PAW HeatBloC K32 Owner's manual

Installation and Operation Instructions
HeatBloC® K32
DN 40 / DN 50
DN 40 DN 50
PAW GmbH & Co. KG
Böcklerstraße 11, 31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
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Table of Contents
1 General Information...................................................................................................3
1.1 Scope of these instructions........................................................................................3
1.2 Designated use........................................................................................................... 3
2 Safety instructions......................................................................................................4
3 Product description.................................................................................................... 5
3.1 Equipment...................................................................................................................5
3.2 Function.......................................................................................................................6
3.2.1 Check valve................................................................................................................. 7
3.2.2 3-way mixing valve [specialist]..................................................................................7
3.2.3 Pump [specialist].........................................................................................................10
3.2.4 Assembly of the actuator........................................................................................... 10
4 Mounting and installation [specialist]].....................................................................12
4.1 Installation of the modular distribution manifold...................................................12
4.2 Installation of the HeatBloC® on the modular distribution manifold.................... 13
4.3 Installation of the HeatBloC® DN 40 on a wall bracket with mounting plate........ 14
5 Scope of delivery [specialist]..................................................................................... 15
5.1 Spare parts K32 DN 40................................................................................................15
5.2 Spare parts K32 DN 50................................................................................................17
6 Technical data............................................................................................................. 18
6.1 Pressure drop and pump characteristic curves DN 40.............................................19
6.2 Pressure drop and pump characteristic curves DN 50.............................................20
7 Disposal....................................................................................................................... 21
8 Notes............................................................................................................................22
Table of Contents
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1 General 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, functioning and the operation of a mixed
HeatBloC®.
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 product may only be used in heating circuits taking into consideration the technical limit values
indicated in these instructions.
It must not be used in drinking water applications.
Improper usage excludes any liability claims.
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.
Only use PAW accessories with the product.
1 General Information
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2 Safety 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 mentioned in these instructions
CAUTION
Personal injury and damage to property!
The product must only be used in heating circuits filled with heating water according
to VDI 2035 / Ö-Norm H 5195-1.
►The product 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
are lost. We do not assume liability nor provide warranty for damage to property resulting from
sealants damaged in this way.
►It is imperative to prevent the EPDM sealing elements from making contact with substances
containing mineral oils.
►Use a silicone- or polyalkylene-based lubricant free of mineral oil such as Unisilikon L250L
and Syntheso Glep 1 from Klüber or a silicone spray.
2 Safety instructions
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3 Product description
The mixed HeatBloC® K32 is a premounted group of fittings for heating circuits. The pump can be
isolated, it is thus not necessary to drain the heating circuit during servicing.
The HeatBloC®s DN 40 can be directly mounted on modular distribution manifolds DN 40.
The HeatBloC®s DN 50 can be directly mounted on modular distribution manifolds DN 50.
3.1 Equipment
Example: K32 DN 40
A-1 Flow to the consumer circuit
A-2 All-metal thermometer with immersion sleeve,
integrated in the ball valve (flow)
B Heating pump
C 3-way mixing valve
C-1 Flow from the heat generator
C-2 Return to the heat generator
D Return pipe
D-1 Check valve, can be opened
E Design insulation with optimised function
F-1 Return from the consumer circuit
F-2 All-metal thermometer with immersion sleeve,
integrated in the ball valve (return)
3 Product description
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3.2 Function
K32 - 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. The mixing valve is
adjusted via an external controller in combination with an
electric actuator.
Application ranges:
●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)
3 Product description
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3.2.1 Check valve
The HeatBloC® is equipped with a check valve in the return line. The check valve can be opened.
Check valve (normal flow direction in the figure: downwards)
Position 0 ("operation)
Check valve is operating,
flow only in flow direction.
Position 180° ("open")
Check valve not operating,
flow in both directions.
3.2.2 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.
Mixing valve with flow on the right:
Position 10: passage, no mixing
flow temperature consumer =
flow temperature heat generator
Position 0: 100% mixing
flow temperature consumer =
return temperature consumer
3 Product description
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Change of the flow line [specialist]
Dismounting of the mixing valve
1. Remove the thermometers from the handles (A-2, F-2), dismount the handles and take off the
insulating front shell.
2. Take off the heating circuit from the insulating back shell.
3. Dismount the mixing valve (C).
Retrofitting 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).
3 Product description
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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. Screw down the front plate (6) using the screws (5).
Mixing valve with flow on the right Mixing valve with flow on the left
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 plug (8) by using the screw (1).
Retrofitting and commissioning of the HeatBloC®
1. Interchange the return pipe (D) with the check valve and ball valve and the flow line with the
pump (B) and the ball valve.
Consider the flow direction of the pump!
Turn the pump head such that the terminal box is directed to the top or to the centre of the
group of fittings.
2. Mount the heating circuit and connect it to the installation.
3. Check all connections before commissioning and firmly tighten them if necessary.
4. Mount the insulation only after having carried out a pressure test.
3 Product description
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3.2.3 Pump [specialist]
The pump can be completely isolated. It can be replaced and maintained without draining the heating
circuit system.
Isolation of the pump
1. Close the ball valves in the flow and the 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).
4. Cut off the expansion tank to depressurise the installation. The mixing valve is now closed and
drop tight. The pump can be dismounted.
3.2.4 Assembly of the 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
3 Product description
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Assembly of the actuator - 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. Only for K32: Mount the stop bolts.
5. Put the actuator on the adjusting knob of
the mixing valve and the two stop bolts.
The actuator must be mounted as shown in
the adjacent figure.
6. Set the actuator to automatic mode.
3 Product description
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4 Mounting and installation [specialist]]
The mixed HeatBloC® K32 is mounted on a modular distribution manifold DN 40, DN 50 or on a
bracket. The modular distribution manifold and the floor or wall bracket are not included in the scope
of delivery.
WARNING
Damage to property!
The installation site must be dry, stable, frost-proof and protected against ultraviolet radiation in
order to prevent material damage of the installation.
4.1 Installation of the modular distribution manifold
Floor bracket (1)
Wall bracket (2)
1. Determine the location of installation.
Floor bracket (1): The distance to the wall must
be about 25 cm. Anchor the floor bracket in the
floor with appropriate screws and wall plugs. The
height of the floor bracket can be adapted by
shortening the support rails.
Wall bracket (2): Anchor the wall bracket in the
wall with appropriate wall plugs and screws.
2. Take off the insulating front shell of the modular
distribution manifold.
3. Put the distribution manifold onto the bracket
and push the screws of the bracket through the
ears at the manifold.
4. Fix the modular distribution manifold to the
bracket by using screws.
4 Mounting and installation [specialist]]
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4.2 Installation of the HeatBloC® on the modular distribution manifold
Mounting example:
For the installation of a HeatBloC® DN 40 on a distribution manifold DN 50, reducing flanges
(item no. 51610) are necessary!
1. Remove the thermometers from the handles, dismount the ball valve handles and take off the
insulating front shell of the heating circuit.
2. Put the heating circuit with the gaskets onto the flanges of the distribution manifold and screw
the flanges together.
3. Connect the heating circuit to the installation by using the pipes. The installation to the piping
must be carried out without any tension. Connect the pump. Consider the flow direction of the
pump!
4. Check all thread connections and carry out a pressure test.
5. Mount the insulating shells and the ball valve handles and insert the thermometers.
4 Mounting and installation [specialist]]
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4.3 Installation of the HeatBloC® DN 40 on a wall bracket with mounting plate
1. Anchor the wall bracket in the wall with
appropriate wall plugs and screws.
2. Put the heating circuit on the wall bracket and
connect the heating circuit to the installation by
using the pipes. Do not forget to insert gaskets
above and below the mounting plate. The
installation to the piping must be carried out
without any tension.
3. Connect the pump.
4. Check all thread connections and carry out a
pressure test.
5. Mount the insulating front shell and the handles
and insert the thermometers.
4 Mounting and installation [specialist]]
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5 Scope of delivery [specialist]
NOTICE
Serial number
Complaints and requests/orders of spare parts will only be processed with information on the serial
number! The serial number is placed on the return pipe of the product.
5.1 Spare parts K32 DN 40
5 Scope of delivery [specialist]
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Item no. heating
circuit
Pump Item no. pump EEI
41221MWY10 Wilo-Yonos PARA HF 30/0.5-10 E12361510 < 0.20
41221MWH12 Wilo-Stratos PARA 30/1-12 E12395132 < 0.23
41221MWY8 Wilo-Yonos PARA HF 40/0.5-8 E1236168 < 0.20
41221MWY12 Wilo-Yonos PARA HF 40/0.5-12 E12361612 < 0.20
41221MGL10 Grundfos Magna1 32-100 E1217310 < 0.21
41221MGL12 Grundfos Magna1 40-120 F E121761 < 0.21
41221MGH12 Grundfos Magna3 40-120 F E121763 < 0.18
Description Item number
Sealing set for mixing valve 41013
5 Scope of delivery [specialist]
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5.2 Spare parts K32 DN 50
Item no. heating
circuit
Pump Item no. pump EEI
51221MWM12 Wilo Yonos MAXO plus 50/0.5-12 E12343812 < 0.20
51221MWY9 Wilo-Yonos PARA HF 50/0.5-9 E1236189 < 0.20
51221MGL12 Grundfos Magna1 50-120 F E121781 < 0.21
51221MGH12 Grundfos Magna3 50-120 F E121783 < 0.18
Description Item number
Sealing set for mixing valve 51013
5 Scope of delivery [specialist]
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6 Technical data
HeatBloC® K32 DN 40 (1½") DN 50 (2")
Dimensions
Centre distance (1) 160 mm 180 mm
Width insulation (2) 320 mm 360 mm
Height insulation (3) 610 mm 660 mm
Installation length (4) 560 mm 630 mm
Minimum distance pipe axis - wall 200 mm 220 mm
Connections
Connection consumer (A-1, F-1) 1½" female thread 2" internal thread
Connection generator (C-1, C-2) Flange DN 40 / PN 6 Flange DN 50 / PN 6
Operating data
Max. pressure 6 bars 6 bars
Max. temperature 110 °C 110 °C
KVSvalue [m3/h] 17.7 25.7
6 Technical data
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HeatBloC® K32 DN 40 (1½") DN 50 (2")
Opening pressure check valve (D-1) 200 mm wc,
can be opened
250 mm wc,
can be opened
Materials
Valves and fittings Brass
Gaskets EPDM / NBR / AFM34
Insulation EPP
6.1 Pressure drop and pump characteristic curves DN 40
6 Technical data
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6.2 Pressure drop and pump characteristic curves DN 50
6 Technical data
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