PRODUCT DEVELOPMENT INNOVATIVE SOLUTIONS

Transcription

1 PRODUCT DEVELOPMENT INNOVATIVE SOLUTIONS COMBUSTION SOLAR SYSTEMS HYDRAULIC

2 A leading company

3 3 Orkli is a company with cooperative values. Its goal is to achieve profitability to the benefit of its customers and workers and to society as a whole. With over 30 years experience, Orkli is today a global company, competitive worldwide. Orkli exports over 80% of its production and currently has manufacturing plants in Spain, China and Brazil. It is structured into three business units: Thermoelectric Safety, Heating and Water Heating. It is a world leader in the manufacture of thermoelectric safety components, with owndesigned products such as thermocouples, magnetic units and actuators acknowledged by the main household appliance manufacturers. It has offices throughout Europe and strategicallylocated sales agents worldwide. Orkli does not tackle the challenges of a globalised world on its own, as it is a member company of the world s largest cooperative group: the Mondragon Corporation. products are recognized by the main brands in the sector and the company s innovative philosophy continues to reinforce its international presence. With its commitment to renewable energies for the Heating sector, Orkli develops and produces components for solar heating installations such as hydraulic pumping units, hydraulic units for large high-efficiency installations, automatic drain units and many more, all of which feature in this catalogue. Orkli engages in innovation in terms of products, quality improvement, production systems, service and logistics: a comprehensive offer that aims to provide new solutions for the market while meeting customer needs. The company s commitment to the environment and to halting climate change has led to products with higher energy efficiency, manufactured through more efficient processes that minimize resource consumption and waste generation. Orkli has been granted the most demanding certifications in the areas of quality, safety and occupational health and safety, as well as protection and respect for the environment. Its

4 4

5 5 When it comes to water heating components, WE KNOW WHAT YOU NEED Just as there aren t two customers the same, there aren t two companies that need the same products or that share the same design. A project requires its own resources, its own technology and, more importantly, its own solutions. The answer to the question is the result of multiple combinations in different areas. At the design level this requires the capability to apply different technologies. At the production level the development of complex solutions, the use of either plastic or brass in response to the reliability-cost equation, as well as the integration of stamping, machining and assembly lines. At the R&D level, continuous training is necessary together with lots of experience in manufacturing and process approval. In addition to all this, there is our exhaustive knowledge of all the European markets, as well as more than 8 years in the Chinese market which guarantee and certify the reliability of Orkli s products. Only in this way can we give all our customers what they need.

6 6

7 7 WHAT MAKES THE DIFFERENCE There are several aspects that put us ahead of our competitors. First of all: our DESIGN capability applied to our customers needs, our PROTOTYPING capability, our modern test laboratory... Although for some people this is the future, we just call it the present. And that is why we are in a condition to offer advantages as important as: - CAD-CAM and all the drawing tools available. - Computerised hydraulic simulation (finite elements). - Integrated prototyping: functional parts in plastic and brass, fast prototyping of plastic or machined parts. High capacity. - Stamping, machining and assembly lines. - Customisation processes. - Full integration of hydraulic controls in brass and in plastic. - Highly integrated functions. - Intelligent solutions for small dimensions. - Fast process development. The are just a few examples of our commitment to offering a fully customised service. A concept that consist of giving every customer just what they need. This is what makes the difference.

8 8

9 9 MADE TO MEASURE (M2M) COMBUSTION SYSTEMS Based on the the know-how of a leading industrial group and a close collaboration with our customers combined with the outstanding properties of our Ceramat burners, Orkli s combustion systems are developed to be implemented in the most advanced condensing boilers. Our plug-in integrated solutions can be easily customized to fit the customer necessities, resulting in a compact high performing system with a wide modulation range that allows a maximum exploitation of the boiler internal space.

10 10

11 11 QUALITY THROUGH AND THROUGH Orkli develops innovative solutions that enable your company to go one step forward in combustion technology. Our R&D department, composed by combustion experts, is supported by: - Leading Research Institutes: CEIT, that focuses on materials and Ikerlan (Mondragon Group), that focuses on new application developments and manufacturing processes improvement. - Computer Aided Engineering: CFD (Fluid-dynamic simulation in combustion system elements), 3D CAD, FEM Analysis (structural simulation of stress and deformation caused by static, dynamic or thermal loads), Thermoacoustic characterization programs (Materiacustica srl). - State-Of-The-Art Facilities: Continuous improvement of our facilities to make available to your business the most avant-garde combustion tools: New laboratory and acoustic chamber. Looking for performances, efficiency and safety, Orkli combustion solutions guarantee outstanding quality. SUCCESSFUL TOGETHER With our customized combustion solutions we at Orkli are committed to contributing to our customers success through close cooperation. Backed by the know-how of a leading industrial group, this is what we strive for in our ongoing research and development. Our mission is to create successful products based on new ideas, a challenge we look forward to meeting in collaboration with you.

12 12 CERAMAT BURNERS Orkli develops and produces a wide range of high performing burners based on the well-known Ceramat combustion technology. We make our know-how and expertise available for our customers to co-develop combustion solutions, independently from the application necessities. Thanks to our complete control of the production process, from obtaining the ceramat material to the final burner assembly, Orkli is able to provide reliable high quality products with oustanding advantages. EASY CUSTOMIZATION OF THE COMBUSTION SURFACE TO OBTAIN 4 FLAME MODES: Yellow Blue Radiant Radiant-Blue: Thanks to its unique characteristics, it is possible to combine a blue and a radiant flame at the same time, obtaining a highly stable-low emission resulting flame with a high-efficient heat transfer in the whole power range.

13 Highly compact and light The high open porosity of approximately 95% allows the gas/air mixture to easily permeate the entire surface, supporting specific loads of up to 40 kw/dm 2. This makes it possible to design small, compact burners and systems. High flame stability The special internal structure of the Ceramat material leads to a highly stable combustion with all the gas families. flashback CERAMAT others lift off Low emissions The simple adaptability of Orkli burner to a specific heating system and its wide radiation range ensure very low CO and NOx values without reducing the performance and flame stability of the burner. - CO emissions < 50mg/kWh. - NOx emissions < 50mg/kWh. Constant Ionization signal - From burner to burner! Due to the high porosity of the CERAMAT burner and the lack of manufacturing process critical nature, from the first one to the last one, all the burners manufactured by us show an identical behaviour. - No assembly stress! The stiffness of the CERAMAT material prevents the need to subject the material to stress during assembly and eliminates an important variable regarding its behaviour. - Great flame anchoring at high voltages and high temperature resistance at low voltages! The CERAMAT material causes the magnetic signal to keep identical during the lifetime of the burner and avoids the corrosion that varies its behaviour. - Despite of the electrode drift! The CERAMAT material makes that the distance from the electrode to the burner to be noncritical, keeping a practically invariable signal during the lifetime of the application. Noise damping Orkli s Ceramat material has been developed addressing thermal acoustic problems. Its unique structure combined with a wide customization possibilities of the flame pattern allow to solve both high and low frequency noises easily. ADVANTAGES RUMBLING NOISE Wide modulation range: from 1 to 40 kw/dm 2 The flame stability and temperature resistance support a modulation range of 1:40. Star-stop emissions due to frequent on-off cycles can be substantially reduced, resulting in lower emissions. Others Ceramat 40 kw/dm 2 1 Wide radiation range This ensures low NOx emissions at low flame temperature. High durability Due to their low thermal conductivity, the effect of the corrosion on the Ceramat burners is so low that is does not affect the application performance along its lifetime. Effect of the corrosion comparing a Ceramat burner with a metal fiber burner after a life test. CERAMAT OTHERS +2% +40% Analysis made by CEIT, research center belonging to IK4. High temperature resistance High surface temperatures are not transmited to lower layers, allowing for a temperature differential of up to 800ºC between the topside and the underside of the combustion surface. There is no danger of flashback and the temperature of the burner housing remains very low, even without additional cooling. With its high resistance to heat and changing temperatures, it can be used under unusually difficult combustion conditions. 950ºC 3,8 mm T=800ºC CERAMAT 150ºC Ceramic with electrical conductivity SiC coating makes Ceramat burner conductive. Electricity can pass through the material, being this a great advantage for the control of the flame detection. The ionization signal is highly stable even at low heat inputs due to the radiative characteristics of the material, pushing the combustion system one step forward more. 13

14 14

15 15 SOLAR SYSTEMS As a home comfort sector leader, ORKLI offers the widest, most competitive range of solutions for efficient domestic hot water production and management. As a specialist manufacturer of all the components needed for developing and assembling these systems, it designs and markets differently-structured comprehensive solutions adapted to the specific requirements of an increasingly demanding market.

16 16 SOLAR DRAIN BACK SYSTEM patented

17 17 Protects the installation, avoiding overheating and freezing problems The Solar Drain Back System is an all-round domestic hot water production solution based on the internationally acclaimed hydraulic units with Orkli s automatic drainback system. The drain-back technology protects the installation, avoiding overheating and freezing problems and making the solar heating installation safe and efficient. It is available in different configurations, according to the household s DHW requirements and the manometric height of the installation (up to 12 metres). As these are preconfigured systems, virtually no system calculations or control unit programming are required: the system is ready to install and run, with no drain valves or expansion tanks required. CHARACTERISTIC - The Solar Drain Back system has the following components: - 1 or 2 vertical solar collectors (highly selective meander type absorber) or 300-litre capacity with 1 coil. - Drain unit pumping system (1 or 2 pumps). - Programmable solar power unit + 3 temperature sensors. - Solar collector support structure. COMPONENTS INCLUDED IN EACH SOLAR DRAIN BACK Collector Hot water tank Drain Unit 74400SO

18 18 FORCED SOLAR PACK SYSTEM

19 19 The system is ready to install and run The Forced Solar Pack system is an all-round DHW production system based on pump units for Orkli forced solar installations. It is available in two different configurations, depending on the household s DHW requirements. As these are preconfigured systems, virtually no system calculations or control unit programming are required: the system is ready to install and run. CHARACTERISTIC - Each solar pack includes the following components: - 1 or 2 vertical solar collectors (highly selective meander type absorber) or 300-litre capacity with 1 coil. - Solar pumping system. - Programmable solar power unit + 3 temperature sensors. - Solar collector support structure. - Drain valve with shut-off valve litre expansion tank. - Expansion tank connection and fixing kit. COMPONENTS INCLUDED IN EACH FORCED SOLAR PACK Collector Hot water tank Solar pumping system73100sohe

20 20 DRAIN UNIT HYDRAULIC UNIT WITH DRAIN-BACK SYSTEM a solution to prevent overheating and freezing patented COMPATIBLE with all the collectors, heat exchangers and regulators on the market BIGGER SAVINGS simply select all the components you need CHARACTERISTIC - Maximum operating temperature: 110ºC. - Maximum peaks: 130ºC. - Safety valve calibration: 3 bar. - Flow indication range: 2-12 litres/min. - Maximum separation volume: 8 litres. - Connections: bicone nut for a Cu15mm o ½ M pipe. - Control options with pre-connections made. - Consult for adaptability to other regulations. - In case of no regulation options, the regulation must comply with the following characteristics: - Solar regulation with a differential relay. - Maximum temperature function of collector 110ºC. (recommended). - Difference in activation temperature 10-15ºC. (recommended).

21 HOW DOES IT WORK? 21 OFF SYSTEM OFF - COLLECTORS EMPTY If the system is idle, all the primary liquid is contained in the drain unit tank. The manifolds and the upper part of the installation are empty (i.e. they contain air), and the system is therefore protected against overheating and freezing. SYSTEM START-UP - FILLING CIRCUIT When the system starts up, the primary liquid stored in the drain unit tank is pumped to the manifolds. ON SYSTEM RUNNING - FORCED CIRCULATION All the air in the manifolds is stored in the drain unit tank and the system works as a forced circulation pumping unit. ON temperatures -0ºC SYSTEM OFF - COLLECTORS EMPTY (no danger of freezing) If there is insufficient solar radiation for the system to start up, all of the primary liquid will be contained in the drain unit tank (for frost protection). OFF maximum temperatures: 65ºC OFF SYSTEM OFF - COLLECTORS EMPTY (no risk of overheating) If the hot water tank setpoint is reached, the system stops and all of the primary liquid is again stored in the drain unit tank. This prevents vaporisation from occurring despite high radiation levels. For INSTALLATIONS with a larger number of collectors than other market alternatives for installations with twice as many solar collectors as the existing system

22 22 HYDRAULIC UNITS HIGH EFFICIENCY The SolarOrkli line opts for technologically innovative products contributing to smarter, more sustainable consumption of renewable energies. An example are the high-efficiency solar hydraulic units, which include components that can increase energy efficiency by almost 50%.

23 23 The optimum efficiency of the sun as a power source CHARACTERISTIC - Maximum working temperature in flow branch: 160ºC. - Maximum working temperature in return branch: 110ºC. - Maximum working temperature of safety valve: 160ºC. - Safety valve calibration: 6 bar. - Thermometer temperature range: 0-120ºC. - Flow meter indication range: 2-12 l/min. (visual flow meter); 2-40 l/min. (electronic). - Hydraulic unit for solar collector fields up to 16 m 2. - Consult for adaptability to other regulations. - Energy count option on models with electronic sensors. - Manometer scale: 0-10 bar. - Connections: 3/4 H. - Branch distance: 95 mm. - Regulation with connections made. - EPP insulation.

24 24 FRESH WATER STATION Is the ideal system for use in homes, residences, sports complexes and it is perfect for use with renewable energy heating installations This system is guaranteed to cover all your domestic hot water requirements, avoiding any hygiene problems by heating the water to over 70ºC to prevent risk of legionella and power loss associated with domestic hot water storage. The optional domestic hot water recirculation kit increases efficiency and home comfort by supplying hot water to the actual point of consumption at the desired temperature, with no waiting or wasteful cold water runoff. Also, the high-efficiency domestic hot water pump supplied works with AutoAdapt technology: it learns the users DHW demand patterns to have hot water ready exactly when it is needed, thus optimising power consumption.

25 Instant hot water whenever you need it and just the right temperature 25 CHARACTERISTIC - Instantaneous domestic hot water production. - Stainless steel 90 kw heat exchanger. - Domestic hot water production capacity 30 l/min. - Flow meter activation = 2 l/min. - DHW temperature controlled by a thermostatic valve acting on the primary circuit s 3-way mixing valve to regulate the heat exchanger flow. - Ensures a low return temperature of the water in the primary circuit (to aid stratification). - Connection for an optional DHW circulating system available. - The highest temperature is concentrated in the component in the lowest location so that the heat is naturally transferred to the top part of the heat exchanger, cooling down the hot zone and preventing problems with scale. COMPONENTS Heating circulation HE pump DHW circulation system DCW inlet Primary circuit intlet DHW outlet Plate heat exchanger DHW outlet temperature sensor Flow switch in DCW inlet. (To activate the pump when DHW is demanded) Primary circuit outlet Mixing 3 ways valve (It controlles DHW outlet temperature, using a distance sensor that acts on the primary water circuit)

26 26 INDIRECT HEAT EXCHANGE SOLAR KIT The indirect heat exchange solar kit is designed for centralised solar heating installations with distributed back-up power. Each home has an individual backup power source and its own interior distribution circuit supplying domestic water. HOW DOES IT WORK? This kit regulates the recirculation inlet to the home from the circuit previously heated by the solar collector. If the kit detects that a tap has been turned on and hot water is required, the flow to the heat exchanger is opened to preheat the domestic water inlet. When the hot water tap is turned off, the 3-way valve opens the bypass again and shuts off the flow to the heat exchanger. The shut-off valves allow the central recirculation system to be completely blocked off at all the inlets. 2 1 CHARACTERISTIC - Dimensions: 350 x 300 x 115 mm. - Heat exchanger power: 35KW. - Activation flow: 2L/min. - Maximum HWR operating flow: 15L/min. - Maximum heating operating flow: 20L/min. - Maximum HWR pressure: 15bar. - Maximum heating temperature: 70ºC. - Connections: ¾ M COMPONENTS 1. Heat exchanger 2. Fastening template 3. Heating output 4. Heating input 5. 3 ways valves 6. HWR input 7. Hydraulic valve 8. HWR output

27 SOLAR DHW KIT 27 A universal kit for connecting a solar hot water tank to a conventional domestic hot water source HYDRAULIC DIAGRAM If water in solar hot water tank >48ºC Unit for connection to the auxiliary domestic water heating units installed between the solar water tank and this back-up power source, normally an instant water heater or a gas or electric water heater. Domestic hot water outlet Mains water connection From the solar hot water tank >48ºC It includes a 3-way valve, which determines whether the water from the solar water tank should be conveyed via the back-up power source or can be directly sent on for consumption, and a mixing valve regulating the outlet temperature of the domestic hot water in the solar heating + conventional back-up system. If water in solar hot water tank <48ºC Domestic hot water outlet Mains water connection From the solar hot water tank <48ºC CHARACTERISTIC - Valve material: brass, according to EN12165 standard. - Closure gasket material: EPDM. - Connections: ½, or 15 mm copper pipes. - Maximum operating temperature: 90ºC. - Maximum operating pressure: 10 bar. - Calibration of 3-way valve/bypass temperature: 48ºC. - Bypass temperature tolerance: +-2ºC. - Thermostatic mixer regulation range: 30-60ºC. - Mixing outlet temperature calibration: 45ºC. - Components suitable for use with domestic water.

28 28 ALL-IN-ONE SOLAR SYSTEM patented This is a solar system that uses solar thermal energy to heat domestic water. It integrates the absorber, the pumpcirculated system, and the 150l tank. Less components, less time to install, less final price, and more m 2 available, the only solar heating product with ZERO C0 2 EMISSIONS, the only independent forced solar heating system no electricity consumption It uses a PV-driven circulating pump, which means it is a fully autonomous system that does not require any external power source. The solar system can be placed anywhere requiring domestic hot water (homes, campsites, community vegetable gardens, country homes and hotels). The ALL-IN-ONE solar system can be placed in a wide variety of places, from a pitched roof (either built-in or not) to a flat surface, a garden or a wall.

29 29 COMPONENTS TO INSTALL A SOLAR SYSTEM COMPONENTS SYSTEM DRAIN BACK SYSTEM ALL-IN-ONE MATERIAL Collector Hydraulic group Tank Solar tube Secondary tube ACCESSORIES ELECTRIC INSTALLATION Structure 45º Expansion tank Sanitary solar fluid Drain valves Electrical legalization Material and labor INSTALLATION TIME 25,5 h. 15,5 h. 9,5 h. CHARACTERISTIC - Pump powered by photovoltaic cell. - Storage capacity: 150 litres. - Useful collection surface area: 2 m 2. - Heat exchanger surface: 0,29 m 2. - External dimensions: - Length: 2024 mm. - Width: 1049 mm. - Depth: 290 mm. - Empty weight including tank: 89 kg. - Weight with glycol: 95 kg. - Structure on floor or flat terrace, structure, sloping roof top structure and wall structure, under request. Roof-integrated structure

30 30

31 31 HYDRAULIC SYSTEMS ORKLI offers top-quality products, but it also provides solutions to help operate and use these products and improve their installation. These solutions guarantee a long lifetime for the components, and available spares if any problems should arise. As an added plus, it also supplies products with customised features and designs. When it comes to internal hydraulics systems, we know we can offer you everything you need.

32 32 CONNECTION TEMPLATES CUSTOMIZED DESIGN Based on the concept of customisation, our aim is to give customers what they need, to anticipate their needs and improve their products. This is what makes us stand out: knowing that the change starts with our work. So we have developed new products and made progress in detecting aspects that although they are good, could be improved. Aspects that form part of our innovation and, therefore, make us different from the rest. We put things into production, on the basis of: - Being a European company with globalised production. - Being open to new challenges with the financial support of a large group (Corporación MONDRAGON). - Working together with technology centres and universities to tackle new projects. ADVANTAGES We are in a condition to offer advantages as important as: - CAD-CAM and all the drawing tools available. - Computerised hydraulic simulation (finite elements). - Integrated prototyping: functional parts in plastic and brass, fast prototyping of plastic or machined parts. High capacity. - A modern test laboratory, where pressure loss tests, functional life tests and hydraulic tests are carried out. - Stamping, machining and assembly lines. - Customisation processes. - Full integration of hydraulic controls in brass and in plastic. - Highly integrated functions. - Intelligent solutions for small dimensions. - Fast process development. These are just a few examples of our commitment to offering a fully customised service. A concept that consists of giving every customer just what they need. This is what makes the difference.

33 FILLLING LOOPS 33 DISCONNECTORS - Type CV approval. - Models without tap, with 1 tap and with 2 taps. HIGH KV ZONE-VALVES These zone valves have a lower pressure drop than the standard valves, which means they have a higher flow. KV = flow with a pressure drop of 1 bar. They provide even greater advantages when used with a heat pump, as a higher flow is needed to obtain more energy efficiency due to the lower temperature gradient.

34 34 different because... we believe in customer-focused INNOVATION For ORKLI, innovation is an attitude. We innovate in all areas of our business, from quality and production systems to service and logistics. Our continuous innovation capacity makes our R&D team one of our top assets. Orkli is a company backed by the most rigorous certification for quality, occupational health and safety, and also for environmental conservation and protection.

35 Commercial network 35 Deutschland Czech Republic U.S.A Orkli Deutschland GmbH Steinlachstraße 109 D Mössingen / Talheim Tel.: + 49 (0) 7473 / Fax.: + 49 (0) 7473 / info@orkli.de Jiri Prec - Orkli, S. Coop. Prumyslova 3143/ Prostejov - Rep. Checa Tel.: Fax: jprec@orkli.cz William (Bill) Lowe Tel.: ORKLI 1 (855) blowe@orkli.com Argentina United Kingdom France Uriarte Taldea S.A. Defensa 2616 Panam. y 197 El Talar de Pacheco - Tigre CP 1618 Tel.: Fax.: mateo@uriarte.com.ar Fred Card - Orkli (UK) Ltd. Unit 1,Trident Court One Oakcroft Road Chessington Surrey KT9 1BD Tel.: +44 (0) Fax: +44 (0) fred.card@orkli.es André Ruiz Tel.: aruiz@orkli.es China Orkli Kunshan shiling@orkli.com.cn Belgium Italy Iran Impex Chaussée de Vleurgat, BRUXELLES - BRUSSEL Belgique Tel.: info@impexsa.be Orkli Italia, S.R.L. Vía Roma Cassina de Pecchi (MI) Tel.: Fax.: rpiccardi@orkli.it Orkid Middle East Co. Fari Iravanian Tehran, I.R Iran Tel: Fax: fi@orkid-int.com Brazil Russia Turkey Orkli do Brasil Av. José Benassi, 300 Galpão 03 FAZGRAN SP - CEP: Pq. Industrial - Jundiaí Fazgran Tel.: +55 (11) Fax: +55 (11) comercial@orkli.com.br MCC Rusia Bolotnaia naberezhnaya, 15, block Moscow - Rusia Tel.: Fax: orkli@mondragon.ru Orkli Turkey Ziya Öztürk ziya.ozturk@orkli.com Korea Sung Sam Lee Tel: Samforu@naver.com

36 ORKLI, S. Coop. Ctra. Zaldibia, s/n / E Ordizia (Gipuzkoa) Tel.: / Fax: whc@orkli.es 02/2015/D