AFRISO PrimoBox ACB 910 Specification sheet
Read the manual before using the device
Pay attention to all information regarding safety
Keep the Operation and installation manual
953.001.0001
AFRISO sp. z o.o.
Szałsza, ul. Kościelna 7
42-677 Czekanów
POLAND
Telefon +48 32 330 33 55
Fax +48 32 330 33 51
www.afriso.pl
Operation and installation manual
PrimoBox ACB 910 mixing unit
for condensing boilers
Instruction manual
2 PrimoBox ACB 910 mixing unit for condensing boilers
Table of Contents
1Explanations to the installation and operation manual............................................3
1.1 Safety messages and hazard categories .....................................................3
2Information on safety ...............................................................................................3
2.1 Intended use.................................................................................................3
2.2 Quality control...............................................................................................3
2.3 Qualification of personnel.............................................................................4
2.4 Modifications to the product..........................................................................4
2.5 Using additional parts and accessories........................................................4
2.6 Liability..........................................................................................................4
3Product description..................................................................................................5
3.1 Construction ................................................................................................6
3.2 Operation......................................................................................................7
3.3 Hydraulic diagram of the ACB 910 unit ........................................................9
3.4 Application scheme ....................................................................................10
4Specification...........................................................................................................11
4.1 Approvals....................................................................................................11
4.2 Available pressure chart.............................................................................12
5Transport and storage ...........................................................................................12
6Installation and commissioning..............................................................................13
6.1 Wall mounting.............................................................................................13
6.2 Flush mounting...........................................................................................14
6.3 Hydraulic connections ................................................................................14
6.3.1 Connection to the heat source ...................................................................14
6.3.2 Connection of individual heating circuits ....................................................15
(direct circuit and mixing circuit) ............................................................................15
6.4 Differential pressure relief valve DU...........................................................15
6.5 Electrical connections.................................................................................15
6.6 Filling and venting.......................................................................................17
7Assembly of the ARM ProClick actuator................................................................18
8Switching the actuator to manual operation ..........................................................19
9Maintenance ..........................................................................................................19
10 Decommissioning, scrapping.................................................................................20
11 Warranty ................................................................................................................20
12 Copyright................................................................................................................20
13 Customer satisfaction ............................................................................................20
14 Addresses..............................................................................................................20
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 3
1Explanations to the installation and operation manual
Installation and operating instructions are an important part
of the delivery. That is why we recommend:
Read the installation and operating instruction before installing
the device.
Keep the installation and operating instruction for the entire life
of the device.
Hand over the installation and operating instructions to any sub-
sequent owner or user of the device.
1.1Safety messages and hazard categories
DANGER
Specifies the type and source of the threat.
Describes what to do to avoid a hazard.
Threats have 3 levels:
Danger
Importance
DANGER
DANGER indicates a hazardous situation, which,
if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situa-
tion, which, if not avoided, can result in serious in-
jury or equipment damage.
NOTICE
NOTICE indicates a hazardous situation, which,
if not avoided, can result in equipment damage.
2Information on safety
2.1Intended use
The PrimoBox ACB mixing unit for condensing boilers is a compact,
prefabricated solution enabling quick and convenient connection
of a radiator system and a underfloor heating, working in a closed
system in accordance with PN-EN 12828.
Any other application than indicated in point 2.1 is forbidden.
2.2Quality control
Construction of the PrimoBox ACB mixing unit for condensing boilers
complies with the current state of the technical standards regarding
safety. Each device is checked for safety before shipment.
The product should only be used if it is in a qualified technical
condition. Read the instructions for assembly and use as well
as observe the relevant safety regulations.
Instruction manual
4 PrimoBox ACB 910 mixing unit for condensing boilers
WARNING
Mains voltage (230 V AC) can cause serious injury or death.
Do not allow the device cover to come into contact with water.
Disconnect the device from the mains before opening the cover.
Disconnect the device from the mains before servicing.
Do not make any changes to the device.
2.3Qualification of personnel
Mixing unit PrimoBox ACB 910 may only be installed, commissioned,
shut down and disassembled by suitably qualified and trained
personnel. Work on electrical circuits should only be carried out by an
authorized electrician.
2.4Modifications to the product
Changes and modifications carried out by unauthorized persons may
cause hazards and are prohibited for safety reasons.
2.5Using additional parts and accessories
Improper additional parts and accessories may damage the device.
Use only original spare parts and accessories
from the manufacturer.
2.6Liability
The manufacturer is not responsible for direct damages or their
consequences resulting from inaccurate reading of assembly
and usage instructions and recommendations.
The manufacturer and the company selling the device are
not responsible for damages and costs incurred by the user or third
parties using the device, in particular for damage resulting
from improper use indicated in chapter 2.1 of assembly and use
instructions, improper or faulty connection or maintenance and non-
compliant operation with manufacturer's recommendations.
AFRISO sp. z o.o. makes every effort to ensure that the information
materials do not contain errors. If errors or inaccuracies are found
in the following installation and operation instructions, please contact:
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 5
3Product description
PrimoBox ACB is a hydraulic unit for managing two heating zones
with different supply temperatures in a system with a condensing
boiler.
The PrimoBox ACB mixing unit consists of connections for a gas
condensing boiler, connections for a direct heating circuit, connections
for a circuit with reduced flow temperature and a pump that supply
reduced temperature circuit. The most important element is the special
4-way valve with 6 ports with a disproportionate valve sleeve.
Hydraulic components are are connected with copper pipes.
Everything is enclosed in a compact, steel housing.
Fig. 1: Dimensions of the ACB mixing kit
Instruction manual
6 PrimoBox ACB 910 mixing unit for condensing boilers
3.1 Construction
1- Shut-off valve with thermometer
2- Reduced temperature zone supply
3- Reduced temperature zone return
4- ARM ProClick actuator
5- Specific 4-way valve with 6 connections
6- Supply from a condensing boiler
7- Differential pressure relief valve
8- Direct zone return
9- Direct zone supply
10-Electric box
11-Circulation pump
Fig. 2: Construction of the ACB mixing unit for the condensing boiler
1
1
1
2
1
3
4
5
6
7
8
9
11
10
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PrimoBox ACB 910 mixing unit for condensing boilers 7
3.2 Operation
PrimoBox ACB is a hydraulic unit for two heating zones with different
supply temperatures, where one of the circuits is direct and on
the other the temperature is lowered via the mixing valve.
This is a solution dedicated only for condensing boilers.
The PrimoBox ACB mixing unit performs the following functions:
•Esures a lower return temperature, which helps condensation
in the gas boiler, increasing its efficiency
•Direct heating zone connection
•Connection for a zone with reduced temperature obtained
by mixing
The PrimoBox ACB unit does not use a standard 3-way mixing valve,
but a special 4-way valve with 6 ports and a disproportionate valve
sleeve. The purpose of this special 4-way valve is to use the medium
returning from the direct zone (without mixing) to supply the zone with
reduced temperature.
Shut-off valves with thermometers
The ACB mixing units are supplied with shut-off valves to facilitate
product maintenance. Check valves have been built into the shut-off
valves and slot for temperature sensors has been prepared. The valve
knobs contain thermometers to control the temperature of the heating
medium. By turning the knob 45°, the non-return valve is forced to
open for easy maintenance and system filling.
Grundfos UPM3 AUTO 15-70 circulation pumps
For the operation of the Grundfos UPM3 AUTO circulation pump
included in the PrimoBox units, please refer to the attached operating
instruction (also available on the pump manufacturer's website).
Instruction manual
8 PrimoBox ACB 910 mixing unit for condensing boilers
PrimoBox ACB unit connctions
Fig. 3: Connections diagram of the ACB 910 mixing unt
gas boiler
direct zone
low temperature zone
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 9
3.3Hydraulic diagram of the ACB 910 unit
Fig. 4: Hydraulic diagram of the ACB 910 set
Instruction manual
10 PrimoBox ACB 910 mixing unit for condensing boilers
3.4 Application scheme
Fig. 5: Sample application diagram - underfloor heating system circuit
and radiator system circuit
1. ACB mixing unit
2. Condensing gas boiler with pump
3. Radiator installation
4. Underfloor heating installation
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
2
3
4
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PrimoBox ACB 910 mixing unit for condensing boilers 11
4Specification
Table 1: Technical data of ACB 910 units
Parameter / part
Value / Description
General specification
Dimensions (W x H x D)
400 x 450 x 160mm
Weight
11,7 kg
Circulation pump
Grundfos UPM 3 AUTO 15-70 130 mm
Rotary mixing valve
Kvs 3,6 with 3-point electric actuator
ARM ProClick 230 V AC 50 Hz
Pressure
max 4,5 bar
Heat source connections
male G¾”
Connection of individual zones
female G¾”
Heating medium temperature
5°C ÷ 95°C
Glycol concentration
max 30%
Installation power
max 26 kW
Water capacity
1 l
Supply voltage
Supply voltage
230 V AC ± 10%, 50 Hz
Power consumption
max 52 W
Housing protection
IPX 0
4.1Approvals
The PrimoBox ACB 910 mixing unit for condensing boilers is subject
to the Pressure Directive 2014/68 / EU and in accordance with art. 4.3
(sound engineering practice) are not CE marked.
The circulating pump provided with the product has a declaration
of conformity, which is available on the manufacturer's website.
The ARM ProClick electric actuator used in the ACB unit complies
with EU directives on LVD low voltage electrical equipment
(2014/35/EU) and EMC electromagnetic compatibility (2014/31/EU).
Instruction manual
12 PrimoBox ACB 910 mixing unit for condensing boilers
4.2Available pressure chart
Fig. 6: Diagram of available pressure on the low temperature zone
5Transport and storage
ATTENTION
Possibility of damage to the device during improper transport.
Do not throw the device.
Protect against water, moisture, dirt and dust.
ATTENTION
Possibility of damage during incorrect storage.
Store the device in a dry and clean room.
Protect against water, moisture, dirt and dust.
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 13
6Installation and commissioning
The PrimoBox ACB mixing unit installation location must provide
weather protection. The ACB kit cannot not be installed outdoors.
The ACB mixing unit cannot be mounted on stands or placed directly
on the floor. If there is visible damage to the product, do not proceed
with installation.
ATTENTION
Possible damage to existing installations
When drilling into walls, pay special attention not to damage
electric cables or other existing cables.
6.1Wall mounting
On the selected, straight wall, mark the places provided for the han-
dles so that they coincide with the holes in the back of the PrimoBox
ACB mixing unit. Drill holes in the wall and place the dowels (included
in the delivery) in them. Hang the module on the dowels. Then check
the correct leveling.
ATTENTION
Possible need for other dowels
It is necessary to verify that the dowels provided are suitable
for the selected wall.
If the dowels provided are not suitable for the selected wall,
replace them with others.
Mounting the PrimoBox ACB unit on the improper dowels can
lead to its breaking off the wall!
Instruction manual
14 PrimoBox ACB 910 mixing unit for condensing boilers
6.2Flush mounting
Check whether the wall is strong and thick enough and that
the PrimoBox ACB 910 mixing unit will fit in the place you choose.
To install the PrimoBox AZB mixing unit in the wall, breach the fins
placed in the housing and bend them with pliers so that they are
outside the unit housing.
Then create a space
in the wall, at least 2 cm larger
than the external dimensions
of the housing of the ACB 910
mixing unit. Fasten the module
in the hole in the wall
with plaster or other suitable
compound. Remember to level
it carefully using a spirit level.
After drying, if necessary,
make an aesthetic finish of the
wall.
Fig. 7: Bending of the housing fins
6.3Hydraulic connections
Before connecting the PrimoBox ACB mixing unit, flush the system
thoroughly, paying special attention to removing residue from solder-
ing, cutting pipes, etc. Make sure that the installation contains safety
components neces-sary for proper and safe functioning.
You should also check on the basis of flow charts whether the required
flow on individual heating circuits will be guaranteed. We recommend
installing strainers before inlet connections. The heating installation
should also contain dirt separators or other similar filter elements.
Make sure you can use the PrimoBox ACB mixing unit for the circuits
connected to it. Remember that the ACB unit is intended for the distri-
bution of the medium into the radiator installation (without mixing)
and the underfloor heating installation (with qualitative temperature
regulation by mixing).
6.3.1 Connection to the heat source
The connection between the ACB unit and the heat source is made
via supply and return connections with G¾" male threads located
in the upper part of the ACB unit.
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 15
6.3.2 Connection of individual heating circuits
(direct circuit and mixing circuit)
The connection between the ACB unit and the heating system is made
via supply and return connections with female G¾” threads located
at the bottom of the ACB unit. The maximum length of underfloor
heating pipes, resistance of flow, as well as the flow of medium by the
circuit with mixing must comply with the permissible values of flows
and resistances according to the chart presented in subsection 4.2.
6.4Differential pressure relief valve DU
In a direct circuit with thermostatic valves
or zone valves, it is necessary to use
a pressure differential bypass valve
(bypass). It is designed to maintain
a constant pressure on the boiler pump,
which also works as a direct zone (radiator
zone) circulation pump. Recommended
DU valve setting is 0.1-0.2 bar
overpressure.
Fig. 8: Differential pressure relief valve AFRISO DU
If the direct installation is characterized by high hydraulic resistance
and the relief valve opens too early (not allowing for adequate flow
on the radiator furthest away from the heat source) the setting should
be increased to 0.2-0.3 bar.
If thermostatic valves are not installed in the direct circuit next
to the radiators and no zone valves are used, set the differential
pressure relief valve DU to 0.5 bar overpressure.
6.5Electrical connections
Make sure that the power supply has been disconnected and
protected against accidental switching on.
Comply with the accident prevention regulations and other rele-
vant accident prevention regulations.
The ACB mixing unit for condensing boilers is connected to 230V AC.
The ACB mixing kit has a built-in electrical box. During assembly
there is only a need to connect the pump and actuator dedicated ca-
bles to the electrical box. The connection between the electrical box
and the pump and actuator is already made at the factory.
Instruction manual
16 PrimoBox ACB 910 mixing unit for condensing boilers
WARNING
Do not allow actuators, built-in electrical box and cables
into contact with water.
Connecting the power cable to the device outside the built-in electrical
box is prohibited.
Electrical connections must be made by experienced and qualified
personnel in accordance with this instruction manual.
Fig. 9: Factory distribution of electric wires
the dotted line indicates the recommended routing of the mixed temperature sensor wire (not included)
Cables for connecting the pump and actuator controller to the ACB
electrical box are not included.
The electrical connections should be made according to the diagram
(Fig. 10).
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 17
Fig. 10: Electrical diagram of the mixing set for condensing boiler
ARM ProClick actuators must be electrically connected to a suitable
3-point controller with a 230 V AC control signal.
The actuator power cord is detachable, which makes assemblyeasier.
To remove the plug from the actuator, lift the lid latch lever (Fig. 11)
and slide the cover off the actuator housing,
then unplug the plug. The plug only fits into
the socket in one position.
Fig. 11: Removing the lid
6.6Filling and venting
After installation, fill the installation with heating medium. Ensure
adequate venting during filling. Also remember to fill the installation
slowly - this way you will reduce the amount of air remaining
in the installation after it has been filled. If the gas boiler does not have
sufficient pressure, the system must be vented again.
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18 PrimoBox ACB 910 mixing unit for condensing boilers
7Assembly of the ARM ProClick actuator
The PrimoBox ACB condensing boiler mixing unit is equipped
with ARM ProClick electric actuators. It is possible to easily disassem-
ble and reassemble the actuator.
The ARM ProClick actuators
are removed from the valve
by pressing the button on the side
of the actuator housing and pull-
ing the actuator towards you.
Fig. 12: Actuator latch release
button on the valve
In order to mount the ARM ProClick actuator on the mixing valve
of the ACB mixing unit, the mixing valve should be set to "50% open",
i.e. the indicator of its cover (Fig. 13) is exactly halfway between
the connection "C" and connection “B”
of the four-way valve.
Fig. 13: Valve closing component indicator
Then slide the actuator onto the mixing valve
until the actuator ProClick mechanism locks
on it. When mounting the ProClick actuator
on a rotary valve, pay attention to the current position of the valve
indicator. The valve stem should be positioned as in Figure 13,
and the actuator position indicator should show half the scale (vertical
position).
If the valve is in a different position, it must be set manually (using a
flat screwdriver, for example) as shown in Figure 13. If the indicator
on the actuator does not indicate the center of the scale (it is not ver-
tical), it should be switched to manual mode, set the actuator
with an allen key so that the indicator is vertical and indicates the cen-
ter of the scale. After putting the actuator on the valve, switch back
to automatic mode.
Instruction manual
PrimoBox ACB 910 mixing unit for condensing boilers 19
8Switching the actuator to manual operation
Switching from automatic to manual operation is carried out by means
of the operating mode button.
Fig. 14: Actuator mode button
The pressed operating mode button enables
manual operation, i.e. free operation
of the actuator with an allen key.
9Maintenance
WARNING
Mains voltage (230 V AC) can cause serious injury or death.
Disconnect the power supply with the external switch before
each operation.
To ensure correct operation of the ACB unit for condensing boiler
and other system components, keep the heating medium at the level
of the smallest possible contamination and at the level of hardness
and pH recommended by the boiler manufacturer. Due to the copper
pipes included in the ACB unit, special attention should be paid
to water hardness, scale and other deposits.
At least once a year, as a precautionary measure,
check the condensing boiler (unless its manufacturer specifies
otherwise), the primary circuit and heating circuits, and the ACB
mixing kit. The following are crucial: visual tightness control,
control of elements integrity, visual control of potential damages,
control of electrical connections and condition of wires.
Before the heating season, it is also recommended to check
the circulation pump by making a test run. PrimoBox ACB mixing units
do not require additional maintenance than those listed in chapter 9.
Instruction manual
20 PrimoBox ACB 910 mixing unit for condensing boilers
10 Decommissioning, scrapping
1. Disconnect the device's power supply.
2. Disassemble the device (see chapter 6, reverse order).
3. In the interests of environmental protection, do not dispose
of the device when it is out of service with unsorted household
waste. The device should be delivered to an appropriate recycling
facility.
Mixing units for a condensing boilers are made of materials that can
be recycled.
11 Warranty
The manufacturer’s warranty for this product is 36 months counted
from the date of purchase from AFRISO sp. z o.o. by the seller. In case
of any alteration in the product or usage against this instruction
manual, thewarranty becomes void.
12 Copyright
Copyrights to the manual belong to AFRISO sp.z o.o. Reprinting,
translation and reproduction, even partial, is prohibited without written
permission. Changing technical details, both in writing and in the form
of images, is prohibited by law. We reserve the right to make changes
without prior notice.
13 Customer satisfaction
For AFRISO sp.z o.o. customer satisfaction is the most important thing.
If you have questions, suggestions or problems with the product,
please contact: zok@afriso.pl, phone number +48 32 330 33 55.
14 Addresses
The addresses of companies representing the AFRISO group around
the world can be found at www.afriso.com.
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