Grundfos PHP A-1 4.0 User manual

PHP A-1 4.0, 5.6, 6.6 & 8.1
Instruction manual
UK version, original instructions

PHP A-1 Instruction Manual / Contents
02
Table of Contents
1. General
2. Mounting
2.1 Installing the device
2.2 Makeup PHP
2.3 Changing the positions of the hydraulic connections
2.4 Usage of devices without degassing
2.5 Usage of cooling vessels
2.6 Temperature sensor T2
2.7 Electric connection
3. Hydraulic diagrams
4. Wiring diagrams
5. Operation and display
5.1 Switching on
5.2 User and display elements
5.3 Display
5.4 Scroll and change values
5.5 Display level
5.6 User level 2
5.7 User level 3
5.8 Manual mode
5.9 Timer programs
6. Commissioning PHP A-1
6.1 Commissioning PHP
6.2 Commissioning the make-up water BREAKTANK
6.3 Commissioning the make up water PUMPS
7. Warnings and fault messages
8. Cleaning and maintenance
8.1 Cleaning
8.2 Maintenance
9. Technical data
9.1 PHP
9.2 Additional expansion vessels for
combination with PHP
10. Spare parts list
11. Hazard notes
12. Appendix
13. EC declaration of Conformity
NOTE
Figures in this document can vary due to model and
configuration of the delivered PHP device.
INFORMATION
This document refers to PHP series devices with software
version V1.23. Design and operation can vary slightly due
to the existing software version.
DISCLAIMER
We improve out products permanently and so we
reserve the right to make modifications anytime and
without previous announcements. We do not assume
any guarantee for the correctness and completeness
of this document.
Any claims, particularly claims for damages and loss of
profit or financial losses must be excluded.

PHP A-1 Instruction Manual / General
1 General
1.1 Tender text
Modular PHP for lossless storage of the expansion volume
and for pressure maintenance in closed heating, climate
and cooling systems. Designed and manufactured acc. to
regulations of EN 12828 and SWKI 93-1.
The control unit is built very compact with two low-noise
pressure maintenance pump(s) which is executed ad
multistage centrifugal pump(s) with high quality floating-
ring type shaft seal. Also the PHP hydraulics includes one
continuously regulating, mechanically set overflow valve.
High-precision measuring of the plant pressure. Hydraulic
connections and necessary shut-off devices for on-site
piping are factory-provided on the right side of the control
unit (possibility for rebuilding to the left side of the control
unit). Temperature monitoring of the media streaming into
the vessel. Prepared connection point for mounting a make-
up module for accurate measuring Combinable with water
softening for standardised make-up water (if required).
All operations are controlled by the microprocessor
electronics. The operator panel is situated ergonomically and
contains an illuminated 4-line text display. The measure- and
control unit is executed in a closed electrical cabinet. Four
potential-free signalling contacts (fault, warning, makeup in
operation, device operation enabled).
For more signals two additional modules can be installed
easily in prepared mounting positions. Remote monitoring
can be done also via SMS-module, bus module or web module.
PHP series devices are equipped by default with integrated
economic low-pressure degassing, based on the principle
of pressure drop. External temperature monitoring via an
optional temperature sensor at the connection point is
prepared too.
PHP unit includes a CAT Break Tank with 2 x Pumps.
Modular PHP:
The PHP device is a nicely shaped,
self-contained unit with a pleasing design. It is designed for
a modular combination with external expansion vessels
(max. 0.5 bar). The connections for suction pipe and
overflow pipe are situated at the back of the device.
Max. operation temperature of the plant: 110 °C
(with cooling vessel)
Max. temperature at the connection point: 70 °C
Max. operating pressure (PN): 10 bar
03

PHP A-1 Instruction Manual / Mounting
2 Mounting
2.1 Installing the device
The PHP device must be installed and fixed through the
applicable holes in the feet of the frame to a horizontal
and solid floor. Suitable lifting devices should be used with
heavy equipment. Please refer to weights and dimensions in
section 9 of this manual.
The connection into the system return must be executed
acc. to the hydraulic diagrams in Chapter 3 “Hydraulic
diagrams”.
Modular PHP devices can be used in plants with max.
temperature of 70 °C at the connection point. If the max.
temperature at the connection point exceeds 70 °C,
cooling vessels must be installed. See Chapter 2.6
“Usage of cooling vessels”.
The connection into the system return must be done at a
position where no external pressures can occur. External
pressures could affect the trouble-free operation of the
pressure maintenance device.
The dimension of the expansion pipe is determined acc. to
the standard ÖNORM H5151-1. See Appendix A.
2.2 Makeup PHP
Ex works modular PHP series devices are delivered without
makeup module EMCF-1 V fitted. The mounting of the
module is done acc. to the assembly instruction which is
delivered with the makeup module for connection to the
break tank.
2.3 Changing the positions of the
hydraulic connections
Ex works the connections from/to system return at modular
PHP are situated at the right side of the device. If necessary,
they can be built to the left side easily. Unused connections
must be closed by using the delivered caps.
The connections from/to expansion vessel for the PHP
are situated on the back of the control unit.
04
INFORMATION
We recommend to install the PHP device with an
expansion pipe size of at least DN 25.

PHP A-1 Instruction Manual / Mounting
05
Figure 1: Changing the positions of the hydraulic connections

PHP A-1 Instruction Manual / Mounting
06
Figure 2a: Gland plate
The electric connections (pre-cut cable bushings in gland
plate) are also situated at the right side of the device. If
necessary they can also be built to the left side (Figure 2a).
The opening on the other side must be closed by using the
blank flange, which is at the left side of the electronic unit
(Figure 2b).
Figure 2b: Blank flange

PHP A-1 Instruction Manual / Mounting
07
2.5 Usage of cooling vessels
PHP modular series devices can be used in plants with a
max. temperature of 70 °C at the point of implementation.
If the temperature at this point can exceed 70 °C, a cooling
vessel must be used.
Depending on the arrangement of the piping from system
return to the cooling vessel, a vent valve must be set at the
upper connection. This valve must be vented in course
of commissioning.
NOTE
Cooling vessels must not be insulated. The entire
expansion overflow pipe from system return to the device
must not be insulated, too.
Figure 7: Usage of a cooling vessel
NOTE
The automatic degassing feature will be disabled if a
bypass set is used.
The degassing function must be disabled using the
“device set-up”-feature.
If not, unnecessary run-time of the pump but no fault.
Figure 6: Connection via bypass set and connection to the
system return
2.4 Usage of devices without degassing
PHP modular series devices can be operated without
degassing. For this purpose the unused connections have
to be connected acc. to Figure 6. This connection can be
built via the optional accessory “bypass set” EMCB-ZB.
The connection can also be executed on site (DN 25).
To connect the PHP device to the system return you must
use only one connection (“EXPANSION OVERFLOW PIPE”).
See Chapter 3 “Hydraulic diagrams”.

2.6 Temperature sensor T2 (Optional)
PHP modular series devices with an attached temperature
sensor T2 (optional accessory) provide a monitoring of the
temperature of the system return respective the expansion
overflow pipe.
Due to this monitoring the degassing feature will be disabled
in case of a too high temperature. Thus the membrane and
the components can‘t be damaged by too hot plant media
during the degassing. We recommend to use the temperature
sensor T2 in systems with a max. operational temperature of
95 °C (set at the system safety temperature limiter).
The installation of the temperature sensor T2 into the system
return must be executed on-site, the sensor must be mounted
immediately in front of the connection to the pressure
maintenance device (Figure 8a). If a cooling vessel is used, the
sensor must be mounted into the expansion overflow pipe on
top of the cooling vessel (Figure 8b).
Figure 8: Installation of the temperature sensor T2 without
(a) and with (b) cooling vessel
PHP A-1 Instruction Manual / Mounting
08
2.7 Electric connection
The supply line has to have a protective earth wire. The electric
connection should be done through an isolator that can either
be unplugged or, in case of a 3 phase supply, can be switched
off (4 pole) and lockable with a readily accessible spur.
WARNING
All relevant electric standards must be adhered to.
INFORMATION
The connected load can be read at the type plate of the
PHP device.

PHP modular with degassing
(standard diagram):
Options:
2 pcs. main vessels with level measurement, 2 pcs.
additional vessels, expansion modules, makeup module
EMCF-1 V, sensor T2
1. Makeup water
2. Expansion overflow pipe from system return min. DN25
3. Expansion pressure pipe to system return min. DN25
4. Discharge hopper for vessel safety valve
5. Suction pipe from expansion vessel
6. Overflow pipe to expansion vessel
7. Gas-side vessel connection DN20
8. Expansion pipe
9. Degassing pipe
PHP A-1 Instruction Manual / Hydraulic diagrams
3 Hydraulic diagrams
09

PHP A-1 Instruction Manual / Hydraulic diagrams
PHP modular without degassing:
Options:
Bypass set, 2 pcs. main vessels with level measurement,
2 pcs. additional vessels, expansion modules, makeup
module EMCF-1 V, sensor T2
1. Makeup water
2. Expansion overflow pipe from system return min. DN25
3. Expansion pressure pipe to system return min. DN25
4. Discharge hopper for vessel safety valve
5. Suction pipe from expansion vessel
6. Overflow pipe to expansion vessel
7. Gas-side vessel connection DN20
10

PHP A-1 Instruction Manual / Hydraulic diagrams
PHP modular without degassing and
cooling vessel:
Options:
2 pcs. main vessels with level measurement, 2 pcs.
additional vessels, expansion modules, cooling vessel,
makeup module EMCF-1 V, sensor T2
1. Makeup water
2. Expansion overflow pipe from system return min. DN25
3. Expansion pressure pipe to system return min. DN25
4. Discharge hopper for vessel safety valve
5. Suction pipe from expansion vessel
6. Overflow pipe to expansion vessel
7. Gas-side vessel connection DN20
11

PHP A-1 Instruction Manual / Wiring diagrams
4 Wiring diagrams
12
4.1

PHP A-1 Instruction Manual / Wiring diagrams
13

PHP A-1 Instruction Manual / Wiring diagrams
14

PHP A-1 Instruction Manual / Wiring diagrams
15
4.2 Breaktank
TITLE PROJECT.
PHP Control Panel
Ed.
3
Original
24378
Date
Date
Replaced by:
11
Revision
10 1716
Appr
Replacement of:
18 1913
5
14
07/05/2019
12
Name
15
PHP Control Panel
Ferryboat Lane, Castletown
Sunderland, Tyne and Wear
SR5 3JL
DRAWING No.
Sheet of 64
99469937
N
N
1
2
F1
1A
(gG/gL)
N
N
1
2
F2
2A
(gG/gL)
MCB N/O Aux opens on Trip MCB N/O Aux opens on Trip
Supply from
supply connector
in Spirotech Panel
1
2
MCB1
4A C
1
2
MCB2
4A C
L N PE
240
24
0
12
PE
TX1
50VA
12/24VAC
11
14
R1
/5.16
21
24
11
14
R2
/5.17
21
24
13
14
Aux1
/5.19
13
14
Aux2
/5.19
1 2
PE
Pump 1
1.8A FLC 1~
M
1 2 PE
1 2
PE
Pump 2
1.8A FLC 1~
M
3 4 PE
PE
112
1 mm²
RD
115
1 mm²
WH
106
1 mm²
PK
100
1 mm²
BN
101
1 mm²
BL
103
1 mm²
BN
104
1 mm²
BL
108
1 mm²
BN
109
1 mm²
BL
100
1 mm²
BN
101
1 mm²
BL
100
1 mm²
BN
101
1 mm²
BL
100
1 mm²
BN
101
1 mm²
BL
102
1 mm²
BN
101
1 mm²
BL
107
1 mm²
BN
101
1 mm²
BL
110
1 mm²
PK
106
1 mm²
PK
105
1 mm²
PK
105
1 mm²
PK
111
1 mm²
BN
114
1 mm²
BL
113
1 mm²
RD
116
1 mm²
WH
4 mm²
GNYE
PE
24VAC
5.10
0VAC
5.10
AUX1 / 5.10
AUX2 / 5.10
TITLE PROJECT.
PHP Control Panel
Ed.
4
Original
24378
Date
Date
Replaced by:
11
Revision
10 1716
Appr
Replacement of:
18 1913
6
14
07/05/2019
12
Name
15
PHP Control Panel
Ferryboat Lane, Castletown
Sunderland, Tyne and Wear
SR5 3JL
DRAWING No.
Sheet of 65
99469937
External Start Signal
VFC
MCB N/C Aux
closes on Trip
Common
Alarm -
Closed Healthy
From terminals
71 & 72 on
Spirotech Panel
To terminals
83 & GND on
Spirotech Panel
7 8
A2
A1
R3
24VAC
Start
/5.16
NCNO
A1
A2
SR1
24VAC
Step Relay
/5.16 /5.16
NCNO
12
11
14
SR1
/5.18
14
11
R3
/5.12
External
Start
A1
A2
R1
24VAC
Start Pump 1
/4.12
/4.12
/5.18
NCNO
A1
A2
R2
24VAC
Start Pump 2
/4.14
/4.14
/5.18
NCNO
13
14
LLF
Closed on
Low Level
9 10
32
31
R1
/5.16
32
31
R2
/5.17
21
22
Aux1
/4.12
21
22
Aux2
/4.15
16
15
T1
/5.14
A3
A2
B3
T1
24VAC
True OFF
Delay
Set at 30s
M
/5.16
NCNO
A1
A2
R4
24VAC
CSH
/5.11
NCNO
14
11
R4
/5.10
CSH
5 6
113
1 mm²
RD
116
1 mm²
WH
117
1 mm²
PK
110
1 mm²
PK
117
1 mm²
PK
106
1 mm²
PK
113
1 mm²
RD
113
1 mm²
RD
120
1 mm²
RD
123
1 mm²
RD
125
1 mm²
RD
116
1 mm²
WH
116
1 mm²
WH
116
1 mm²
WH
116
1 mm²
WH
116
1 mm²
WH
116
1 mm²
WH
113
1 mm²
RD
118
1 mm²
RD
113
1 mm²
RD
119
1 mm²
RD
119
1 mm²
RD
113
1 mm²
RD
113
1 mm²
RD
113
1 mm²
RD
113
1 mm²
RD
124
1 mm²
RD
125
1 mm²
RD
125
1 mm²
RD
113
1 mm²
RD
113
1 mm²
RD
120
1 mm²
RD
123
1 mm²
RD
122
1 mm²
RD
121
1 mm²
RD
116
1 mm²
WH
110
1 mm²
PK
24VAC / 4.17
0VAC / 4.17
AUX1
/4.15
AUX2
/4.15

PHP A-1 Instruction Manual / Wiring diagrams
16
Legend
PHP A-1
Marketing Description
-A1 Control-electronics: basic circuit board, type 200331
-A2 Control-electronics: central processing board, type ABCO10
-S1 Motor of pump 1: thermal motor protection (motor-integrated)
-S2 Motor of pump 2: thermal motor protection (motor-integrated) (OPTION)
-M1 Motor of pump 1
-M2 Motor of pump 2 (OPTION)
-Y1 Makeup module: magnetic valve (OPTION)
-B1 Makeup module: water meter: pulse output (OPTION)
-B2 Lower vessel pressure transmitter (PL2u*)
-B3 Upper vessel pressure transmitter (PL2o*)
-B4 Plant pressure transmitter (P1*)
-B5 Temperature sensor (T1*), sending element type KTY10-6 or compatible
-B6 Temperature sensor (T2*), sending element type KTY10-6 or compatible
-B7 Lower vessel pressure transmitter (PL2u*) (OPTION)
-B8 Upper vessel pressure transmitter (PL2o*) (OPTION)
-X4 Terminal

PHP A-1 Instruction Manual / Operation and display
5 Operation and display
5.1 Switching on
After connecting power supply the expansion and pressure
maintenance device starts and the display shows the current
software version.
Approx. 10 seconds later the main display appears
automatically. This waiting time can be reduced by pressing
the key “F1” (next).
5.2 User and display elements
17
Software version
UE (User element) Description Notice
Device “ON” Enable device (All actuators are controlled acc. to the internal control electronics.)
Device “OFF” Disable device (All actuators are disabled. Only the sensor system remains
active.) Caution: no pressure maintenance in this mode.
Execute function The function displayed above the key is executed directly.
Change values Keys to raise and reduce numerical values resp. to select the days in
timer programs.
Scroll Scroll through menus, displays and settings upwards and downwards.
Back to main display By pressing this key the display jumps back to the main display directly.
DE (Display element) Description Notice
Fault existing An error exists so the device can‘t be operated correctly. Check and repair the
cause of the error.
Warning existing Warnings are existing, the device is still in operation.
No warning No warnings or errors
Main display

P1: 2.8 L : 47 %
T1: 58.0 DEG: off
M1: off M2: off
disPl-=
oPer-=te

PHP A-1 Instruction Manual / Operation and display
5.3 Display
The PHP microcomputer features an illuminated 4-line LCD
display to show all data in a clear and well-arranged way.
Generally the executable functions are shown above the
associated keys “F1” and “F2”.
If there is enough space, additional hints are shown on demand.
5.4 Scroll and change values
If settings must be done, they are signalised at the LCD
display via a flashing cursor
18
UE (User element) Description Notice
Select/apply Selecting a menu item resp. applying changed settings.
Back Back to previous menu resp. previous display without confirming any changes.
Change values Keys to raise and reduce numerical values resp. to select the days in timer programs.
Scroll Scroll through menus, displays and settings upwards and downwards.
OPERATING MODE ...
+_-=mount-controlled
ch-=n9e
with t
-=nd
-=PPl b-=ck
F
F
1
1
F
F
2
2
Flashing cursor
Illuminated 4 line LCD display
Executable functions
Function keys
User level which is active in
the background
Additional hints

PHP A-1 Instruction Manual / Operation and display
5.5 Display level
By pressing the key “F1” (display) the display level can
be entered.
This level is used to show measured values and the current
operation status.
After accessing the display level, a number in brackets is
shown. This number is the current active user level, which
will also influence the display level’s items.
DISPLAY LEVEL - MENU STRUCTURE:
Display level... (2)
Pressure maintenance
Current system pressure and vessel level L
Show setpoint
operation pump 1
operation pump 2 1)
overflow pipe temperature T1
Level L1/level L2 8)
operating mode pumps 1) 3)
current priority pump 1)
operating mode level 8)
makeup
current vessel level L and operation makeup
show setpoint
previous overall amount 2)
remaining amount/remaining amount and
remaining time 2) 4)
softening MWE6 remaining capacity resp.
MWE12 remaining capacity 2) 11)
desalination MVE2 remaining capacity resp.
MVE4 remaining capacity 2) 14)
operating mode 3)
degassing 9)
current operating stage state
remaining time
fast degassing 10)
remaining time
operating hours
operating mode 3)
timer program 5)
temperature sensor T2 7)
monitoring 13)
min. pressure: P1 min and current state
max. pressure: P1 max and current state
min. level: L min and current state
max. level: L max and current state
min. temperature: T1 min and current state
max. temperature: T1 max and current state
min. temperature: T2 min and current state
max. temperature: T2 max and current state 7)
statistics
pump M1
operating hours from the displayed time
resettable
pump M2
1)
operating hours from the displayed time
resettable
degassing
9)
operating hours from the displayed time
resettable
temp. measurement T1
peak and time it occurred
resettable
temp. measurement T1
minimum and time it occurred
resettable
temp. measurement T2 7)
peak and time it occurred
resettable
temp. measurement T2
7)
minimum and time it occurred
resettable
press. measurement P1
peak and time it occurred
resettable
press. measurement P1
minimum and time it occurred
resettable
makeup
2)
amount from the displayed time
resettable
water treatment
2) 11)
cartridge changed on ...
not resettable, entry happens when changing
the cartridge
press. maintenance
pressure set-up on ...
not resettable, entry happens when setting the
working pressure
level measurement L1
peak and time it occurred
resettable
level measurement L1
minimum and time it occurred
resettable
level measurement L2
8)
peak and time it occurred
resettable
level measurement L2
8)
minimum and time it occurred
resettable
temp. measurement T1 < ...
operating hours from ...,the blocking temperature
was underrun
19

resettable
temp. measurement T1 > ...
operating hours from ..., the temperature limit
was overrun
resettable
temp. measurement T2 < ... 7)
operating hours from ...,the blocking temperature
was underrun
resettable
temp. measurement T2 > ... 7)
operating hours from ..., the temperature limit
was overrun
resettable
temp. measurement T1 < ...
number of times the blocking temperature was
underrun from ...
resettable
temp. measurement T1 > ...
number of times the temperature limit was
overrun from ...
resettable
temp. measurement T2 < ... 7)
number of times the blocking temperature was
underrun from ...
resettable
temp. measurement T2 > ... 7)
number of times the temperature limit was
overrun from ...
resettable
general version
time and date
device type
enable contact
SMS module
12)
PHP A-1 Instruction Manual / Operation and display
20
1. Only in systems PHP
2. Only if EMCF-1 V makeup module is enabled
3. Operating mode acc. to menu item settings
4. Depending on the selected operating mode
5. Only in operating mode “timer program”
6. Only in operating mode “time-controlled”
7. Only if sensor T2 is enabled
8. Only if level measurement L2 is enabled
9. Only if degassing is enabled (without bypass)
10. Only if fast degassing is activated
11. Only if softening MWE is enabled
12. Only if SMS module is enabled
13. Only if at least one value is monitored and user level 3 is active
14. Only if desalination MVE is enabled