank, we
recommend the installation of a cap valve
or a tank connector on the expansion tank.
NOTICE
Note regarding the expansion tank
During the flushing and filling of the station, the expansion tank must not be connected in order
to avoid that dirt particles are washed in.
9. Adapt the initial pressure of the expansion tank to
the installation and connect the expansion tank.
Please observe the separate instructions regarding
the expansion tank!
10. Check all thread connections and tighten them
if necessary.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
10 9960910CIT01-mub-en –V01 2017/04
3.1 Controller connection
WARNING
Risk to life and limb due to electric shock!
Prior to commencing electrical work on the controller, pull the mains plug!
Only after completing all installation work as well as the flushing and filling,
the mains plug of the controller can be plugged into a socket.
An unintentional start of the motors is thus avoided.
NOTICE
Damage at the pump!
An improper electrical connection of the pump to the mains and to the controller leads
to irreparable damages of the pump!
Observe the electrical connections between the pump and the corresponding
voltage source.
1. Connect the pump to the controller
(not included in the scope of delivery):
1 = Controller connection (PWM signal)
2 = Connection mains plug
Please observe the separate
instructions regarding the controller!
2. Tighten all union nuts and thread connections.
The assembly of the station is now completed
and the station can be put into operation.
PWM
control signal /
low voltage
230 V - load
bl
br
bl
ye/gr
PE
br

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 11
4Commissioning [specialist]
Please observe the following safety instructions regarding the commissioning of the station:
WARNING
Risk of burning and scalding!
The valves and fittings can heat up to more than 100 °C. It is therefore not
allowed to flush or fill the installation when the collectors are hot (intense solar
radiation). Please note that hot solar fluid can leak from the pressure relief
valves if the system pressure is too high! During venting, solar fluid may
escape as vapour and cause scalding!
Only flush and fill the installation if the collector temperatures are
below 70 °C.
NOTICE
Risk of frost!
It often happens that the solar system can not be completely drained after flushing.
There is thus a risk of late frost damage when flushing with water. Therefore, flush
and fill the solar installation only with the solar fluid used later.
Only use the original HT fluid from CitrinSolar as solar fluid.
NOTICE
Note regarding the commissioning sequence
Flush and fill the installation in the following order:
1. Flush the storage tank (to remove scale residues).
2. Fill the storage tank circuit.
3. Flush and fill the solar circuit of the heat exchanger.
4. Flush and fill the collector field.
5. Flush and fill the (entire) solar circuit.
This avoids that dirt particles are flushed into the heat exchanger and guarantees
that possibly absorbed heat can be dissipated.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
12 9960910CIT01-mub-en –V01 2017/04
4.1 Preparations before flushing and filling
NOTICE
Note regarding the expansion tank
To prevent that dirt particles of the solar system are washed into the expansion tank, some
manufacturers recommend to disconnect the expansion tank from the solar circuit during
flushing and filling. Please observe the instructions of the manufacturer on this topic.
4.2 Flushing and filling the storage tank circuit
The storage tank circuit is filled by means of the valves and fittings of the heating system.
To avoid that dirt particles are washed into the heat exchanger, shut the ball valves of the
module and wash out the present dirt particles/scale residues before the initial commissioning
of the storage tank. Make sure to only use purified heating water according to VDI 2035 /
Ö-Norm H 5195 1.
1. Open the ball valves [D|E] and put the check
valves in the ball valve [E] out of operation
(45°, see next page).
2. Vent the storage tank circuit by activating the
pressure relief valve [A] on the secondary side.
Make sure that the electrical components do not
get wet.
3. Fill the storage tank circuit with heating water
by means of the fill and drain valve of the heating
installation.
4. Set the required operating pressure after filling
the storage tank circuit.
5. During commissioning, vent the station at the
pressure relief valve [A] to eliminate the air
still present in the heat exchanger.
Storage tank circuit

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 13
4.3 Flushing and filling the solar circuit
The fill and drain valves necessary to flush and fill the installation are integrated in the station.
Make sure not to flush dirt particles possibly present in the system into the heat exchanger
and the expansion tank. For this purpose, disconnect the expansion tank from the solar circuit
during flushing and filling if necessary and only use flush and fill stations with fine filters.
Ball valve with integrated check valve
(Normal flow direction in the figure: downwards)
0°
45°
90°
Check valve is operating,
flow only in flow direction.
Check valve is not operating,
flow in both directions.
Ball valve closed,
no flow.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
14 9960910CIT01-mub-en –V01 2017/04
Airstop
The Airstop with manual vent valve is used to vent the solar
installation. To ensure a perfect venting of the solar circuit,
the flow velocity in the flow line must be at least 0.3 m/s.
Pipe diameter [mm]
Flow rate at 0.3 m/s
∅outside
∅inside
l/h
l/min
15
13
~ 143
~ 2.4
18
16
~ 217
~ 3.6
22
20
~ 339
~ 5.7
28
25
~ 530
~ 8.8
The air separated from the solar fluid accumulates in the upper part of the Airstop
and can be released via the vent plug [j].
WARNING
Danger of scalding due to vapour escape!
The escaping fluid can reach temperatures of more than 100 °C and cause
scalding.
Carefully open the vent plug and close it again as soon as fluid escapes.
Venting the solar installation after commissioning
At the beginning, vent the solar installation daily and then weekly or monthly,
depending on the quantity of vented air. An optimum operation of the solar
installation is thus ensured. Check the system pressure after venting and
increase it to the specified operating pressure if necessary.
j

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 15
1. Disconnect the expansion tank from the solar
installation. This avoids that dirt particles still
present in the pipes are washed into the
expansion tank. Please observe the separate
instructions regarding the expansion tank!
2. Put the check valve out of operation by
turning the ball valve [a] into position 45°
(see page 13).
3. The return ball valve [b] must be
closed (position 90°, see page 13).
4. Connect the flush and fill station:
- Pressure hose to the fill valve [d]
- Flush hose to the drain valve [h].
5. Open the fill and drain valves [d|h] and
put the flush and fill station into operation.
6. Slowly open and close the return ball valve [b]
during flushing in order to vent the pump
section.
7. Flush the solar circuit until the solar fluid
exits without bubbles (see page 14).
8. Close the drain valve [h] with the filling pump
running and increase the system pressure to
about 5 bars. The system pressure can be
read on the pressure gauge [e].
9. Close the fill valve [d] and switch off
the pump of the flush and fill station.
10. Check the pressure gauge to see if the
system pressure decreases and eliminate
leaks if necessary.
Observe the pressure (max. 10 bars)!
Solar circuit

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
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11. If necessary, reduce the pressure at the drain
valve [h] to the system-specific pressure.
12. Connect the expansion tank to the solar circuit
and set the operating pressure of the solar
system by means of the flush and fill station
(for the required operating pressure, see the
manual of the expansion tank).
13. Close the fill and drain valves [d|h].
14. Put the check valves into operating position
by turning the ball valves [a|b] into position 0°
(see page 13).
WARNING
Risk to life and limb due to electric shock!
Check if the sensors and pumps are properly connected to the controller
and if the controller housing is closed.
Only then, the mains plug of the controller can be plugged into a socket.
15. Connect the controller to the mains and set the
solar circuit pump in the manual mode to ON
according to the controller instructions.
16. Let the pump of the solar circuit run at maximum
revolution speed for at least 15 minutes.
Meanwhile, vent the solar system several times
at the vent plug [j] of the Airstop until the solar
fluid exits without bubbles (see page 14).
17. If necessary, increase the system pressure to
the operating pressure.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 17
18. Remove the hoses of the flush and fill station
and screw the sealing caps onto the fill and
drain valves.
19. Mount the insulating front shell.
20. Set the controller to automatic mode
(see controller instructions).
The commissioning of the solar installation is now
completed.
Please fill in completely the commissioning report
on page 27.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
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5Maintenance [specialist]
Depressurise the installation for service and maintenance work on the station.
WARNING
Risk of burning and scalding!
The valves, fittings and the solar fluid can heat up to more than 100 °C.
The solar fluid can escape as vapour and cause scalding.
Only carry out maintenance work if the collector temperatures
are below 50 °C.
Wait until the solar fluid has cooled down to maximum 50 °C.
Separation system M
1. Close the ball valves [a|b] and release the solar fluid
at the fill and drain valve [h]. Make sure that the
solar fluid is collected in a heat-resistant container.
2. Replace the faulty part by the new part.
3. Fill the solar circuit as described in the chapter
4.3 Flushing and filling the solar circuit
(see page 13).

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
2017/04 9960910CIT01-mub-en –V01 19
5.1 Draining the solar system
1. Switch off the controller and make sure that
a restart is not possible.
2. Open the check valves in the flow and return
ball valves [a|b] by turning them into position 45°
(see page 13).
3. Connect a heat-resistant hose to the
drain valve [i] of the transfer station.
Make sure that the solar fluid is collected
in a heat-resistant container.
WARNING
Danger of scalding due to hot solar fluid!
The escaping solar fluid may be very hot.
Place and secure the heat-resistant collecting container in such a way
that people standing nearby are not endangered during the draining of
the solar installation.
4. Open the drain valve [h] of the transfer station.
5. To accelerate the draining of the solar circuit, the vent valve possibly
present at the highest point of the solar installation can be opened.
6. Dispose of the solar fluid observing the local regulations.
5.2 Deinstallation
1. Drain the solar installation as described above.
2. Disconnect the pipe connections to the solar system.
3. Disconnect the cable connections between the controller
and the sensors (collector / storage tank).
4. Loosen the fastening screws of the station and take the station off the wall.

CitrinSolar GmbH
Böhmerwaldstr. 32; D-85368 Moosburg
Phone: [phone]; Fax: 33 40 40
www.citrinsolar.de / [email protected]
20 9960910CIT01-mub-en –V01 2017/04
6Spare parts [specialist]
NOTICE
Complaints and requests/orders of spare parts will only be processed with information on
the serial number!
The serial number is placed in the upper right corner of the support sheet of the station.
In case of a complaint, please send us the entirely completed commissioning report
on page 27.
6.1 Primary circuit separation system M (198245)