Kioto Solar SL 50 e User manual

InstallatIon and operatIng manual Stratified Charging Station
1
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Installation and operating manual
STRATIFIED CHARGING STATION EN
SL 50 E
March 2016

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Table of content
General 3
Use 3
Application example 3
Description 3
Warning 3
Warranty 3
Structure of the stratied charging station 4
Technical Data 5
Installation and Commissioning 6
Installation 6
Positioning 6
Wall mounting 6
Drilling plan 7
Buffer mounting 8
Hydraulic connections 9
Electrical connections 9
Commissioning 9
 Fillingandushingofcollectorcircuit 10
Regulations 11
Pump characteristic lines 11

InstallatIon and operatIng manual Stratified Charging Station
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General
Beforeyouinstallyournewstratiedchargingstation,pleasereadallchaptersthoroughlyandpayspecialattentiontowar-
nings provided in chapter "Warning". Incorrect handling can result in damage to the installation.
Use
TheSL50Estratiedchargingstationenablestheloadingofabuffertankdependingonthetemperature.
Stratiedlayerloadingisspeedregulated,energyefcientandsuitableforlargebuffertanks.
Application example
S3
S1
S5
S7
Speicher 1
V1
(P2)(P1)
R4
R3R1
S2
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
S2 S3 S4 S5 S6 S7 S8
R4 R5
IP20
R5
N
R1-R4
100 ... 240 V~
50-60 Hz
T4A
1 (1) A (100 ... 240) V~
4 (1) A 240 V~
4 (1) A 24V
R5
R3 R2 R1
L' L
Temp. Sensor
RPD
N
Isolate mains before removing cover!
Vor Öffnen Gerät spannungslos schalten!
Use ground common terminal block
Masse-Sammelklemme benutzen
Use neutral conductor common terminal block
Neutralleiter-Sammelklemme benutzen!
Use PE Common terminal block
Schutzleiter-Sammelklemme benutzen
VFD
DeltaSol®BX PlusV2
KIOTO Clear Energy AG
A - 9300 St.Veit a.d. Glan
S9
V40 S10 V40
PWMA
0-10V
PWMB
0-10V
PWMC
0-10V
PWMD
0-10V
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CS10 VBus
Description
TheSL50Estratiedchargingstationisusedforconnectingasolarcollectorsystemofupto50m²toabuffertank.
Thesolarheatfromthecollectorsystemistransferredtothebuffersystemwithhighly-efcientheatexchangers.Thereby,it
providesanintelligentcontrolsystem,dependentonsunlight,foroptimuminteractionbetweenthesolarandbufferloading
pumpandguaranteeshighheattransfercapacity.Thestationisspeedregulatedfromthebuffersideanddependentonthe
temperatureoftherespectivetanktemperaturezone.
Warning
• Installationandoperationshouldbeexecutedinaccordancewiththelocallyapplicablespecicationsandstandardpractices.
• Onlyqualiedtechnicalpersonnelmaycarryoutinstallation,maintenanceandcleaningofthelayerloadingstation.
• Unauthorisedmodicationsorchangesarenotpermittedforsafetyreasonsandwillinevitablyleadtothevoidingofthe
warranty for the machine.
• Theoperatingpressuresprovidedmaynotbeexceeded!
• Ifanyerrorsoccur–nomatterofwhattype–pleasecontactyourinstaller.Pleasedonotcarryoutanyrepairsyourself,
sincethesearenotpermittedbylawandyoucanexposeyourselftohazardsasaresult.
Warranty
The manufacturer provides a warranty of 2 years from the date of delivery on the supplied products and components.
Unauthorisedmodicationsorchangesarenotpermittedforsafetyreasonsandwillinevitablyleadtothevoidingofthewarrantyforthemachine.
Forfurtherinformationseewww.kiotosolar.com

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3
7
5
8
9
4
1
2
6
FG
E
D
C
A
B
H
10
11
12
13
14
1 Temperaturesensorbufferow
2Actuator (electrical)
3Plate heat exchanger
4Resetvalvebuffercircuit
5High-efciencypumpbuffercircuit
6Flowmeterbuffercircuit(electronic)
7Pressurereliefvalve6bar
8Resetvalvesolarcircuit,returnow
9 Manometer
10 High-efcientpumpsolarcircuit
11 Flow meter solar circuit (mechanical)
12 Solar vent
13 Valvesolarow
14 Temperaturesensorsolarowline
Connections
AKFEvalveAllingnozzlesolar
BKFEvalveBdrainingnozzlesolar
CBuffer return
DBufferowlinecentre
EBufferowlinetop
FSolarowline
GSolar return line
HExpansiontank
Structure of the stratied charging station
Duetotechnicaladvancements,wereservetherighttomakeconstructionalchangesonourproducts.Eachofthese
changesaretakenintoconsiderationintheoperatingmanualbyreplacingtherespectivepages.
Thestationappearancemaysometimesvaryfromtheillustration!

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Technical Data
Stratied charging Station SL 50 E
Width x Height x Depth [mm] 496 x 930 x 325
Cover EPP black
Solar piping [mm] Copper pipe - Ø 22 x 0,8
Buffer piping [mm] Metal hose stainless steel 1.4404 - Ø 26,2 x 0,18
Weight [kg] 25
Connections
AKFEvalvellingnozzle G ¾" AG
BKFEvalvepurgingnozzle G ¾" AG
CBufferreturnlinecoldballvalve G1" AG
DBufferinowlinewarmballvalve G1" AG
EBufferinowlinehotballvalve G1" AG
FSolarinowline G1" AG
G Solar return line G1" AG
HExpansiontank G¾" AG
Maximum operating pressure
Collectorcircuit[bar] max. 6
Buffercircuit[bar] max. 3
Solar pump Yonos Para HU 25/7.0
Nominalvoltage[VAC/Hz] 230 / 50
Nominaloutput[W] 3 - 45
max.deliveryheight[m] max. 7
Buffer charging pump Yonos Para HU 25/7.0
Nominalvoltage[V/Hz] 230 / 50
Nominaloutput[W] 3 - 45
max.deliveryheight[m] max. 7
Plate heat exchanger (glycol/water)
Power[kW] 26
Inlettemperature[°C](glycol/water) 60 / 29
Outlettemperature[°C](glycol/water) 35 / 54
Flowrateamount[l/h] 1000

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Installation and Commissioning
Installation
Theerectionandinstallationmustbedonebyanapprovedtechnicalfacility.Thisfacilitywillalsotakeontheresponsibility
forcorrectinstallationandcommissioning.Adry,frost-freeroomthatprovidessufcientspaceformaintenancework
is requried as the installation site.
Thestratiedchargingstationmustbeinstalledsothatitisprotectedfromsplashingwaterandmayonlyberunatroom
temperaturesbelow40℃.
Positioning
Itisrecommendedthatinstallationtakeplacenearthebuffertankinordertopreventheatloss.
Thisshouldtakeplaceonalevelandstructurallysuitablesurfacethatisprovidedforlevelingadjustablestandfeet.
Pulling too hard on the installation screws damages the isolation.
Wall installation
Wallinstallationtakesplaceasfollowswiththeincludedattachmentmaterial
(3xM8stairbolts,M8nutsand3M8washers):
• Drill at least 8 cm deep on the designated drill points with a ø 10 mm drill according to the drillling template included.
• Afterwards,insertthewallplugintotheholeandscrewthestairboltsintothewalluntilthewallplugthreadsarenolongervisible.
• Now,hangthestratiedchargingstationonthethreadedstudsandinstallitwithnutsandwashers.

InstallatIon and operatIng manual Stratified Charging Station
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Drillling template for wall installation
496
930
154
745
591
120
35,7
31,8

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Tank installation
Thebuffersensorinthebufferterminalblockismountedbeforethestationisassembled.
• Step 1
Beforemountungthestratiedstationthebuffersensorshavetobemounted.
• Step 2
Installandtightenthe3threadedboltsandthe3corrugatedtubeincl.sealsontotherespectivetankconnectors.
• Step 3
Slidethestratiedchargingstationoverthecorrugatedtubesandthethreadedboltsandfastenthestationtothetank
using washers and nuts.
• Step 4
Tightenthe3corrugatedtubestothestationwiththeseals.
max. 70 Nm
max. 10 Nm
max. 70 Nm
Dichtung immer zwischen
Kugelhahn und Ringwellschlauch
1
3
2
4
Schnitt C-C
M1 : 6
C
S7
S2
TRENNBLECH

InstallatIon and operatIng manual Stratified Charging Station
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Hydraulic connection
Lineconnectiontakesplaceaccordingtotheinstallationlayoutinthismanual,(see"Applicationexample")
• Thelinepathstothebuffershouldbeasshortaspossible!
• We recommend steel or copper piping as line material.
Theinstallationorderhastobefollowedforalllinesandttingsinordertopreventelectro-chemicalcorrosion.
• Installationofagravitationalheatingsystemisnotpermitted!
• Connectionofthecollectioncircuitexpansiontankmusttakeplaceasadirectconnection.
• Installationofshut-offvalves(exceptforsuitablemaintenancemoduleslikecapvalves)isnotpermitted!
• Connectionshavetobetightenedonlyafterthetubinghasbeensealed.Tighteningtorqueand/orforceeffectson
preinstalledstationcomponentsandjointsmustbeavoided!
Additionally,checkallatsealingscrewsforproperswivelnuttighteningtorque(screwscanbecomelooseduringtransport!).
Electrical connections
Internalwiringofelectricalequipmentisconductedonsite.Connectiontothepowersupply(230V/AC,50Hz)takesplaceby
meansofthepreclampedsupplycable.
Thebuffersensorsincludedareinstalledontherespectivebuffertankmeteringpointsandconnectedtotheaffectedcontrol
clampsaswellasthecollectorsensorincludedinthescopeofdelivery.Detailledinformationabouttheintegratedcontrolin
thestationcanbefoundinthecontrollermanual.
Workonlivestationpartsmustonlytakeplaceunderconsiderationfortherespectiveguidelinesofthepowercompanyand
valid,correspondingstandards.
Commissioning
Onlyusewaterpreparedaccordingtothestandards(e.g.ÖNORMH5195-1:2010).Alllinesmustbediffusionresistant.
Fillingandcommissioningmustbedonebyanapprovedtechnicalfacilityandconcessionarypersonnel.Here,thefunctionand
tightnessagainstleaksoftheentireplantincludingthepartsassembledinthemanufacturingworksshouldbechecked.Safety
valvefunctionalityhastobecheckedatregularintervals.Annualmaintenancebyanapprovedtechnicalfacilityisrecommended.
Slowlyopeningtheballvalveonthestationinletsandoutletspreventspressureblowsduringcleaningmode.Usethecleaning
connectionsprovidedforllingthecollectorcircuit.See"Stucture".
Thellingandrinsingmustbecarriedoutuntilitisensuredthatthesystemiscompletelyde-aerated.Flownoisesduringbuf-
ferpumpoperationindicatethatthereisstillairinthemachinethatcanberemovedviathepumpandmanualprimer.
Closethecollectorreturnlineattheendofthellingprocessandadjustthesystempressuretoapprox.3bar(thisappliesto
expansiontankswithasystempressureof2.5bar,thestaticheightofthemachinemustbetakenintoconsiderationaswell).
Beforeopeningthecontrolboxhousing,ensurethatitisdisconnectedfromthepowersupply!
Donotllindirectsunlight,becausethiscanleadtosteamhammering!

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Cleaning and lling the collector circuit
Thellingandrinsingmustbecarriedoutuntilitisensuredthatthesystemiscompletelyde-aerated.Flownoisesduring
collectorpumpoperationindicatethatthereisstillairinthemachinethatcanberemovedviathemanualprimer
Beforestartingwiththecleaningand/orllingprocess,pleasereadcarefullythroughthefollowingpointsthoroughly!
Solar-side (collector side)
• Onlyglycolwatermixtures(frost-resistanttoatleast-25°)maybeusedforllingthesolarcircuit
• Beforestartingwithcleaningandlling,ensurethatallconnections(solarforward/returnows,etc.)
are provided with correct seals and are tightly connected.
• ConnectthellpumpforwardowtoKFEvalveA(llingnozzle).
• ConnectthellpumpreturnowtoKFEvalveB(purgingnozzle).
• First,openKFEvalveA(handleinowdirection).
• Now,openKFEvalveB(handleinowdirection).
• Startthecleaningprocessofthesolarcircuitbyswitchingonthellingpump.
• Letthepumprununtiltheglycolwatermixtureowsbackintothetankwithoutbubbles.
• CloseKFEvalveB(handleagainstowdirection).
• Pay attention to the gauge.
• Whenthegaugehasreachedthedesiredoperatingpressure,closeKFEvalveA(handleagainstowdirection).
• Now,thepumpcanbeswitchedoffandthellingpumpconnectionscanbedisconnectedfromtheKFEvalvesAandB.
• Thesolarcircuitisnowcompletelylledandreadyforuse.
• Shouldairnoisebediscoveredinthecircuitduringoperation,thenbeginwithpoint1again.
Buffer-side
• OnlyheatingwatermustbeusedaccordingtonormÖNORMH5195-1:2010forllingthebuffercircuitandbuffertank.
• Beforestartingtoconnecttheconnectionlinesfromthestationtothebuffertank,
closeballvalvesC,DandE(handleagainstowdirection)onthestation
• Beforestartingthelling,makecertainthatallconnectionsareprovidedwithcorrectsealsandaretight.
• Now,openallvalvestotheconnectionlinesonthebuffertank.
• Now,openvalveC,thenvalveDandnallyvalveEonthestation.
• Ifnowaternoiseisheard,switchthebuffercircuitpumponmanually.
• Letthisprocessrunforseveralminutes.Afterwards,switchthepumpoff.
• Ventthebuffertankandtop-offwithheaterwaterifnecessary.
• Thebuffercircuitisnowcompletelylledandreadyforuse.

InstallatIon and operatIng manual Stratified Charging Station
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Pump characteristic lines
Regulations
Thestationistobeconnectedwithconsiderationtothefollowingnorms,country-specicguidelines
and local water company regulations.
• DINEN12828  Heatingsystemsinbuildings
• DIN1988   Technicalrulesfordrinkingwatersupplyinstallation
• DIN 4708 Central heat water installations
• DIN 4751 Heating system safety equipment
• DIN4753   Waterheaterandwaterheatingsystemfordrinkingwaterandservicewater
• DIN 4757 Solar heating and solar-thermal systems
• DIN 18380 Central heating systems and service water systems
• DIN18381   Gas,wateranddrainageinstallationworks
• DIN18382   Electricalcableandwiringsystemsinbuildings
• DIN EN 12975 Thermal solar systems and their components
• VDE 0100 Setting up electrical operating equipment
• VDE 0185 General notes for setting up lightning protection systems
• VDE 0190 Main potential equalisation of electrical systems
• ÖNORMENISO9488 Solarenergy–Vocabulary(ISO9488:1999)
• ÖNORM ENV 12977-1 Thermal solar system and their components – customised systems
• ÖNORMM7700  Solarenergy-termswithdenitions
• ÖNORM M7701 Solar engineering systems - approximation methods for measuring
•     atcollectorsinhotwatertreatmentsystems
• ÖNORM M7731 Solar heating plants for heating water – requirements and tests

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