STI SOLBOX User manual

sti-solar.de
SOLARE KOMPETENZ
AUS SACHSEN
sti-solar.de
ASSEMBLY INSTRUCTION
SOLBOX

2
Table of contents
Content Page
Technical data 3
Structure of the SolBox 4
Installation scheme 7
Assembly of the SolBox 8
Hydraulic connection collector eld 9
Filling of the SolBox 10
Initial operation of the SolBox 11
Fast operation 16
SolBox extension 17
Connection of the SolBox with the extension module 19
Capacities 21
Initial operation 23
Scheme of the installation 24
Notes 26

3
1.100 mm
400 mm
SolBox Specications
Collector eld size up to 25 m²
Control unit TDC
High-e󰀩ciency pump for discharge heads up to 11 m, optionally expandable up to bis 22 m,
according to the standard EU Norm 2015
Solar station comprising a rinsing and lling unit DN 20 and a safety valve 6 bar including
Manometer a maximum operating pressure 6 bar
Weight ca. 23 kg (without liquid) // ca. 65 kg (with liquid)
Capacity 40 l
Insulation 50 mm according to the latest standard DIN EN13501-1
Power connection 230 V
Material Container steel, untreated // not suitable for drinking water
Technical data

4
Connections on top
AG 3/4“ AG 3/4“
Collector connection cold
(2)
Collector connection hot
(1)
Venting unit // AG 3/4“
(3)
Illustration 1
Control
unit (4)
Controller pump
temperature sensor
input
Power cable pump
Power cable/plug
controller
Illustration 2
Controller
Structure of the SolBox

5
Connections at
the bottom
AG 3/4“
Heat exchanger connection
hot (6)
High-e󰀩ciency pump
(5)
AG 3/4“
Connection lling unit
(7)
Connection lling unit
(9)
Ball valve
lling unit
(8)
1/2“ connection pipe //
AG 3/4“
Illustration 3
Heat exchanger connection
cold
(10)
Illustration 4
Structure of the SolBox

6
Manometer
(11)
Safety valve 6 bar
(12)
IG 3/4“
Illustration 5
Connections at
the bottom
Technical data
Closure cap (13)

7
A
Installation scheme
cold side
Hot side
Static height
When assembling the SolBox, please note the distance which results from measure A:
- bottom edge of the collector // upper edge of the SolBox - minimum distance of 100 mm
- center pump SolBox // connection of the uppermost solar heat exchanger -
minimum distance of 100 mm
Illustration 6
Supply of cold water
Tank
Extraction of hot water
Installtion scheme as an example
SolBox
Collector eld
Please pay attention that the roof feed-through of
the pipe is urgently required to happen below the
hydraulical connection.
Installation scheme
A
max. 11 m

8
240 mm
240 mm
124 mm
11 mm
The assembly of the SolBox happens at the
three xing points at the back.
Prior to the beginning of the assemly it
is necessary to inspect the sustainability
of the building ground by the customer.
Subsequently, dimensions and style of
the xtures have to be adjusted and to be
provided by the customer.
After placing of the xtures, the SolBox has
to be hooked in the xing points and needs to
be secured.
Now install further pipelines in the solar
systems. Pay attention to the accurate
connection of the pipelines upon the collectors
- see illustration 6.
Connect the pipelines comming from the
collectors with the designated connections
(1) and (2) at the SolBox - see illustration 1.
Please pay attention that the pipelines have
to be installed with downgrade from the
collectors towards the SolBox.
notice total weight of 65 kg
Illustration 8
Connect the SolBox with the heat
exchanger in the storage tank. For this
purpose use the connections (6) and (10).
Please pay attention that the pipelines
have to be installed with downgrade from
the SolBox to the heat exchanger in the
storage tank.
Apply the prewired sensor at designated
place at the storage tank and secure it -
see illustration 2.
Install further sensors and wire these
with the solar controller - see assembly
instruction solar controller.
Plug in the power plug of the solar
controller - see illustration 2.
Assembly of the SolBox

9
hot side
1 - 6
collectors
1
hot side
1 - 15
collectors
1, 2
cold side
hot side
Multi-row
collector elds
1, 2
1) Only applies for collectors of the STI GmbH.
2) Please consider the size of the collector eld! For collector elds of more than 30 m², please ask for the
extension of the SolBoxn with your supplier.
For the combination with the SolBox, only self-draining collectors can be used. If you should
have any questions, please contact your supplier!
Illustration 7
Hydraulic connection collector eld
cold side
cold side

10
General
Now ll the system with a suitable glycol-water mixture via the lling unit on the SolBox using a lling
station.
First determine the lling quantity using the table on page 22.
Filling quantity = collector content + content pipes + content heat exchanger + content SolBox
Volumes
- The volume of the collectors is shown in the table on page 21.
- Refer to tables 4 and 5 on page 22 or the manufacturer’s specications for the volume of the lines.
- The volume of the heat exchanger can be taken from the information on the storage tank, the fresh
water station or the external plate heat exchanger.
- The SolBox has a volume of 40 l. When lling, make sure that the glycol-water mixture is pumped
into the system at room temperature (15° - 25°C).
Filling of the installation Operation of the installation
Connection lling unit
(7)
Connection lling unit
(9)
Ball valve
lling unit
(8)
Illustration 9
Filling of the SolBox

11
Now connect a hose, which pumps the glycol-
water mixture from the lling station into the
system, to the connection (9). The ball valve
at connection (9) is opened - see gure 4 // 10.
The tap (8) is closed - see gure 4 // 10.
A hose is also connected to connection (7).
This leads back into the container of the lling
station. The ball valve on connection (7) is
opened - see gure 4 // 10.
Now pump the glycol-water mixture with
the lling station into the system until liquid
emerges at connection (7). Switch o󰀨 the lling
station and close the ball valves at connection
(7) and (9).
Step 1: Filling of the installation
Now open the tap (8) and let the system run
in manual mode for approx. 15 minutes - see
installation instructions for the controller - in
order to trap any air pockets from the system
in the SolBox.
Initial operation of the SolBox

12
3
Now connect a hose to the breather unit (3)
- see gure 1. The hose leads back into the
container of the lling station. The ball valve
on the breather unit (3) is opened.
Connect a hose, which pumps the glycol-
water mixture from the lling station into the
system, to the connection (7). The ball valve
at connection (7) is opened - see gure 4 // 9.
The valves (8) and (9) are closed.
Now pump the glycol-water mixture into the
system again using the lling station until
glycol-water mixture emerges at the bleeding
unit. The system is now lled.
Now partially empty the system to obtain the necessary air volume in the system.
Step 2: Venting the system
Initial operation of the SolBox

13
3
Draining volume = collector content + volume collection pipe + expansion volume
Volumes
The volume of the collectors - see Table 1 on
page 22.
If the collectors are installed in several rows
one above the other, lateral collecting lines
are installed for hydraulic connection of the
collector row.
A collecting pipe set (2 collecting pipes)
contains 2 l of liquid.
In addition to the volume of the collectors, the
expansion of the liquid when the temperature
rises must also be taken into account.
Sample calculation:
6 collectors 240 H, two rows,
Collection pipe set
Filling quantity: 80 l
Volume collectors: 16 l
Volume collection pipe: 2 l
Volume expansion: 6 l
Total: 24 l
Step 3: Partial emptying of the system
After the emptying volume has been
determined, drain the exact volume from the
system.
To do this, connect a hose to the breather
unit (3) - see Figure 1 - which leads into
a collecting vessel. The ball valve on the
breather unit (3) is opened.
Continue to connect a hose to the lling unit
(7) - see Figure 4 // 10 - which also leads into
the collecting vessel.
The ball valve (7) is opened. The valves (8)
and (9) remain closed.
Now drain the exact volume from the system
according to the previous determination!
After the emptying volume has been drained,
the ball valve on the venting unit (3) and on
the lling unit (7) is closed.
Initial operation of the SolBox
First, determine the draining volume by using the overview below.
Depending on the system content of the solar
system, expansion volume must therefore
be drained - see Table 3.

14
Step 4: Enhancement of the pressure
To prevent a negative pressure within the system it is recommended to run the system with
approx. 0.5 bar pressure (above system pressure from static height).
Option I - Enhancement of the pressure with compressor
- Connect a compressor with the venting unit (3) and open the ball valve - see illustration 1.
- Increase the pressure about 0.5 bar (to be read o󰀨 at the manometer).
- Pay attention that the pre-pressure in the compressor is situated higher than the installation pressure.
Otherwise solar uid may pour into the compressor.
Initial operation of the SolBox

15
Option II - Enhancement of the pressure through additional draining and lling
For that, rst determine the installation volume by the overview below.
- In dependency to the installation volume now a dened volume is released from the system - see
table 2.
- Connect a pipe with the venting unit (3) - see illustration 1. The pipe leads back to the container of
the lling station. Now the ball valve at the venting unit (3) needs to be opened.
- Further, connect a pipe with the lling station (7) that leads to the container as well.
- Now the ball valve (7) needs to be opened. The ball valves (8) and (9) stay closed.
- Next release the exact colume according to previous determination from the system!
- After releasing the draining volume, the ball valve at the venting unit (3) needs to be closed.
- Now pump the drained uid back into the system by connection (7) of the lling station. Close the
ball valve of the lling station (7).
installation volume = lling vol. - draining vol.
Important: Please note that the uid in the installation needs to be able to circulate
free in any direction. No automatic barrier systems may be installed in the whole solar
system.
Initial operation of the SolBox

16
This fast operation is only for expert installers who are familiar with the setup and functioning
of drain back systems.
The following instruction gives a description of a fast and easy way to take the system into operation.
Assembly and installation
Assemble the system and install all pipelines - see “Installation scheme” at page 7.
Specication of draining volume
Calculate or specify the draining volume - see “Initial operation of the SolBox” at page 11.
Filling and venting
Fill and vent the system completely through the lling station - see “Draining volume” at page 13.
Release of draining volume
Release the calculated or specied draining volume from the installation - see “Draining volume” at
page 13.
Testing the system pressure
Test the pressure of the installation. When lling the installation in a warm condition, a low pressure
may occur after cooling down of the solar circle. To compensate this, open the ball valve at the venting
unit (3) shortly and even up the occured low pressure.
Fast operation

17
Technical data
SolBox extension Specications
Collector eld size up to 50 m² (in connection with the SolBox)
Measures diameter: 400 mm, height: 800 mm
Weight ca. 23 kg (without liquid) // ca. 65 kg (with liquid)
Capacity 40 l
Insulation 50 mm according to the latest DIN EN13501-1
Material container made of steel, untreated // not suitable for drinking water
SolBox extension

18
240 mm
11 mm
500 mm
124 mm
240 mm
The assembly of the SolBox extension
module takes place at the three xation points
at the back of the module. Prior to starting
the assembly, it is necessary to check the
building site for its load capacity.
Dimension and type of the fastening material
have to be adjusted hereon and will be
e󰀨ected by the customer.
Assembly SolBox extension module
Please pay attention to the overall weight of 65 kg.
Illustration 10
For a proper functionality, the extension
module has to be assembled at the same
level as the SolBox.
After placing the fastening material, the
SolBox will be hooked into the xtation
points and xed there.
Assembly SolBox extension module
Required space: ca. 900 mm

19
Remove the drain plug at the venting unit of the
SolBox and install it into the lateral outow of the
upper T-piece of the SolBox.
Install the double connection 1/2“ into the T-piece
of the venting unit of the SolBox.
Install the stainless steel corrugated pipe DN15
at the venting unit of the Solbox and connect it
with the upper T-piece of the SolBox extension
module.
Connection of the SolBox with the
extension module

20
Install the stainless steel corrugated pipe
DN20 at the bottom of the SolBox and
connect it with the bottom of the SolBox
extension module.
Remove the end cap at the bottom of the
SolBox.
Connection of the SolBox with the
extension module