Alpha innotec PHZ PHZM Owner's manual

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9

Boiler connection system DN 25

Installation and operating instructions for the specialised installer

GB

R

ead installation and operating instructions in their

entirety before installing the boiler connection sys-

tem!

I

nstallation, initial operation, operation and main-

tenance must only be carried out by qualified tra-

d

esmen!

The installation and operating instructions, as well

as other valid documents must remain with the

user of the system!

Content

1 General information . . . . . . . . . . . . . . . . . . . . 9

2 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Transport, storage and packaging . . . . . . . . 10

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Construction and function . . . . . . . . . . . . . . 13

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 16

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 16

Illustr. 1.1 Pump group with three-way mixing valve

DN25 180 mm with pump ball valve

1 General information

1.1 Information regarding installation and operating

i

nstructions

These installation and operating instructions serve the

i

nstaller to install the differential pressure regulator

professionally and to put it into operation.

Other valid documents – manuals of all system com-

ponents, especially the operating instructions of the

circulation pump, as well as valid technical rules –

must be observed.

1.2 Keeping of documents

These installation and operating instructions should

be kept by the user of the system.

1.3 Copyright

The installation and operating instructions are copy-

righted.

1.4 Symbol explanation

Safety guidelines are displayed by symbols. These

guidelines are to be observed to avoid accidents, da-

mage to property and malfunctions.

Subject to technical modification without notice.

DANGER indicates an immi-

nent dangerous situation which will lead to death or

serious injury if the safety guidelines are not obser-

ved.

WARNING indicates a pos-

sible dangerous situation which may lead to death or

serious injury if the safety guidelines are not obser-

ved.

ATTENTION indicates a pos-

sible damage to property which may occur if the safety

guidelines are not observed.

PRECAUTION indicates a

possible dangerous situation which may lead to minor

or moderate injury if the safety guidelines are not ob-

served.

DANGER

ATTENTION

!

WARNING

!

PRECAUTION

!

10

3 Transport, storage and packa-

ging

3.1 Extent of supply

– Pre-assembled Pump group DN25 product group

– Thermal insulation

– Pump groups with 130 mm-pumps: with standard

thermal insulation; consisting of front and rear in-

sulation shell

– Pump groups with 180 mm-pumps: with universal

thermal insulation of modular construction; con-

sisting of front and rear insulation shell and inser-

tion block suitable for the installation of standard

high-efficiency pumps

– Sealing set (4 fold)

– Pump installation set (stations without pump)

Heavy product group!

Risk of injury! Suitable transport and lifting devi-

ces are to be used. Wear suitable protective clot-

hing (e.g. safety shoes) during installation and use

safety devices. External components like hand-

wheels or pressure test points must not be mis-

used for the absorption of external forces, e.g. as

connection point for lever tools etc.

Hot and cold surfaces!

Risk of injury! Do not touch the boiler connection

system without safety gloves. It may get very hot

during operation.

Sharp edges!

Risk of injury! Only touch with safety gloves. Threads,

bore holes and edges are sharp.

Allergies!

Health hazard! Do not touch the boiler connection

system and avoid any contact if allergies against

the used materials are known.

WARNING

!

2 Safety notes

2

.1 Correct use

Safety in operation is only guaranteed if the boiler con-

nection system is used correctly.

T

he boiler connection system allows a time- and

space-saving connection of the boiler to the pipework.

A

ny use of the boiler connection system outside the

above applications will be considered as non-compli-

a

nt and misuse. Claims of any kind against the manu-

facturer and/or his authorised representatives due to

damages caused by incorrect use cannot be accep-

t

ed.

The observance of the installation and operating in-

s

tructions is part of the compliance terms.

2.2 Possible dangers at the installation locati-

on and during transport

The case of an external fire has not been taken into

consideration when constructing the boiler connection

system.

3

.2 Transport inspection

Upon receipt check delivery for any damages caused

during transit.

A

ny damage must be reported immediately upon re-

ceipt.

3.3 Packaging

Packaging material is to be disposed of environmen-

t

ally friendly.

4 Technical data

4

.1 Models

These installations and operating instructions are valid

for the following Pump group models:

For pumps with a length of 130mm:

– Pump group DN 25 with standard thermal insula-

tion

– Pump group with three-way mixing valve DN 25

with standard thermal insulation

– Pump group with four-way mixing valve DN 25 with

standard thermal insulation

For pumps with a length of 180mm:

– Pump group DN 25 with universal thermal

insulation

– Pump group with three-way mixing valve DN 25

with universal thermal insulation

– Pump group with four-way mixing valve DN 25 with

universal thermal insulation

– Pump group DN 25 with pump ball valve with uni-

versal thermal insulation

– Pump group with three-way mixing valve DN 25

with pump ball valve with universal thermal insulation

– Pump group with four-way mixing valve DN 25 with

pump ball valve with universal thermal insulation

4.2 Performance data

Nominal dimension DN 25

Max. operating temperature

for standard pumps +110°C

Max. operating temperature

for high-efficiency pumps with

standard thermal insulation +85°C

Max. operating temperature

for high-efficiency pumps with

universal thermal insulation +95°C

Max. operating pressure p

s

10 bar

Opening pressure of the

check valve 20 mbar

Kv-value Pump group 7.4

Pump group with three-

way mixing valve 4.3

Pump group with four-

way mixing valve 4.2

Distance between pipe centres 125 mm

Connections G1½ flat sealing

Fluids: Non-aggressive fluids (e.g. water and suitable

water and glycol mixtures according to VDI 2035). Not

suitable for steam or oily and aggressive fluids.

Suitable measures (e.g. safety valves) have to be

taken to ensure that the maximum working pres-

sures and maximum and minimum working tem-

peratures are not exceeded or undercut.

DANGER

!

11

4

.3 Materials

Valves and fittings brass

Pump cast iron body

H

andles PA 6.6

Insulation EPP

F

langed pipe copper

Seals EPDM

Four-way mixing valve

(

Pump groups with four-

way mixing valve) bronze

4

.4 Dimensions/Connection dimensions

Illustr. 4.1 Pump group DN 25 130 mm

Illustr. 4.2 Pump group with three-way mixing valve

DN 25 130 mm

Illustr. 4.3 Pump group with four-way mixing valve

DN 25 130 mm

Illustr. 4.4 Pump group DN 25 180 mm

12

Illustr. 4.5 Pump group with three-way mixing valve

DN 25 180 mm

Illustr. 4.6 Pump group with four-way mixing valve

DN 25 180 mm

Illustr. 4.7 Pump group DN 25 180 mm with pump ball

valve

Illustr. 4.8 Pump group with three-way mixing valve

DN 25 180 mm with pump ball valve

13

Illustr. 4.9 Pump group with four-way mixing valve

DN 25 180 mm with pump ball valve

4.5 Flow chart

Flow chart for Pump groups 130 mm and Pump groups

180 mm

As for the models with mixing-valve, the latter is fully

opened.

5 Construction and function

5

.1 Summary and functional description

The product group is available with and without circu-

lation pump.

T

he individual components of the model without pump

are supplied loosely connected. After installation of

t

he pump, the connections have to be tightened.

The connection box of the pump must be in 9 o’clock

p

osition.

On delivery, the supply pipe is on the right hand side.

B

ut the supply and the return can be changed on site

(see 6.1). The mixing valve does not have to be

changed.

The standard pump group allows the isolation of the

heating circuit. It consists of an isolation device with

thermometers in the handles and a distance piece for

length compensation in the supply pipe. The check

valve integrated in the return pipe avoids gravity cir-

culation.

The pump group with three-way mixing valve has the

same design and function as the standard pump

group. It is additionally equipped with a three-way mi-

xing valve and an actuator. The three-way mixing valve

serves to regulate the flow temperature and has a by-

pass with manual presetting. A manually set return

flow share can be added to the supply pipe via this

bypass in order to reduce the flow temperature of a

surface heating e.g.

The pump group with four-way mixing valve has the

same design and function as the standard pump

group. It is additionally equipped with a bronze four-

way mixing valve and an actuator. The four-way mixing

valve serves to regulate the flow temperature. The re-

turn temperature of the boiler is increased at the same

time. The bypass with manual presetting integrated in

the mixing valve serves to regulate the flow tempera-

ture in systems with a high boiler temperature and a

low flow temperature (e.g. surface heating systems).

This bypass constantly adds return water to the supply

pipe.

5.2 Check valve

The product group is supplied pre-assembled. During

heating operation, the slot for opening the check valve

must be in horizontal position.

Illustr. 5.1 Position check valve

Check valve closed Check valve opened

Operating position: Check valve closed, passage only

in flow direction.

When putting the system into operation and during

maintenance work (filling and flushing), the check valve

must be opened.

Isolation function inactive: Check valve opened, flow

is possible in both directions.

During heating operation, the check valve must be set

to operating position.

Pressure loss ∆p [mbar|

·

Flow rate V [l/s]

Pressure loss ∆p [Pascal|

14

W

hen the circulation pump is switched off, a low

gravity circulation depending on the circulation

pressure is still possible within the heating system

d

espite the check valve as the latter is not tight

sealing.

ATTENTION

5

.3 Setting of the bypass at the three-way mixing

v

alve (Pump groups with three-way mixing

valve)

T

he pump groups with three-way mixing valve are ad-

d

itionally equipped with a bypass with manual preset-

ting at the three-way mixing valve. When leaving the

f

actory, the bypass is closed (Slot of the bypass stem

turned by 90° towards the bypass channel, position

“off”, see illustr. 5.2).

By turning the bypass stem by 90°, i.e. slot running

parallel to the bypass channel, position “on”, the ma-

ximum flow rate can be reached.

Kv-values:

Mixing valve (I ➝ II) and bypass stem

fully opened: Kv = 4.7

Mixing valve closed (III ➝ II),

bypass fully opened Kv = 2.6

Mixing valve fully opened (I ➝ II),

bypass closed Kv = 4.3

The safety screw of the bypass stem is marked with

a coat of lacquer. This safety screw must

never be loosened when the system is under pressure.

There is danger that hot water may escape uncon-

trollably.

WARNING

!

Illustr. 5.2 Bypass setting

Safety

screw

5.4 Actuator (Pump groups with three/four-way mi-

xing valve)

The electrical connection must be carried out in

accordance with the valid regulations!

WARNING

!

The pump groups with mixing valve are supplied with

an actuator.

The following models are available:

Actuator NR230 for 230V

Actuator NR24 for 24V

T

he actuators NR24 and NR230 are used for the mo-

torised actuation of three- and four-way mixing valves.

The actuators can be activated via any commercial

c

ontrol system with a three point output. If the actuator

rotates clockwise, the flow temperature increases until

t

he limit stop of the actuator is reached (supply ope-

ned, bypass closed). The flow temperature drops if

the actuator rotates anticlockwise until the opposite

l

imit stop is reached (supply closed, bypass opened).

T

echnical data actuator:

Operating current NR230: 230V 50Hz

N

R24: 24V 50Hz

Protective system II (shockproof)

Torque 5 Nm

Operating time 140 s

Manual setting mechanical gear release

Ambient temperature 0°C up to +50°C

Length of cable 2.2m

The angle of rotation is limited to 90°. Having reached

the limit stops, the actuator is switched off electrically

and is without current. In case of malfunction of the

control system, the actuator can be converted to ma-

nual operation with the help of an additional rotary

knob.

Illustr. 5.3 Connection diagram three point control

5.5 Markings

– CE marking on the pump:

CE-marking

– Indications on the body:

OV Oventrop

DN Size

PN Nominal pressure

Controller

black

white

brown

white

blue

Controller

15

6 Installation

I

nstallation, initial operation, maintenance and repair

are to be carried out by a specialist installer. (EN 5011

part 1 and VDE 1000 part 10 for work on electrical in-

s

tallations).

O

bserve warning advice under paragraph 2 (safety

notes)!

!

Before starting work, make sure that the pipework

a

nd components have cooled down and been

drained.

Before starting work, disconnect electrical com-

ponents (controllers, pumps, etc.) from power!

W

ARNING

!

The pipework has to be flushed thoroughly before in-

stalling the connection group. Installation is possible

in any position (horizontal, oblique or vertical in as-

cending or descending sections). It is important to

note that the direction of flow must conform to the ar-

row on the assembly.

After all work has been completed, check all installation

points for leaks.

6.1 Change of supply and return

Installation of the supply pipe on the left hand side is

carried out as follows:

– Unscrew flanged pipe with check valve on the return

(left hand side of the pump group) and screw it back

on the right hand side.

– Install pump on the left hand side.

– The switching box of the pump must be turned to 3

o’clock position. To do so, loosen the hexagon

screws and turn the pump head by 180° so that the

switching box of the pump is in 3 o’clock position.

Now tighten hexagon screws and ensure that the

pump head is not jammed.

– Remove and interchange the red and blue plugs on

the front of the insulation.

Red = supply, Blue = return

– A modification of the mixing valve is not required.

6.2 Use of high-efficiency pumps

The product groups are suitable for use with standard

high-efficiency pumps.

A modification of the thermal insulation is not per-

missible. The pump motor must not be covered.

T

he maximum fluid temperature must be obser-

ved!

ATTENTION

The high-efficiency pumps are electronically controlled

a

nd offer different settings. The pump setting should

be chosen depending on the application.

The following settings are recommended by the pump

m

anufacturers:

Application radiator heating (two pipe system)

– Automatic setting; alternatively

–

∆p-v Differential pressure variable

Application radiator heating (one pipe system)

– ∆p-v differential pressure variable

6.3 Installation of the actuator (Pump groups with

three-/four-way mixing valve)

Contrary to the three-way mixing valve, the actua-

tor is turned around by 180° when mounting it

onto a four-way mixing valve.

ATTENTION

– Mount antirotation device (1) onto the valve body.

– Push adapter (2) onto the spindle of the mixing valve

(3) until stop. Ensure flat surfaces on spindle and

adapter are aligned!

– Set spindle of the mixing valve in such a way that

the nose of the adapter points downwards in the

direction of the axis of the connection thread. In this

position, the supply is closed by the spindle of the

mixing valve (bypass fully opened, cold).

– Place actuator (4) onto the shaft of the mixing valve.

– Place rotation indicator (5) onto the actuator as

illustrated.

– Slip handle for manual setting (6) onto the shaft of

the mixing valve with the arrow being in the blue

zone (factory setting: Anticlockwise sense until stop,

operating position “A” automatic operation).

– Introduce and tighten screw (7) together with the

serrated lock washer.

16

I

nstallation in intermediate position:

Factory setting misaligned – actuator has not reached

l

imit stop.

–

Place actuator onto the shaft of the mixing valve.

– Set operating switch to manual operation.

–

Place rotation indicator onto the actuator as illus-

trated.

– Push handle for manual setting onto the shaft of

t

he mixing valve.

T

he handle can only be engaged easily in a snap-

in position. Do not use excessive force!

ATTENTION

– Turn handle for manual setting to the left until stop.

Arrow of the handle is in the blue zone.

– Introduce and tighten screw together with the ser-

rated lock washer.

– Set operating switch to “A” (automatic operation).

Illustr. 6.2 Installation three-way mixing valve

7 Operation

7

.1 Deaeration of the system

Before initial operation, the installation must be filled

and bled with due consideration of the permissible

o

perating pressures.

7

.2 Correction factors for water and glycol mixtu-

res

T

he correction factors of the antifreeze liquid manu-

facturers must be observed when setting the flow rate.

8 Accessories

T

he tailpipe sets for the connection to the pipework

are to be ordered separately.

A bracket for fixing the pump group onto the wall is to

be ordered separately.

When installing certain high-efficiency pumps (e.g.

Grundfos Alpha2), there may be a collision of pump

plug and actuator. Oventrop offers a right angle plug

for this application..

The complete range of accessories can be found in

the catalogue.

9 Maintenance

The boiler connection system is maintenance-free.

Tightness and function of the regulator and its con-

nection points have to be checked regularly during

maintenance. The product group must be easily ac-

cessible.

Illustr. 6.3 Installation four-way mixing valve

“nose”

b

lue

“nose”

blue

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