Daikin EKSRDS2A User manual

Operating and
installation instructions
Operating and installation instructions
Solar pressure station English
EKSRDS2A
Solar pressure station

2FA EKSRDS2A - 06/2015
Table of contents
1This instruction manual.............................................................................4
1.1 Precautions.....................................................................................4
2Safety .......................................................................................................5
2.1 Intended use...................................................................................5
2.2 Predictable incorrect application .....................................................5
2.3 Safe handling..................................................................................5
2.4 Staff qualification.............................................................................6
2.5 Modifications to the product............................................................6
2.6 Usage of spare parts and accessories............................................6
2.7 Liability information.........................................................................7
3Product description...................................................................................8
4Technical specifications.......................................................................... 10
4.1 Approvals, tests and conformities .................................................12
5Transport and storage.............................................................................12
6Mounting and commissioning.................................................................. 12
6.1 Mounting DAIKIN EKSRDS2A ......................................................13
6.2 Connecting DAIKIN EKSRDS2A................................................... 15
6.3 Electrical connection.....................................................................18
6.4 Commissioning DAIKIN EKSRDS2A.............................................18
7Operation................................................................................................20
7.1 Reading mark at flow meter.......................................................... 20
7.2 Venting the system ....................................................................... 21

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8Maintenance...........................................................................................22
9Troubleshooting......................................................................................22
10 Decommissioning, disposal.....................................................................24
11 Warranty.................................................................................................24
12 Copyright ................................................................................................28

This instruction manual
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1 This instruction manual
This instruction manual is part of the product.
Read this manual before using the product.
Keep this manual during the entire service life of the prod-
uct and always have it readily available for reference.
Always hand this manual over to future owners or users of
the product.
1.1 Precautions
WARNING
WORD
Type and source of the hazard are shown here.
Precautions to take in order to avoid the hazard are
shown here.
There are three different levels of warnings:
Warning word
Meaning
DANGER
Immediately imminent danger!
Failure to observe the information will result in
death or severe injuries.
WARNING
Possibly imminent danger!
Failure to observe the information may result
in death or severe injuries.
CAUTION
Dangerous situation!
Failure to observe the information may result
in minor or severe injuries as well as damage
to property.

Safety
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2 Safety
2.1 Intended use
The solar pump assembly DAIKIN EKSRDS2A may only be
used to circulate the following liquids in intrinsically safe,
closed, solar systems.
Standard heat transfer fluids (solar liquids) suitable for so-
lar systems such as water-glycol mixtures
The integrated safety group assembly serves to secure
against excessive pressure.
Any use other than the application explicitly permitted in this
instruction manual is not permitted.
2.2 Predictable incorrect application
The solar pump assembly PrimoSol®must never be used in
the following cases:
Operation with swimming pool water
Use with adherent, corrosive or flammable fluids
Temperatures in excess of or below the permissible tem-
peratures and pressures, see table 1, page 11
2.3 Safe handling
This product represents state-of-the-art technology and is
made according to the pertinent safety regulations. Each
product is subjected to a function and safety test prior to ship-
ping.
Operate the product only when it is in perfect condition.
Always observe the operating instructions, all pertinent lo-
cal and national directives and guidelines as well as the

Safety
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applicable safety regulations and directives concerning
the prevention of accidents.
WARNING
Severe burns or death caused by mains voltage
(AC 230 V, 50 Hz) in the pump head.
Avoid any contact of the pump head with water or solar
liquid.
Disconnect the mains voltage supply before opening the
pump head or before performing maintenance and clean-
ing work and make sure it cannot be switched on.
Do not tamper with the pump head in any way whatsoev-
er.
2.4 Staff qualification
The product may only be mounted, commissioned, operated,
maintained, decommissioned and disposed of by qualified,
specially trained staff.
Electrical work may only be performed by trained electricians
and in compliance with all applicable local and national direc-
tives.
2.5 Modifications to the product
Changes or modifications made to the product by unauthor-
ised persons may lead to malfunctions and are prohibited for
safety reasons.
2.6 Usage of spare parts and accessories
Usage of unsuitable spare parts and accessories may cause
damage to the product.

Safety
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Use only genuine spare parts and accessories of the
manufacturer.
2.7 Liability information
The manufacturer shall not be liable in any form whatsoever
for direct or consequential damage resulting from failure to
observe the technical instructions, guidelines and
recommendations.
The manufacturer or the sales company shall not be liable for
costs or damages incurred by the user or by third parties in the
usage or application of this product, in particular in case of
improper use of the product, misuse or malfunction of the
connection, malfunction of the product or of connected
products. The manufacturer or the sales company shall not be
liable for damage whatsoever resulting from any use other
than the use explicitly permitted in this instruction manual.
The manufacturer shall not be liable for misprints.

Product description
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3 Product description
Complete, pre-assembled and tightness-tested solar pump as-
sembly with all required safety and functional components, in-
cluding form-fit heat insulation. The heat insulation is also
used to package the product for safe transport.

Product description
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1
Flow
2
Return
3
Ball valve, blue, can
be shut off, with grav-
ity brake and ther-
mometer
4
Safety group assem-
bly
5
Safety valve
6
Discharge opening
7
Pressure gauge with
mounting valve
8
Connection for ex-
pansion vessel.
9
Circulation pump
1
0
Shut-off
1
1
Filling and flushing
valves
1
2
Flow meter
1
3
Heat insulation
1
4
Vent pot
1
5
Vent valve with hand
wheel
1
6
Ball valve, red, can
be shut off, with grav-
ity brake and ther-
mometer
Fig. 1: DAIKIN EKSRDS2A,
flow and return with filling and flushing valves and vent pot

Technical specifications
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4 Technical specifications
Fig. 2: Dimensions [mm] DAIKIN EKSRDS2A

Technical specifications
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Table 1: Technical specifications
Parameter
Value
System connection
Compression fitting DN 22
General specifications
Weight
Max. 5.5 kg
Material of fittings
Brass CW617N
Material heat insu-
lation
Polypropylene EPP
System pressure
Max. 6 bar
Operating temperature range
Ambient
Max. 40 °C
Medium
Max. 120 °C, short-term max. 160 °C
Flow meter
Pump connection
Pump side with flange and union nut
G1½.
Measuring range
2-12 l/min
Combination valve red (flow)
Range
0 °C to +120 °C
Combination valve blue (return)
Pump connection
Pump side with flange and union nut
G1½.
Range
0 °C to +120 °C
Safety group assembly
Connection for
expansion vessel
G¾ for flex pipe, flat-sealing with union
nut
Safety valve
6 bar
Pressure gauge
Ø 63 mm, 0-10 bar

Transport and storage
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4.1 Approvals, tests and conformities
The safety valve of the safety group assembly complies with
Pressure Equipment Directive (97/23/EC).
See enclosed operating instructions of the manufacturer of the
circulation pump for circulation pump.
5 Transport and storage
CAUTION
Damage to the product due to improper transport.
Do not throw or drop the product.
CAUTION
Damage to the product due to improper storage.
Protect the product from shock when storing it.
Store the product in a clean and dry environment.
6 Mounting and commissioning
WARNING
Scalding due to hot solar liquid and escaping steam.
Take all necessary measures during mounting, commis-
sioning and maintenance of the solar pump assembly to
ensure that hot liquid does not pose any hazard to per-
sons.
Install the solar pump assembly in such a way that no
steam can get into the expansion vessel during stagna-
tion.
If the expansion vessel is mounted at the same height as
the solar pump assembly or higher than the solar pump
assembly, install a heat trap siphon.

Mounting and commissioning
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During heating up, liquid must be able to escape via the
discharge line of the safety valve (no obstructions).
Install the safety valve in such a way that it cannot be
shut off.
Do not install shut-off valves, filters or similar equipment.
Install the solar pump assembly in such a way that no ex-
ternal forces can act on the components after it has been
installed.
Do not overheat the components by welding or soldering
work performed on the system. Install the solar pump as-
sembly after completion of such welding or soldering
work.
Thoroughly flush the pipes prior to installing the solar
pump assembly. Impurities such as weld beads, hemp or
metal chips cause leaks of the safety valve and the check
valves.
Verify that the nominal pressure of the solar pump as-
sembly corresponds to the specification value of the sys-
tem.
Verify that the liquid in the system and the application ar-
ea of the solar pump assembly are compatible.
6.1 Mounting DAIKIN EKSRDS2A
Sealing surfaces have been check for cleanliness and
damage.
All pipe ends are perpendicular and have been deburred.
DAIKIN EKSRDS2A is delivered ready to be installed. Do not
disassemble parts.
1. Remove the upper insulation.
2. Hold DAIKIN EKSRDS2A with the lower insulation to the
wall (align with a level) and mark two positions.

Mounting and commissioning
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3. Drill holes (Ø 10 mm) at the position of the two marks and
insert the enclosed dowels. Screw the long hanger bolt in-
to the top hole, the short hanger bolt into the bottom hole.
4. Fit DAIKIN EKSRDS2A with the bottom insulation and se-
cure it with a washer and a nut.
5. Connect the pipes of the solar circuit to the connections of
the fittings.
6. Refit the upper insulation.
Fig. 3: Mounting DAIKIN EKSRDS2A

Mounting and commissioning
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6.2 Connecting DAIKIN EKSRDS2A
1. Connect the pipes of the solar circuit to the connections of
the fittings.
2. Connect the pipe or flex pipe of the expansion vessel to
the safety group assembly.
1
Safety group assem-
bly
2
Flat gasket
3
Flex pipe, flat-sealing
Fig. 4: Connection flex pipe G¾
3. Connect the discharge line of the safety valve to the safe-
ty group assembly, see below.
4. Connect the unit electrically, see chapter 6.3, page 18.

Mounting and commissioning
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6.2.1 Discharge line of the safety valve
The discharge opening is designated by an arrow on the valve
body.
WARNING
Injuries and hazard of scalding due to hot liquid or steam
escaping via the discharge opening.
Install the discharge line in such a way as to avoid any
damage or injuries due to escaping liquid and that the liq-
uid can be safely collected in a suitable collector tank for
solar liquid.
Fig. 5: Discharge line with container or collector tank for solar
liquid
The discharge line must have a gradient; its cross section
must have at least the same cross section as that of the
discharge opening.
The length of the discharge line must not exceed 2 m; the
maximum number of elbows is 2.
The discharge line must be accessible and observable.

Mounting and commissioning
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Drain the liquid discharged via the discharge line into a
container that can hold the total capacity of the system.
The discharged liquid must be collected and returned to
the system or disposed of by a specialised company.
Do not drain the discharged liquid into the sewage sys-
tem.

Mounting and commissioning
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6.3 Electrical connection
Mains voltage is interrupted and cannot be switched on.
1. Connect the circulation pump described in the enclosed
operating instructions.
2. Route the connection cable of the circulation pump
through a cable duct to the bottom and connect it to the
solar controller. Observe the operating instructions of the
solar controller.
3. Standard shielded cable 3 x 1.5 mm² and up to Ø 10 mm
can be used to extend the connection cable.
6.4 Commissioning DAIKIN EKSRDS2A
In the case of DAIKIN EKSRDS2A, filling is possible via the fill-
ing and flushing valves at the flow meter.
1. Attach a label in the vicinity of the discharge line or to the
safety valve with the following text:
"For safety reasons, liquid must be able to escape via
the discharge line during heating. Do not shut off!"
2. Verify that all connections are tight.
3. Set both ball valves to 45° position.
0°
Operation –open in the direc-
tion of flow of the solar liquid
45°
Commissioning, filling, vent-
ing, flushing –both sides open
(backflow preventer not active)
90°
Maintenance –closed
Fig. 6: Ball valves

Mounting and commissioning
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4. Screw hose connectors to the filling and flushing valves
and connect hoses. Open the shut-off valves (1, 2) and
close the shut-off (3) for filling.
5. Fill the system with solar liquid via the upper valve (1).
6. As soon as solar liquid escapes via valve (2), close this
valve.
7. Apply pressure to the system.
8. Close the upper valve. Turn back the shut-off (3).
9. Vent the system, see chapter 7.2, page 21.
10. Set both ball valves to 0° position.
11. Fit the upper part of the heat insulation onto the fitting
group.
12. The heat insulation of the pipes should reach into the cor-
responding recess of the heat insulation of the solar pump
assembly.
The solar pump assembly is ready for operation.

Operation
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7 Operation
For safety reasons, liquid must be able to escape via the dis-
charge line of the safety valve during heating.
Do not shut off the safety valve.
If the safety valve has responded, check the system prior
to resuming operation.
Proper operation is only possible if the ball valves are open (0°
setting, see fig. 6, page 18).
7.1 Reading mark at flow meter
The lower edge of the float is the reading mark at the flow me-
ter.
Fig. 7: Reading mark at flow meter