PAW HeatBloc MC42 User manual

PAW GmbH & Co. KG
Böcklerstr. 11, D-31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
2018/11 9945x1051x-mub-en – V03 1
Installation and Operation Instructions
HeatBloC
MC42 / MC43 DN 40
MC42 DN 50

1General Information
2 9945x1051x-mub-en – V03 2018/11
Item no. 9945x1051x-mub-en – Version V03 – Issued 2018/11
Translation of the original instructions
We reserve the right to make technical changes without notice!
Printed in Germany – Copyright by PAW GmbH & Co. KG
PAW GmbH & Co.KG
Böcklerstr. 11
D-31789 Hameln, Germany

1General Information
2018/11 9945x1051x-mub-en – V03 3
Contents
1General Information.........................................................................................................4
1.1 Scope of these instructions ..........................................................................................4
1.2 Designated use ............................................................................................................4
2Safety instructions ...........................................................................................................5
3Product description..........................................................................................................6
3.1 Equipment....................................................................................................................6
3.2 Function .......................................................................................................................7
3.3 3-way mixing valve [specialist] .....................................................................................8
3.4 Pump [specialist] ..........................................................................................................8
3.4.1 Commissioning (only Grundfos Magna 3)..............................................................9
3.4.2 Configuration (only Grundfos Magna 3).................................................................9
3.5 Check valve ...............................................................................................................10
3.6 Actuator......................................................................................................................11
4Change of the flow line [specialist] .................................................................................12
4.1 Conversion of the mixing valve...................................................................................13
5Assembly and installation [specialist]..............................................................................14
5.1 Installation of the HeatBloC........................................................................................15
5.2 Electrical connection and configuration of the pump (only Grundfos Magna 3)........... 17
5.3 Cabling.......................................................................................................................19
5.4 Optional accessories: Communication set (not included in the scope of delivery) ...... 21
6Scope of delivery [specialist] ..........................................................................................22
6.1 Insulation and controller DN 40 ..................................................................................22
6.2 Hydraulics DN 40 with Grundfos Magna 3.................................................................. 23
6.3 Hydraulics DN 40 with Grundfos UPMXL ...................................................................24
6.4 Insulation and controller DN 50 ..................................................................................25
6.5 Hydraulics DN 50 .......................................................................................................26
7Technical data...............................................................................................................27
7.1 Dimensional drawing DN 40 with Grundfos Magna 3.................................................. 28
7.2 Dimensional drawing DN 40 with Grundfos UPMXL ................................................... 28
7.3 Dimensional drawing DN 50.......................................................................................29
7.4 Pressure drop and pump characteristic curves DN 40................................................ 29
7.5 Pressure drop and pump characteristic curves DN 50................................................ 30

1General Information
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1General Information
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1.1 Scope of these instructions
These instructions describe the installation, commissioning, function and the operation of
the mixed HeatBloC MC42 / MC43 DN 40 and DN 50.
For other components of the installation, such as the pump, the controller or the modular
distribution manifold, please observe the instructions of the corresponding manufacturer.
The chapters called [specialist] are intended for specialists only.
1.2 Designated use
The HeatBloC may only be used in heating circuits taking into consideration the technical
limit values indicated in these instructions.
The HeatBloC must not be used in drinking water applications.
Improper usage of the HeatBloC excludes any liability claims.
Only use PAW accessories with the HeatBloC.
This product complies with the relevant directives and is therefore labelled with the CE mark.
The Declaration of Conformity is available upon request, please contact the manufacturer.
The wrapping materials are made of recyclable materials and can be disposed of with
recyclable materials.

2Safety instructions
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2Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable
level of knowledge [specialist].
The following must be observed during installation and commissioning:
•relevant local and national regulations
•accident prevention regulations of the professional association
•instructions and safety instructions of this manual
CAUTION
Personal injury and damage to property!
The HeatBloC must only be used in heating circuits filled with
heating water according to VDI 2035 / Ö-Norm H 5195-1.
The HeatBloC must not be used in drinking water applications.
NOTICE
Material damage due to mineral oils!
Mineral oil products cause lasting damage to seals made of EPDM, whereby the sealant
properties get lost. We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.
It is imperative to avoid that EPDM gets in contact with substances containing
mineral oils.
Use a lubricant based on silicone or polyalkylene and free from mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.

3Product description
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3Product description
The HeatBloC is a preassembled group of fittings for heating circuits. The pump can
be isolated, it is thus not necessary to drain the heating circuit during servicing.
The nominal value for the differential pressure between the flow and the return is adjusted
at the controller. On this basis, the controller regulates the pump. Thus, the hydraulic
balancing at the distribution manifold is assured and an energy-saving operation of
the pump is guaranteed at any time.
For the MC43, a nominal value for the flow temperature is set at the controller.
The controller actuates the actuator on this basis.
The PAW HeatBloC can be mounted on a PAW modular distribution manifold or on a
PAW bracket.
3.1 Equipment
A-1 Flow to the consumer circuit
A-2 Flow ball valve with temperature
sensor TVand thermometer
B Heating pump
C 3-way mixing valve
C-1 Flow from the heat generator
C-2 Return to the heat generator
D-1 Check valve, can be opened
D Return pipe
E Design insulation
according to EnEV directive
F-2 Return ball valve with temperature
sensor TRand thermometer
F-1 Return from the consumer circuit
G Differential pressure sensor
H Controller MCom

3Product description
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3.2 Function
MC42 / MC43 – HeatBloC with 3-way mixing valve
The flow temperature of the heating circuit is
controlled by the integrated mixing valve. Hot water
from the boiler and cold return water are mixed to
obtain the desired flow temperature of the heating
circuit. For the MC42, the mixing valve is adjusted
via an external controller in combination with the
electric actuator. For the MC43, the actuator is
controlled by the MCom controller.
Application range:
•Installations with several heating circuits
and different flow temperatures (radiators
and radiant floor heating)
•Installations with high fluctuations of the
flow temperature due to the heat generator
(solid fuel boilers, installations with power-
heat cogeneration)

3Product description
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3.3 3-way mixing valve [specialist]
The 3-way mixing valve (C), driven by an electric actuator, adjusts the flow temperature of
the consumer circuit to the required value by means of the flow sensor and the controller.
Position 10: Passage, no mixing,
flow temperature consumer =
flow temperature boiler
Position 0: 100% mixing
flow temperature consumer =
return temperature consumer
3.4 Pump [specialist]
The pump can be completely isolated. It can be replaced and maintained without draining the
heating installation.
The pump must be connected to the power supply on site. The pump Grundfos Magna 3 must
be configured after the electrical commissioning. For the pump Grundfos UPMXL GEO 32-125
(only DN 40), no configuration is necessary.
Isolation of the pump
1. Close the ball valves in the flow and return (A-2, F-2).
2. Remove the actuator from the mixing valve.
3. Turn the rotary knob of the mixing valve such that the black nose is directed to "VL zu"
(flow closed).
Cut off the expansion tank to depressurise the installation.
The mixing valve is now closed and drop tight. The pump can be dismounted.
10
0

3Product description
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3.4.1 Commissioning (only Grundfos Magna 3)
1. Connect the control cable to the pump and the controller
MCom. The cable gland is enclosed.
2. Connect the pump to the power supply. The cable
gland is provided in the pump housing. Please
observe the separate instructions of the pump!
3. Remove the protective film from the display.
3.4.2 Configuration (only Grundfos Magna 3)
The configuration is carried out via the pump display. Please observe the separate instructions
of the pump for operating the display.
I) Set the control type
1. You are in the menu Settings .
2. Select
Control mode and confirm by pressing OK.
3. Select
Constant curve and confirm by pressing OK.
4. Press the Home button to return to the main menu.
II) Set the nominal value
1. You are in the menu Settings .
2. Select
Nominal value and confirm by pressing OK.
3. Press OK.
4. Set
100% as nominal value and confirm by pressing OK.
5. Press the Home button to return to the main menu.
III) Set the analogue input
1. You are in the menu Assist .
2. Select
Analogue input setup and confirm by pressing OK.
3. Continue to scroll.
4. Select
External nominal value adjustment and continue to scroll.
5. Select
0-10 V as signal type and continue to scroll.
6. Check the displayed summary and confirm by pressing OK.
Signal
-
white
+10 V
brown

3Product description
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IV) Set the setpoint influence
1. You are in the menu Settings .
2. Select
Nominal value adjustment and confirm by pressing OK.
3. Select
External nominal value function and confirm by pressing OK.
4. Select
Linear to MIN and confirm by pressing OK.
5. Press the Home button to return to the main menu.
NOTICE (only Grundfos Magna 3)
A stop of the pump via the controller MCom is not possible, it must be carried out via the
heating controller or the building control system.
3.5 Check valve
The HeatBloC is equipped with a check valve (D-2) in the return line. The check valve can be
opened.
Check valve
(Normal flow direction in the figure: downwards)
Position 0°
Check valve is operating,
flow only in direction of flow.
Position 180°
Check valve is not operating,
flow in both directions.

3Product description
2018/11 9945x1051x-mub-en – V03 11
3.6 Actuator
For mixing valves with flow on the left, the scale must be turned by 180°.
for mixing valve with flow on the right for mixing valve with flow on the left
Assembly of the actuator
for mixing valves with flow on the right:
1. Turn the rotary knob of the
mixing valve into position 0.
2. Set the actuator to manual
mode by turning the selector
switch.
3. Turn the rotary knob of the
actuator to the left to the
position shown on the
adjacent figure.
4. Put the actuator on the
adjusting knob of the mixing
valve and the two stop bolts.
The actuator must be mounted
according to figure 5.
5. Set the actuator to automatic
mode.
Stop bolts
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
blue blue
blue
red red

4Change of the flow line [specialist]
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4Change of the flow line [specialist]
1. Dismount the temperature sensors
and the thermometers of the ball valves
(A-2 and F-2).
2. Unscrew the return line from the mixing
valve.
3. Retrofit the mixing valve as described
in chapter
4.1 Conversion of the mixing
valve.
4. Interchange and mount the flow and
return line. Please observe the position
of the opening mechanism of the check
valve (D-1).
5. Mount the pump.
6. Loosen the screw connections (J-1 and
J-2) between the sensor (G) and both
copper pipes.
7. Turn the sensor (G) by 180°.
8. Mount the sensor (G) between the
screw connections (J-1 and J-2).
9. Mount the screw connections (K-1 and
K-2) to the ball valves (A-2 and F-2).
The marking "P1" on the sensor (G)
must point towards the pump.
10. Firmly tighten the clamping-ring
compression fitting.
11. Mount the temperature sensors TR
and TVinto the ball valves.
Observe the correct attribution:
Red = Flow
Blue = Return
12. Convert the actuator as described
in chapter
3.6 Actuator
.

4Change of the flow line [specialist]
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13. Please observe the instructions of the
boiler control manual when changing
the flow line.
14. Mount the HeatBloC as described
in chapter
5.1 Installation of the
HeatBloC.
4.1 Conversion of the mixing valve
1. Loosen the screw (1).
2. Take off the rotary knob (2) from the cock rod.
3. Loosen the screws (3).
4. Remove the cover plate (scale) (4).
5. Loosen the two screws (5).
6. Remove the front plate (6).
7. Dismount the sealing bush (7). Pull out the valve cock (8) from the housing of the
mixing valve.
8. Loosen the screws (10) on the rear side of the mixing valve.
9. Take off the cover (9) from the rear side of the mixing valve.
10. Reverse the housing of the mixing valve such that the two channels lying upon each
other are on the flow side. Please observe the flow direction arrows on the housing.
11. Put the mixing valve cover in again on the other side of the mixing valve and fix it by
using the screws (10).

5Assembly and installation [specialist]
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12. Insert the valve cock (8) from the front into the channel of the mixing valve.
Fix the valve cock with screws.
13. Fix the front cover (6) by using the screws (5).
14. Turn the cover plate (4) in such a way that the marking PAW is at the bottom
and that the scale is positioned as shown in the figure above.
15. Fix the cover plate (4) by using the screws (3).
16. Put the rotary knob (2) onto the cock rod.
17. Fix the rotary knob (2) on the cock (8) by using the screw (1).
5Assembly and installation [specialist]
The PAW HeatBloC can be mounted on a PAW modular distribution manifold or on a
PAW bracket.
NOTICE
Damage to property!
The location of installation must be dry, load-carrying, frost-proof and protected against
ultraviolet radiation in order to prevent material damage of the installation.
Mixing valve with flow on the right Mixing valve with flow on the left
Flow
Flow

5Assembly and installation [specialist]
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5.1 Installation of the HeatBloC
NOTICE
Verify if the grounding cable holds securely in place at the differential pressure sensor!
Carry out the following mounting instructions in parallel at each heating circuit of the
system.
1. Mount the modular distribution
manifold or the bracket. Please
observe the separate instructions!
2. Remove the station from the
packaging.
3. Remove the thermometers from
the handles.
4. Take off the insulating front shells
of the HeatBloC.
5. Put the HeatBloC with the gaskets
onto the flanges of the distribution
manifold or of the bracket and
screw the flanges together.
6. Only Grundfos Magna 3: Mount
the pump. Please observe
the instructions of the pump!
7. Connect the HeatBloC to the
installation by using the pipes.
The installation to the piping must
be carried out without any tension.

5Assembly and installation [specialist]
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8. Mount the enclosed sensor (G)
with copper pipes and screw
connections (K-1 and K-2) between
the flow and return ball valve (A-2
and F-2).
Observe the marking on the sensor
housing: P1 = flow; P2 = return.
The bend of the copper pipe points
backwards. The sensor cable is
led out at the top of the insulation.
9. Repeat these steps for all the
HeatBloCs that are mounted.
10. Check all thread connections
and carry out a pressure test.
11. Mount the actuator (see page 11)
and run the cable backwards.
12. Only for MC42: Connect the power
supply of the actuator to the heating
controller.
13. Fix the rail to the pipe observing
a distance of 15 cm above the
ball valves (see figure).
For DN 40 use the inner holes,
for DN 50 the outer holes.

5Assembly and installation [specialist]
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14. Loosen the screws of the controller
insulation.
15. Dismount the insulating front shell
of the controller.
16. Fix the controller on the mounting rail
(see figure).
5.2 Electrical connection and configuration of the pump (only Grundfos Magna 3)
1. Connect the control cable to the pump and the controller
MCom. The cable gland is enclosed.
2. Connect the pump to the power supply. The cable gland is
provided in the pump housing. Please observe the
separate instructions of the pump!
3. Remove the protective film from the display.
4. Put the pump into operation and flush the installation.
5. Configure the pump. The configuration is carried out via
the pump display. Please observe the separate
instructions of the pump for operating the display.
Signal
-
white
+10 V
brown

5Assembly and installation [specialist]
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I) Set the control type
1. You are in the menu Settings .
2. Select
Control mode and confirm by pressing OK.
3. Select
Constant curve and confirm by pressing OK.
4. Press the Home button to return to the main menu.
II) Set the nominal value
1. You are in the menu Settings .
2. Select
Nominal value and confirm by pressing OK.
3. Press OK.
4. Set
100% as nominal value and confirm by pressing OK.
5. Press the Home button to return to the main menu.
III) Set the analogue input
1. You are in the menu Assist .
2. Select
Analogue input setup and confirm by pressing OK.
3. Continue to scroll.
4. Select
External nominal value adjustment and continue to scroll.
5. Select
0-10 V as signal type and continue to scroll.
6. Check the displayed summary and confirm by pressing OK.
IV) Set the setpoint influence
6. You are in the menu Settings .
7. Select
Nominal value adjustment and confirm by pressing OK.
8. Select
External nominal value function and confirm by pressing OK.
9. Select
Linear to MIN and confirm by pressing OK.
10. Press the Home button to return to the main menu.

5Assembly and installation [specialist]
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5.3 Cabling
1. Connect the temperature sensors,
the actuator (only for MC43) and the
differential pressure sensor to the
controller (see below).
2. Connect the wall power supply to the
socket X6.2 (see below) at the last (right)
controller.
3. Connect the bus line from controller 1 to
controller 2 in the socket X6.1. As the two
sockets of the bus line (X6.1 and X6.2)
are connected in parallel, the position
has no importance.
4. Repeat these steps for all HeatBloCs.
5. Remove the bus line from the first
controller. Keep the bus line as spare part.
X1 X2 X3 X4 X5 X6.1 X6.2
X1 not used X4 Temperature sensor TV, flow,
red marking
X2 PWM signal of the pump X5 Differential pressure sensor
X3 Temperature sensor TR, return,
blue marking
X6.1
X6.2
Supply voltage or bus line
(connected in parallel and
therefore interchangeable)
Optional communication set

5Assembly and installation [specialist]
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6. If you do not mount the communication
set, continue at point 10.
7. If you additionally mount the optional
communication set, run the bus line
of the communication set to the first
(left) controller. For this purpose,
disconnect the plug of the bus
line from the mini PC of the
communication set.
8. Make sure that the plug does not
get wet.
9. Mount the optional communication
set now. Please observe the
separate instructions of the
communication set!
10. Carry out the electrical
commissioning of the controllers
(see controller instructions).
11. Carry out the electrical commissioning
of the communication set (see
instructions of communication set).
12. Mount the insulating front shell of
the controller.
13. Screw the screws in the controller
insulation.
14. Mount the insulating front and back
shells of the HeatBloC.
15. Mount the handles and insert the
thermometers.
16. Mount the insulating front and back
shell of the distribution manifold.