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.
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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