Kaukora FIL-SPL User manual

FIL-SPL
Flow-through heater for central heating
with 0 - 10 V EP 15-30 control unit
USER MANUAL
Kaukora LTD.
D106159 r3.0

Contents
1. Important information .............................................................................................................................. 5
Safety information......................................................................................................................................... 5
General .......................................................................................................................................................... 5
Marking.......................................................................................................................................................... 5
Serial number ................................................................................................................................................ 5
Inspection of the installation......................................................................................................................... 6
2. Delivery and handling................................................................................................................................ 7
Transport ....................................................................................................................................................... 7
Physical installation ....................................................................................................................................... 7
Supplied components.................................................................................................................................... 7
3. Structure and measures of FIL-SPL boilers ................................................................................................ 8
Models of 31 - 112 kW .................................................................................................................................. 8
Models of 150 - 300 kW ................................................................................................................................ 9
Models of 400 - 1600 kW ............................................................................................................................ 10
4. Pipe connections ..................................................................................................................................... 11
General pipe connections............................................................................................................................ 11
System diagram ........................................................................................................................................... 12
5. Electrical connections.............................................................................................................................. 13
General ........................................................................................................................................................ 13
Connections................................................................................................................................................. 14
Optional connections .................................................................................................................................. 15
6. Commissioning and adjusting.................................................................................................................. 21
Preparations ................................................................................................................................................ 21
Filling and venting........................................................................................................................................ 21
Start-up and inspections.............................................................................................................................. 21
7. Control..................................................................................................................................................... 22
Display unit.................................................................................................................................................. 22
Menu system ............................................................................................................................................... 23
8. Control - Menus....................................................................................................................................... 24
Menu 1 - Info ............................................................................................................................................... 24
Menu 1.1 Temp ....................................................................................................................................... 24
Menu 1.1.1/1 Setting............................................................................................................................... 24
Menu 1.1.1/2 OutdoorComp................................................................................................................... 25
Menu 1.2 Step ......................................................................................................................................... 26
Menu 1.3 AC in ........................................................................................................................................ 26

Menu 2 - Service.......................................................................................................................................... 27
Menu 2.1 Step ......................................................................................................................................... 27
Menu 2.1.1 Max....................................................................................................................................... 27
Menu 2.1.2 Time...................................................................................................................................... 27
Menu 2.2 Current .................................................................................................................................... 27
Menu 2.2.1 Max....................................................................................................................................... 28
Menu 2.2.2 Marginal ............................................................................................................................... 28
Menu 2.3 Effect factor............................................................................................................................. 29
Menu 2.4 S.time test ............................................................................................................................... 29
Menu 3 - Test manually............................................................................................................................... 30
Menu 3.1 Contactor 1.............................................................................................................................. 30
Menu 3.2 Contactor 2.............................................................................................................................. 30
Menu 3.3 Contactor 3.............................................................................................................................. 30
Menu 3.4 Contactor 4.............................................................................................................................. 30
Menu 3.5 Alarm....................................................................................................................................... 30
Menu 3.6 0 –10 V.................................................................................................................................... 30
Menu 4 - Setup ............................................................................................................................................ 31
Menu 4.1 Language (selected language)................................................................................................. 31
Menu 4.2 Model ...................................................................................................................................... 31
Menu 4.3 Input........................................................................................................................................ 31
Menu 4.4 Output ..................................................................................................................................... 32
Menu 4.5 OutdoorComp ......................................................................................................................... 32
9. Service ..................................................................................................................................................... 33
Service actions............................................................................................................................................. 33
Backup mode........................................................................................................................................... 33
10. Disturbances in comfort ...................................................................................................................... 34
Troubleshooting .......................................................................................................................................... 34
11. Accessories .......................................................................................................................................... 35
Jäspi current transformers (200 018) .......................................................................................................... 35
Jäspi outdoor temperature sensor (200 035).............................................................................................. 35
12. Technical data...................................................................................................................................... 36
Technical specifications............................................................................................................................... 36
Electrical properties of FIL-SPL boilers ........................................................................................................ 37
External control voltage (input) values and corresponding power steps in different modes. ................... 38
Status output voltage values and corresponding status data in different modes...................................... 39
Temperature sensor resistance values in different temperatures ............................................................. 40

Recommended circulation pumps............................................................................................................... 41
Pressure drop table ..................................................................................................................................... 42
Electrical circuit diagrams, models of 31 - 112 kW ..................................................................................... 43
Electrical circuit diagrams, models of 150 - 300 kW ................................................................................... 46
Electrical circuit diagrams, models of 400 - 1600 kW ................................................................................. 49

1. Important information
Safety information
This appliance is not intended for use by children or persons, whose physical,
sensory or mental disabilities or lack of experience and knowledge would prevent
the safe use of the appliance, if they are not under the supervision of a person
responsible for ensuring their safety or have been training in the proper use of the
appliance.
Rights to make any design or technical modifications are reserved.
General
This user manual must be left with the customer.
Note! After the main switch has tripped, ensure that the main switch is reset by first positioning the switch
to “0” (off) and then back to “I” (on) position.
Note! When the temperature limiter, dry-boiling preventer or current limit in the main switch are activated,
the main switch is tripped.
Note! Always use original or equivalent spare parts.
Note! Check and tighten the boiler's wire connections after 100 operating hours and then at least once a
year.
Marking
FIL-SPL is CE marked and fulfills IP20.
The CE marking means that Kaukora ensures that the product meets all regulations that are placed on it
based on relevant EU directives. The CE mark is obligatory for most products sold in the EU, regardless
where they are made.
Serial number
The serial number can be found from the type plate at the left side of the boiler, on the top right corner.
Note! Always give the product's serial number when reporting a fault.

Inspection of the installation
Current regulations require the heating installation to be inspected before it is commissioned. The
inspection must be carried out by a suitably qualified person. Fill in the page for information about
installation data.
INSTALLATION INSPECTION
Description
Notes (fill: OK / YES / NO/ NA / write more info)
Heating medium
Water circulation system
installed accordingly
Safety valve installed accordingly
Installations according to HVAC
diagram
System is vented
Pressure of the system
__________ bar
Plumping installation company:
Telephone:
Installer:
Date:
Signature:
______________________________
______________________________
______________________________
______________________________
Electrical connections
Main fuses (of the property)
__________ A
Fuses of FIL-SPL
__________ A
Primary side current transformers
installed
conversion ratio: __________
Secondary side current
transformers installed
Current transformer for
observation of internal power
consumption installed
Power limitation taken into use
Electrical installation company:
Telephone:
Installer:
Date:
Signature:
______________________________
______________________________
______________________________
______________________________
Settings
Max. number of allowable power
steps (Menu 2.1.1 Max)
Step time (Menu 2.1.2 Time)
Max. current limit
(Menu 2.2.1 Max)
Miscellaneous
Serial number
Currently measured boiler
temperature
__________ °C
Functionality tested and approved
Note! The installation inspection must be filled for
meeting requirements for manufacturers guarantee.

2. Delivery and handling
Transport
The FIL-SPL must be transported and stored vertically in a dry place. The FIL-SPL boiler should be lifted only
from the lifting point on top of the boiler.
Physical installation
Mount FIL-SPL boiler on a firm base that can take the weight, preferably on a concrete floor or foundation.
The boiler must be mounted in an upright position and bolted on the floor, preferably in a dry and warm
space with a floor drain.
A clearance of approximately 300-500 mm must be left behind the boiler for pipe connections and for
ventilation. According to safety regulations, at least 1 meter of free space must be left in front of the boiler.
With models from 31.5 to 300 kW, either side of the boiler may be close to a wall. With these models,
approximately 1 meter space should be left above the boiler for possibly replacing resistor elements.
With models from 400 to 1600 kW, there must be left space for possibly replacing resistor elements that
are located on one side that is depending on construction. With these models pipe and electrical
connections are on the top of the boiler and thus requires space.
Note! When selecting mounting location, bear in mind that pipe installations, control valves and other
plumping arrangements needs also space.
Note! Leave enough space for servicing boiler and external circulation pump.
Supplied components
Jäspi current transformers can be ordered as an accessory. The Jäspi current transformers can be used as
secondary current transformers for load monitoring of main fuses or for observation of internal power
consumption for alarm. If both properties are needed, one set of Jäspi current transformers and one extra
Jäspi current transformer must be ordered. The transform ratio of Jäspi current transformers is 300/1.

3. Structure and measures of FIL-SPL boilers
Models of 31 - 112 kW
No.
Name
1
Safety main switch (CB + switch disconnector + trip)
2
Control unit
3
Temperature gauge
4
Control voltage switch
5
Heating mode selection switch
6
Temperature limiter
7
Placeholder for sensor of dry-boiling preventer
9
Connection for draining
10
Placeholder for electrical cables
11
Lifting point

Models of 150 - 300 kW
No.
Name
1
Safety main switch (CB + switch disconnector + trip)
2
Control unit
3
Temperature gauge
4
Control voltage switch
5
Heating mode selection switch
6
Temperature limiter
7
Sensor of dry-boiling preventer
8
Dry-boiling preventing unit
9
Connection for draining
10
Placeholder for electrical cables
11
Lifting point

Models of 400 - 1600 kW
No.
Name
1
Safety main switch
(CB + switch disconnector + trip)
2
Power step contactors
3
Power step fuses
4
Heating mode selection switch
5
Control voltage switch
6
Dry-boiling preventing unit
7
Control unit
8
Backup heating thermostat
9
Connectors
10
Time delay relay
11
Control voltage transformer
12
Placeholder for electrical cables
13
Sensor of dry-boiling preventer
14
Temperature sensors
(limiters and thermostat)
15
Heating elements
16
Connection for draining
17
Temperature gauge
18
Thermostat/temperature limiter
19
Door for heating element service
20
Required space for service of
heating elements
21
Lifting point
A
2000 mm
B
1150 mm
C
1800 mm for 400…800 kW
2000 mm for 801…1200 kW
2400 mm for 1201…1600 kW