Kaukora FIL-SPL User Manual Download

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FIL-SPL

Flow-through heater for central heating

with 0 - 10 V EP 15-30 control unit

USER MANUAL

Kaukora LTD.

D106159 r3.0

Summary of Contents for FIL-SPL

Page 1: ...FIL SPL Flow through heater for central heating with 0 10 V EP 15 30 control unit USER MANUAL Kaukora LTD D106159 r3 0 ...

Page 2: ...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 ...

Page 3: ... 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 value...

Page 4: ...mended 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 ...

Page 5: ... 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 marki...

Page 6: ..._ ______________________________ 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 Instal...

Page 7: ... 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 i...

Page 8: ...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 ...

Page 9: ...ector 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 ...

Page 10: ...0 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...

Page 11: ... or property damage When installing pipes special attention must be given to the installation of safety valves expansion installations and possibility for air discharge in the electric boiler discharge pipe The direction of flow must be marked on the supply and return pipes Note Any high points in the climate system must be equipped with air vents Note The pipe systems need to be flushed out befor...

Page 12: ... be found from Technical data Recommended circulation pumps Note The water circulation in the FIL SPL boiler must be ensured in all possible cases unless the boiler is intentionally shut down with the main switch The boiler can be used directly for heating or indirectly to produce hot water for general use Typical applications include industry apartment blocks row houses or similar The boiler is s...

Page 13: ...SPL boiler has integrated main switch The main switch operates as an isolator switch if temperature limiter or dry boiling preventer detects an error or in case of overload Note The main switch must not be moved to I on until the system has been filled with water and water circulation is ensured Otherwise the temperature limiter thermostat and the immersion heater etc can be damaged Note After the...

Page 14: ...ed fuses the cable lengths installation method and applicable standards The main supply is connected directly to the main switch phases to neutral connector neutral and to equipment grounding protective earth Note Models from 400 to 1600 kW uses 4 wire connection neutral is not needed Mandatory external circulation pump The FIL SPL boiler is a flow through heater and thus requires an external circ...

Page 15: ...eventing effect of for example morning sun Note Remember to first enable the property from Menu 4 5 OutdoorComp and to set configurations accordingly from Menu 1 1 1 2 OutdoorComp Note Sensor cables to external connections must not be laid closer than 20 cm to high voltage cables External blocking The boiler can be forced to disable all electrical power of heating with potential free closed contac...

Page 16: ...add warning label of external control voltage 0 10 V external control External analogue inputs 0 10 V 20 90 C can be used for controlling boiler temperature Note that external control voltage does not overrule internal settings and thus for example the max temperature that is set will be overruling Connect external 0 10 V control voltage to X 8 and X 9 The external 0 10 V control property must be ...

Page 17: ...e The minimum area of Jäspi current transformer cables must be 1 5 mm up to 500 m Recommendation is to use shielded cable Note With main fuses of the property smaller than 3 x 70 A the Jäspi current transformers may be used directly for load monitor On the left side of the figure above is connection of relatively small main fuses 70 A when Jäspi current transformers TF1 3 can be used directly depe...

Page 18: ...ion of internal power consumption property must be enabled and configured accordingly in the software More information can be found from Menu 2 3 Effect factor 0 10 V status output Status data of the FIL SPL boiler can be shown out via analog voltage message Connect status output to X 6 and X 7 As a status following information can be given Target temperature value Measured temperature value Curre...

Page 19: ... 10 Note Remember to add warning label of external control voltage Note The alarm relay output can have maximum load of 2 A 230 V AC in total Alarm relay output of the main switch The FIL SPL boiler has an extra alarm relay in the main switch If the main switch trips for some reason the changeover contact in the main switch can be used as an alarm source for example for building automation Connect...

Page 20: ... label of external control voltage High temperature alarm in switchboard only with 800 1600 kW models The FIL SPL boiler automatically starts cooling fans if the temperature of the switchboard increases However if the temperature exceeds 50 C an alarm will be given The information can be used for example in building automation Connect the alarm information of the high temperature in switchboard to...

Page 21: ...t the water circulation of the heater is operating 3 Verify that the safety valve s operates accordingly 4 Turn the main switch first to 0 off position especially if the main switch has tripped 5 Start the FIL SPL boiler by turning the main switch to I on position 6 Turn the control switch to position I on 7 Turn the heating mode normal backup selection switch to normal heating mode 8 Turn the ext...

Page 22: ... button is used to Move up in the menu Increase selected value Move to menu from default screen D Select button The select button is used to Select property to be modified Move to menu from default screen E Move down button The move down button is used to Move down in the menu Decrease selected value Move to menu from default screen Note Presentation X Y indicates that X is currently measured valu...

Page 23: ... Menu 1 Info Display of temperature and other operating information and access to the service menu Menu 2 Service Advanced settings and access to the test and setup menus Menu 3 Test Manually Advanced tests for maintain and service Menu 4 Setup Advanced setup for controlling the device ...

Page 24: ...ue Setting range 30 99 C Default value 70 C The target temperature is set in the control unit The measured value of temperature sensor located inside the boiler is compared to the target value and appropriate power step is taken into use Hysteresis of the temperature is 2 The controller has a P range of 3 C and is constantly adjusting to maintain the set temperature If the temperature increases or...

Page 25: ...ple min max below Setting range 30 95 C Default value 80 C Mintemp is the minimum allowable boiler temperature ie cuts the curve at low end See example figure example min max below Setting range 0 50 C Default value 10 C Curve is the heating curve of the boiler The curve name is the value of the curve at 0 C The boiler temperature is adjusted against heating curve that indicates heating requiremen...

Page 26: ...this way user can achieve fine adjusting for heating curve See figure example parallel below Setting range 20 20 C Default value 0 C Menu 1 2 Step Currently used power step maximum usable power step in parenthesis Informative reading Menu 1 3 AC in Currently measured input voltage in percentages compared to 230 V AC Informative reading ...

Page 27: ...r to use higher power steps i e limits the power of the boiler Menu 2 1 2 Time Used step time for increasing power i e at least this time is spent between enabling next power step Settable value Setting range 20 250 s Default value 90 s Note Too short step time can cause constant fluctuation Fluctuations can be eliminated by decreasing or increasing the step time depending on the pump capacity and...

Page 28: ... 2 Marginal The current marginal determines how much below current limit the measured current must be for enabling next power step Setting correct value eliminates unnecessary enable disable of power steps for achieving longer lifetime of components Settable value Setting range 0 1 1 0 A Default 1 0 A Note The setting values are indicative as many issues affects to the accuracy such as accuracy of...

Page 29: ...rsion ratio of primary side current transformer and phase to neutral voltage Calculation 3 𝑃ℎ𝑎𝑠𝑒 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑖𝑜 𝑜𝑓 𝑝𝑟𝑖𝑚𝑎𝑟𝑦 𝑠𝑖𝑑𝑒 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟𝑠 1000 𝑉𝑎𝑙𝑢𝑒 𝑡𝑜 𝑏𝑒 𝑢𝑠𝑒𝑑 Calculation example Phase to neutral voltage 230 V used primary side current transformers 250 5 3 230 250 5 1000 3 230 50 1000 34500 1000 34 5 With this example the value 35 should be set as effect factor Menu 2 4 S tim...

Page 30: ...or 3 Force control of contactor 3 Enable contactor 3 by setting value to 1 and disable by setting value to 0 Settable value Setting range 0 1 Default 0 Menu 3 4 Contactor 4 Force control of contactor 4 Enable contactor 4 by setting value to 1 and disable by setting value to 0 Settable value Setting range 0 1 Default 0 Menu 3 5 Alarm Force control of alarm relay Activate alarm by setting value to 1...

Page 31: ...the control unit cannot enable disable power steps accordingly and illegal behavior will occur Strong recommendation is not to modify this setup at all Menu 4 3 Input Setting of 0 10 V control voltage input More information about voltage levels can be found from Technical data External control voltage input values and corresponding power steps in different modes Settable value Setting range Disabl...

Page 32: ...Target boiler temperature Default Menu 4 5 OutdoorComp Selection whether outdoor temperature control is enabled or disabled With this property the control unit adjusts power steps automatically according to measured outdoor temperature and selected temperature curve Setting range no Disabled not used yes Enabled the boiler is automatically controlled by outdoor temperature Default no Note For taki...

Page 33: ...on pressed until the main switch trips Now you can release the KOESTUS button Reset the main switch by first positioning the switch to 0 off and then back to I on position The safety valve of the system must be inspected four times a year Test the safety valve by turning the knob Small amount of outflow water should run at the time approximately one liter per inspection The test of safety valve is...

Page 34: ...ater in the system If both indicator lights HÄLYTYS and TOIMINTA are off and the device has power check the 50 mA fuse of the dry boiling preventer Replace only with 5 x 20 mm class tube fuse of type 50 mA T that meets IEC127 standard If replacing the fuse does not solve the issue there is a system malfunction in the dry boiling preventer Use only original spare part as a replacement Reset the mai...

Page 35: ...s are for load monitoring of main fuses The same type of current transformers can be used also for observation of internal power consumption Jäspi outdoor temperature sensor 200 035 Jäspi outdoor temperature sensor is to be used when the outdoor temperature control is enabled ...

Page 36: ...full power after power cut longer than 30 s 2 h Secondary side current of Jäspi current transformer 0 5 A Power steps Models 31 5 112 7 steps Models 150 1600 15 steps General Operating temperature 0 35 C Design temperature 110 C Maximum structural pressure 10 bar Operating temperature environment 10 40 C Operating temperature boiler 30 99 C Cut off temperature temperature limiter 105 C Pipe connec...

Page 37: ... x 50 25 mm2 FIL SPL 70 70 101 3 x 125 4 x 70 35 mm2 FIL SPL 84 84 230 400 V 121 3 x 160 4 x 70 35 mm2 FIL SPL 105 105 3L N PE 152 3 x 200 4 x 95 50 mm2 FIL SPL 112 112 AC 50 Hz 162 3 x 200 4 x 95 50 mm2 FIL SPL 150 150 217 3 x 250 4 x 120 70 mm2 FIL SPL 180 180 260 3 x 315 4 x 185 95 mm2 FIL SPL 225 225 325 3 x 400 4 x 150 70 mm2 FIL SPL 300 300 433 3 x 500 4 x 185 95 mm2 FIL SPL 400 400 577 2 x ...

Page 38: ...emp Model 15 Model 7 Model 15 Model 7 V Pwr step V Pwr step V Pwr step V Pwr step V C 0 00 0 0 00 0 0 00 15 0 00 7 0 00 20 00 0 70 1 1 50 1 0 60 14 1 30 6 1 50 30 00 1 40 2 2 80 2 1 30 13 2 60 5 2 90 40 00 2 00 3 4 00 3 1 90 12 3 90 4 4 00 50 00 2 60 4 5 20 4 2 50 11 5 20 3 5 80 60 00 3 20 5 6 50 5 3 20 10 6 50 2 7 30 70 00 4 00 6 8 00 6 3 90 9 8 00 1 8 70 80 00 4 60 7 10 00 7 4 50 8 10 00 0 10 00...

Page 39: ...step V C V C 0 00 0 0 00 0 4 00 20 00 4 00 20 00 0 70 1 1 40 1 5 00 30 00 5 00 30 00 1 40 2 2 80 2 6 00 40 00 6 00 40 00 2 00 3 4 10 3 7 00 50 00 7 00 50 00 2 60 4 5 60 4 8 00 60 00 8 00 60 00 3 20 5 7 00 5 9 00 70 00 9 00 70 00 4 00 6 8 40 6 10 00 80 00 10 00 80 00 4 60 7 10 00 7 5 20 8 5 90 9 6 50 10 7 20 11 7 80 12 8 50 13 9 20 14 9 80 15 Maximum current of 0 10 V status output is 1 mA ...

Page 40: ...esistor values of the sensors at different temperatures Boiler temperature NTC22K Temperature Resistance C kΩ 0 66 00 10 42 00 20 27 00 30 18 00 40 12 00 50 9 00 60 6 00 70 4 20 80 3 10 90 2 30 100 1 80 110 1 30 Outdoor temperature sensor 151R Temperature Resistance C Ω 30 1883 25 1443 20 1115 15 868 10 681 5 538 0 428 5 342 10 276 15 224 20 182 25 151 30 123 35 102 ...

Page 41: ...versus different FIL SPL models Model Pump FIL SPL 31 5 300 kW UPS 25 80 F FIL SPL 400 kW UPS 32 50 F FIL SPL 500 kW UPS 32 60 F FIL SPL 600 kW UPS 32 60 F FIL SPL 700 kW UPS 40 60 4 F FIL SPL 800 kW UPS 40 60 4 F FIL SPL 900 kW UPS 40 60 4 F FIL SPL 1000 kW UPS 40 60 2 F FIL SPL 1200 kW UPS 40 60 2 F FIL SPL 1600 kW UPS 50 60 4 F ...

Page 42: ...L SPL 84 0 6 1 0 0 5 324 33 FIL SPL 105 0 8 1 3 0 6 507 52 FIL SPL 112 0 9 1 3 0 4 204 21 FIL SPL 150 1 1 1 8 0 5 364 37 FIL SPL 180 1 4 2 2 0 6 525 54 FIL SPL 225 1 7 2 7 0 8 821 84 FIL SPL 300 2 3 3 6 0 7 380 39 FIL SPL 400 3 1 4 8 0 6 553 56 FIL SPL 500 3 8 6 0 0 8 867 88 FIL SPL 600 4 6 7 2 0 9 1247 127 FIL SPL 700 5 3 8 4 1 1 1695 173 FIL SPL 800 6 1 9 6 1 2 2218 226 FIL SPL 900 6 9 10 7 1 4 ...

Page 43: ...Electrical circuit diagrams models of 31 112 kW ...

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Page 46: ...Electrical circuit diagrams models of 150 300 kW ...

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Page 49: ...Electrical circuit diagrams models of 400 1600 kW ...

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Page 53: ...We reserve rights to changes Kaukora Ltd 2019 D106159 r4 0 ...

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