ALONE. Project No TREN/FP7EN/ ALONE. small scale solar cooling device. Collaborative Project Small or Medium-scale Focused Research Project

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1 ALONE small scale solar cooling device Project No TREN FP7EN Project No TREN/FP7EN/ ALONE small scale solar cooling device Collaborative Project Small or Medium-scale Focused Research Project DELIVERABLE D3.4 The hydraulic implementation of Energy Box Due date of Deliverable: 30 th November 2012 Works finalized Start date of the project: October 2008, Duration: 48 months RIELLO Co-Ordinator of the Responsible Beneficiary: Giuseppe Toniato Authors: RIELLO Giuseppe Toniato Co-Ordinator of the Project: Maurizio De Lucia 1

2 ALONE small scale solar cooling device Project No TREN FP7EN Summary 1. Energy Box - Description... 3 CONTAINER... 3 PIPING: STEAM LINES... 4 PIPING: HOT WATER LINES FROM HEAT EXCHANGER S PIPING: HOT WATER LINES HEAT EXCHANGER S2 AND CHILLED WATER SUPPLY.. 5 PIPING: HOT WATER LINES HEAT EXCHANGER S2 AND CHILLED WATER RETURN. 5 ELECTRICAL PANEL Laboratoty tests - BRONZOLO Laboratoty tests MISERICORDIA ATTACHMENTS

3 ALONE small scale solar cooling device Project No TREN FP7EN Energy Box - Description The Energy Box is a hydro-unit operated by a control panel operated via PLC for the control and supervision of the system, integrated in a container 10' The Energy Box is designed to be integrate a system for the production of heated and superheated water by solar collectors and chilled water by means of a steam chiller and water chiller. Through suitable heat exchangers and diverter valves it controls the production of water at medium or low temperature for heating and chilled water for cooling / conditioning. The symbols legend, components types and models are indicated in the file Controls and components - rev. 06th The Energy Box consists of: Container 10 ', piping and components, electrical panel CONTAINER Container 10 is made in painted sheet steel, sheet aluminum tread floor, gateway walked with inward opening and panic lock, front door with lock rod to fully opening of the front for maintenance, sides openings for pipes connection, anti-rain metal ventilation grilles. Painting RAL

4 ALONE small scale solar cooling device Project No TREN FP7EN PIPING: STEAM LINES The steam lines connect the following components: Pump P1, V1, V3, V4, Mass Flow Meters M1, M6 Temperatures Probes T1, T2, T35, T3, T4, T5, T7, T39 Heat - Exchanger S2 Pipes and flanges in stainless steel AISI 304. Diameter pipes: DN40 Flages: DN40PN25 Insulation on vapor side by 30 mm ceramic-fiber. PIPING: HOT WATER LINES FROM HEAT EXCHANGER S2 Hot water pipes coming out from the exchanger S2 connect the following components: Pump P2, Mass Flow Meter M2 Temperature Sensors T8, T9 Heat Exchanger S2 4

5 ALONE small scale solar cooling device Project No TREN FP7EN Pipes and flanges in galvanized steel. Diameter pipes DN mm of polyurethane insulation with PVC finish, suitable for hot water up to 90 C. T max PIPING: HOT WATER LINES HEAT EXCHANGER S2 AND CHILLED WATER SUPPLY The hot water heat exchanger S6 lines connecting the following components: Pump P4, P5, Valves V11, V12, V13, Temperature Sensors, T15, T32, T33, T18, T38, T40, T41, T31, t36 S6 exchanger Playing with pipes and flanges in galvanized steel. Diameter pipes DN mm of polyurethane insulation with PVC finish, suitable for hot water up to 90 C. T max. PIPING: HOT WATER LINES HEAT EXCHANGER S2 AND CHILLED WATER RETURN The lines hot water hot water and chilled water return link the following components: Mass Flow Meters M5, M6, Temperature Sensors T17, T37, T14, T16 Pipes and flanges in galvanized steel. Diameter pipes DN mm of polyurethane insulation with PVC finishing, suitable for hot water up to 90 C. T max. 5

6 ALONE small scale solar cooling device Project No TREN FP7EN ELECTRICAL PANEL Electrical panel designed as CE EN with overall dimension of: 1600/1800xH2100xP500 mm containing the following components: Main switch 4P 32 A; N 01 transformer 500VA P0-400V/S0-24V; N 04 Power Supplies 24Vac/24Vdc 5 A; N 02 Sockets 2P + T; PLC and National Instrument signal acquisition card with configuration as the figure below Protection circuit for 220Vac, 24Vdc and 24Vdc; N 01 starter through inverter 4kW; N 01 starter through inverters 0.55 kw; Safety module 3TK28; Buttons and switches diameter 22 on the door; N 01 thermostat; N 01 heater control panel; N 05 viewers water flow; N 01 conditioner for electrical panels; N 01 Interface Relay ; N 04 Diris A40 110/400Vca 120/350Vcc; N 04 Ethernet Modules Diris A40 No. 01 Phoenix SF 8TX Ethernet Switch Current transformers TCA21 50/5A Protection for Viewers Instrument Configuration Fuses Protection for Dry-cooler Terminals Wiring accessories and installation on the machine; 6

7 ALONE small scale solar cooling device Project No TREN FP7EN Laboratoty tests - BRONZOLO Once the EB was manufactured tests in lab were carried out for checking electrical connections between the control panel and instrumentation for monitoring and control of the plant, and for verifying the correct functioning. Subsequently to the electrical verifications, hydraulic head curves on each loop have been evaluated. First functional tests were carried out at Riello s facilities in cooperation with EURAC in order to check if everything was working properly and in conformity with the specifications defined in previous WP 7

8 ALONE small scale solar cooling device Project No TREN FP7EN Laboratoty tests MISERICORDIA As well as Bronzolo, the same activities were progressed for the Misericordia plant 8

9 4. ATTACHMENTS ALONE small scale solar cooling device Project No TREN FP7EN

10 CONTROLLI COLLEGAMENTI ENERGY BOX

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12 [V1] V 1 Present = "FALSE" System OK Button v 1 = "FALSE" [V2] V 2 Present = "TRUE" System OK Button v 2 = "TRUE" [V3] V 3 Present = "TRUE" System OK Button v 3 = "TRUE" [V4] V 4 Present = "TRUE" System OK Button v 4 = "TRUE" [V5] V 5 Present = "FALSE" System OK Button v 5 = "FALSE" [V6] V 6 Present = "FALSE" System OK Button v 6 = "FALSE" [V7] V 7 Present = "FALSE" System OK Button v 7 = "FALSE" [V8] V 8 Present = "FALSE" System OK Button v 8 = "FALSE" [V9] V 9 Present = "FALSE" System OK Button v 9 = "FALSE" [V10] V 10 Present = "FALSE" System OK Button v 10 = "FALSE" [V11] V 11 Present = "FALSE" System OK Button v 11 = "FALSE" [V12] V 12 Present = "FALSE" System OK Button v 12 = "FALSE" [V13] V 13 Present = "FALSE" System OK Button v 13 = "FALSE" [V14] V 14 Present = "TRUE" System OK Button v 14 = "TRUE" [V14] V 14 Present = "TRUE" System OK Button v 14 = "TRUE" [P1] P 1 Present = "TRUE" System OK Button p 1 = "TRUE" max P 1 = "0,000000" min P 1 = "0,000000" [P2] P 2 Present = "TRUE" System OK Button p 2 = "TRUE" max P 2 = "0,000000" min P 2 = "0,000000" [P3] P 3 Present = "FALSE" System OK Button p 3 = "FALSE" max P 3 = "0,000000" min P 3 = "0,000000" [P4] P 4 Present = "TRUE" System OK Button p 4 = "TRUE" max P 4 = "0,000000" min P 4 = "0,000000" [P5] P 5 Present = "TRUE" System OK Button p 5 = "TRUE" max P 5 = "0,000000" min P 5 = "0,000000" [M1] M 1 Present = "TRUE" System OK Button m 1 = "TRUE" [M2] M 2 Present = "TRUE" System OK Button m 2 = "TRUE" [M3] M 3 Present = "FALSE" System OK Button m 3 = "FALSE" [M4] M 4 Present = "TRUE" System OK Button m 4 = "TRUE" [M5] M 5 Present = "TRUE" System OK Button m 5 = "TRUE" [M6] M 6 Present = "TRUE" System OK Button m 6 = "TRUE" [T1] T 1 Present = "FALSE" System OK Button T 1 = "FALSE" MSE T 1 = "0,000000" T 1 = "850,000000" [T2] T 2 Present = "FALSE" System OK Button T 2 = "FALSE" MSE T 2 = "0,000000" T 2 = "850,000000" [T3] T 3 Present = "TRUE" System OK Button T 3 = "TRUE" MSE T 3 = "0,000000" T 3 = "25,349054" [T4] T 4 Present = "TRUE" System OK Button T 4 = "TRUE" MSE T 4 = "0,000000" T 4 = "29,755093" [T5] T 5 Present = "TRUE" System OK Button T 5 = "TRUE" MSE T 5 = "0,000000" T 5 = "32,270550" [T6] T 6 Present = "TRUE" System OK Button T 6 = "TRUE" MSE T 6 = "0,000000" T 6 = "20,654610" [T7] T 7 Present = "TRUE" System OK Button T 7 = "TRUE" MSE T 7 = "0,000000" T 7 = "21,952385" [T8] T 8 Present = "TRUE" System OK Button T 8 = "TRUE" MSE T 8 = "0,000000" T 8 = "24,804298" [T9] T 9 Present = "TRUE" System OK Button T 9 = "TRUE" MSE T 9 = "0,000000" T 9 = "24, [T10] T 10 Present = "FALSE" System OK Button T 10 = "FALSE" MSE T 10 = "0,000000" T 10 = "850,000000" [T11] T 11 Present = "FALSE" System OK Button T 11 = "FALSE" MSE T 11 = "0,000000" T 11 = "850,000000" [T12] T 12 Present = "FALSE" System OK Button T 12 = "FALSE" MSE T 12 = "0,000000" T 12 = "850,000000" [T13] T 13 Present = "FALSE" System OK Button T 13 = "FALSE" MSE T 13 = "0,000000" T 13 = "850,000000" [T14] T 14 Present = "TRUE" System OK Button T 14 = "TRUE" MSE T 14 = "0,000000" T 14 = "21,247429" [T15] T 15 Present = "TRUE" System OK Button T 15 = "TRUE" MSE T 15 = "0,000000" T 15 = "20,846870" [T16] T 16 Present = "FALSE" System OK Button T 16 = "FALSE" MSE T 16 = "0,000000" T 16 = "850,000000" [T17] T 17 Present = "TRUE" System OK Button T 17 = "TRUE" MSE T 17 = "0,000000" T 17 = "22,080574"

13 [T18] T 18 Present = "TRUE" System OK Button T 18 = "TRUE" MSE T 18 = "0,000000" T 18 = "21,968407" [T19] T 19 Present = "TRUE" System OK Button T 19 = "TRUE" MSE T 19 = "0,000000" T 19 = "21,295494" [T20] T 20 Present = "TRUE" System OK Button T 20 = "TRUE" MSE T 20 = "0,000000" T 20 = "21,199364" [T21] T 21 Present = "TRUE" System OK Button T 21 = "TRUE" MSE T 21 = "0,000000" T 21 = "21,359581" [T22] T 22 Present = "FALSE" System OK Button T 22 = "FALSE" MSE T 22 = "0,000000" T 22 = "850,000000" [T23] T 23 Present = "TRUE" System OK Button T 23 = "TRUE" MSE T 23 = "0,000000" T 23 = "19,164572" [T24] T 24 Present = "TRUE" System OK Button T 24 = "TRUE" MSE T 24 = "0,000000" T 24 = "21,343559" [T25] T 25 Present = "TRUE" System OK Button T 25 = "TRUE" MSE T 25 = "0,000000" T 25 = "24,387741" T26] T 26 Present = "TRUE" System OK Button T 26 = "TRUE" MSE T 26 = "0,000000" T 26 = "24,019226" [T27] T 27 Present = "FALSE" System OK Button T 27 = "FALSE" MSE T 27 = "0,000000" T 27 = "850,000000" [T28] T 28 Present = "FALSE" System OK Button T 28 = "FALSE" MSE T 28 = "0,000000" T 28 = "850,000000" [T29] T 29 Present = "FALSE" System OK Button T 29 = "FALSE" MSE T 29 = "0,000000" T 29 = "850,000000" [T30] T 30 Present = "FALSE" System OK Button T 30 = "FALSE" MSE T 30 = "0,000000" T 30 = "850,000000" [T31] T 31 Present = "FALSE" System OK Button T 31 = "FALSE" MSE T 31 = "0,000000" T 31 = "850, [T32] T 32 Present = "FALSE" System OK Button T 32 = "FALSE" MSE T 32 = "0,000000" T 32 = "850,000000" [T33] T 33 Present = "FALSE" System OK Button T 33 = "FALSE" MSE T 33 = "0,000000" T 33 = "850,000000" [T34] T 34 Present = "FALSE" System OK Button T 34 = "FALSE" MSE T 34 = "0,000000" T 34 = "850, [T35] T 35 Present = "FALSE" System OK Button T 35 = "FALSE" MSE T 35 = "0,000000" T 35 = "850,000000" [T36] T 36 Present = "FALSE" System OK Button T 36 = "FALSE" MSE T 36 = "0,000000" T 36 = "850,000000" [T37] T 37 Present = "TRUE" System OK Button T 37 = "TRUE" MSE T 37 = "0,000000" T 37 = "23,714813" [T38] T 38 Present = "TRUE" System OK Button T 38 = "TRUE" MSE T 38 = "0,000000" T 38 = "24,499893" [T39] T 39 Present = "TRUE" System OK Button T 39 = "TRUE" MSE T 39 = "0,000000" T 39 = "21,599899" [T40] T 40 Present = "FALSE" System OK Button T 40 = "FALSE" MSE T 40 = "0,000000" T 40 = "850,000000" [T41] T 41 Present = "FALSE" System OK Button T 41 = "FALSE" MSE T 41 = "0,000000" T 41 = "850,000000" [T42] T 42 Present = "FALSE" System OK Button T 42 = "FALSE" MSE T 42 = "0,000000" T 42 = "850,000000" [T43] T 43 Present = "FALSE" System OK Button T 43 = "FALSE" MSE T 43 = "0,000000" T 43 = "850,000000" T44] T 44 Present = "FALSE" System OK Button T 44 = "FALSE" MSE T 44 = "0,000000" T 44 = "850,000000" [T45] T 45 Present = "FALSE" System OK Button T 45 = "FALSE" MSE T 45 = "0,000000" T 45 = "850,000000" [T46] T 46 Present = "FALSE" System OK Button T 46 = "FALSE" MSE T 46 = "0,000000" T 46 = "850,000000" [T47] T 47 Present = "FALSE" System OK Button T 47 = "FALSE" MSE T 47 = "0,000000" T 47 = "850,000000" [T48] T 48 Present = "FALSE" System OK Button T 48 = "FALSE" MSE T 48 = "0,000000" T 48 = "850,000000"

14 VERIFICA COMANDI VALVOLE ENERGY BOX BOLZANO

15 SCHEMA BOLZANO T T23 T5 T20 T21 T7 T39 T6 T3 T T15 T T17 T18 T38 T T19 T8 T T T

16 NOTE 1)Componenti che non devono essere gestiti dall EB: - V Ric, P Ric, P7, V16, T43, T44, T45, T46, T47 Pgeo, P11, UTA. 2) La T24 all interno dell EB non la colleghiamo, ma usiamo la sonda installata sui pannelli solari. 3) Attenzione: Durante le verifiche di collegamento elettrico dell EB abbiamo notato la seguente cosa: AB A Le valvole DN 40 funzionano in questo modo: AB-B=0 AB-A=12 (V15,V19,V21,V18,V14). Le valvole DN 32 funzionano in questo modo: AB-B=12 AB-A=0 (V2,V3,V4). B

17 VALVOLA V2 DN32 BLOK 3 (DO401) ALON CH 1 AB A CH1=0 BLOK 10 (DI304) ALONE 2 CH2=1 B CH1=1 BLOK 10 (DI304) ALONE 2 CH3=1

18 VALVOLA V3 DN32 BLOK 3 (DO401) ALON CH 2 BLOK 10 (DI304) ALONE 2 CH4=1 B CH2=0 AB A CH2=1 BLOK 10 (DI304) ALONE 2 CH5=1

19 VALVOLA V15 DN40 BLOK 3 (DO401) ALON CH 0 BLOK 10 (DI304) ALONE 2 CH0=1 A CH0=0 AB B CH0=1 BLOK 10 (DI304) ALONE 2 CH1=1

20 VALVOLA V19 DN40 BLOK 3 (DO401) ALON CH 11 BLOK 10 (DI304) ALONE 2 CH23=1 A CH11=1 AB B CH11=0 BLOK 10 (DI304) ALONE 2 CH22=1

21 VALVOLA V4 DN32 BLOK 1 (AO210) ALON CH 0 AB A CH0=10V BLOK 5 (AI110) ALONE 5 CH0=10V B CH0=0V BLOK 5 (AI110) ALONE 5 CH0=0V

23 VALVOLA V18 DN40 BLOK 1 (AO210) ALON CH 4 BLOK 5 (AI110) ALONE 5 CH4=0V A CH4=0V AB B CH0=10V BLOK 5 (AI110) ALONE 5 CH4=10V

25 VERIFICA PREVALENZE DISPONIBILI CIRCUITI ENERGY BOX

26 Circuito 1 PUNTI DI MISURA

27 CIRCUITO 1 l/h M1 DP mbar V P1 l/h M v v v v v v v v v 0 CIRCUITO 1 l/h M1 DP mbar V P1 l/h M v v v v v v 0 CIRCUITO 1 l/h M1 DP mbar V P1 l/h M v v v 0 DP mbar Circuito 1 VP1 10V VP1 5V VP1 0V l/h

29 l/h M1 CIRCUITO 2 DP mbar V P v v v v v v v v v l/h M1 CIRCUITO 2 DP mbar V P v v v v v v CIRCUITO 2 l/h M1 DP mbar V P v v v DP mbar Circuito 2 VP1 10V VP1 5V VP1 0V l/h

31 l/h M1 CIRCUITO 3 DP mbar V P v v v v v v v v v l/h M1 CIRCUITO 3 DP mbar V P v v v v v v CIRCUITO 3 l/h M1 DP mbar V P v v v DP mbar Circuito 3 VP1 10V VP1 5V VP1 0V l/h

33 CIRCUITO 4 l/h M1 DP mbar V P1 l/h M v v v v v v v v v 0 CIRCUITO 4 l/h M1 DP mbar V P1 l/h M v v v v v v 0 CIRCUITO 4 l/h M1 DP mbar V P1 l/h M v v v 0 DP mbar Circuito 4 VP1 10V VP1 5V VP1 0V l/h

35 CIRCUITO 5 l/h M2 DP mbar V P v v v v v v v v CIRCUITO 5 l/h M2 DP mbar V P v v v v v CIRCUITO 5 l/h M2 DP mbar V P v v v DP mbar Circuito 5 VP2 10V VP2 5V VP2 0V l/h

37 CIRCUITO 6 l/h M5 DP mbar V P v v v v v v v v CIRCUITO 6 l/h M5 DP mbar V P v v v v v DP mbar Circuito 6 VP5 10V VP5 5V VP5 0V CIRCUITO 6 l/h M5 DP mbar V P v v v l/h

39 CIRCUITO 7 l/h M5 DP mbar V P v v v v v v v v CIRCUITO 7 l/h M5 DP mbar V P v v v v v DP mbar Circuito 7 VP5 10V VP5 5V VP5 0V CIRCUITO 7 l/h M5 DP mbar V P v v v l/h

41 l/h M5 CIRCUITO 8 DP mbar V P v v v v v v v v l/h M5 CIRCUITO 8 DP mbar V P v v v v v CIRCUITO 8 l/h M5 DP mbar V P v v v DP mbar Circuito 8 VP5 10V VP5 5V VP5 0V l/h

43 l/h M4 CIRCUITO 9 DP mbar V P v v v v v v v v l/h M4 CIRCUITO 9 DP mbar V P v v v v v CIRCUITO 9 l/h M4 DP mbar V P v v v DP mbar Circuito 9 VP4 10V VP4 5V VP4 0V l/h

44 SCHEMA BOLZANO 2 3 T23 T24 T20 T21 T5 T7 T39 T6 T3 T T15 T T17 T18 T38 T T19 T8 T T T

45 NOTE 1)Componenti che non devono essere gestiti dall EB: - V Ric, P Ric, P7, V16, T43, T44, T45, T46, T47 Pgeo, P11, UTA. 2) La T24 all interno dell EB non la colleghiamo, ma usiamo la sonda installata sui pannelli solari. 3) Attenzione: Durante le verifiche di collegamento elettrico dell EB abbiamo notato la seguente cosa: AB A Le valvole DN 40 funzionano in questo modo: AB-B=0 AB-A=12 (V15,V19,V21,V18,V14). Le valvole DN 32 funzionano in questo modo: AB-B=12 AB-A=0 (V2,V3,V4). B