PAW K35 Owner's manual

Installation and Operation Instructions
HeatBloC® K35 - DN 25
with 3-temperature mixing valve
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 3-temperature mixing valve [specialist]...................................................................6
3.2.2 Change of the flow line [specialist]........................................................................... 7
3.2.3 Check valve and non-return valve [specialist]......................................................... 10
3.3 Accessories: Actuator (optional)............................................................................... 12
4 Mounting and installation [specialist]].....................................................................13
4.1 Accessories: Cutting-ring compression fitting (not included in the scope of
delivery).......................................................................................................................14
4.2 Mounting of the HeatBloC®........................................................................................15
5 Scope of delivery [specialist]..................................................................................... 17
6 Technical data............................................................................................................. 19
6.1 Pressure drop and pump characteristic curves........................................................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.
WARNING
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 HeatBloC® K35 is a preassembled group of fittings for heating circuits. The HeatBloC® is mounted
directly onto a mounting plate or onto a distribution manifold. The distance between the pipe axis of
the HeatBloC® and the wall must be at least 10 cm, as the connection C-3 is on the back side of the
mixing valve.
Attention: To use the PAW piping sets (item no. 36092KS2 / KS3 / KS4), the centre distance, that is the
distance to the wall, must be at least 150 mm!
3.1 Equipment
Rear view of mixing valve with flow on the
right
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-temperature mixing valve
C-1 High-temperature flow from the buffer tank
C-2 Return to the buffer tank
C-3 Additional connection for the supply of the
low-temperature flow on the back side of the
mixing valve
C-4 Non-return valve, can be opened
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
K35 - 3-temperature mixing valve with additional
connection for a second flow temperature
The 3-temperature mixing valve is used in combination
with a buffer tank which can be heated either by a solar
installation, a solid fuel boiler or a conventional boiler.
If the consumer only needs a low temperature level, such
as for radiant panel heating systems, the 3-temperature
mixing valve first takes the flow water from the
intermediate part of the storage tank. Only when the
temperature in this part is no longer sufficient, the hot
water from the upper part of the tank is used.
Application range:
●Heating systems with buffer
tank & solar heating support
●Control of radiant floor
heating & panel heating
systems
By using two parts of the storage tank for two different
flow temperatures, the energy from the buffer tank can be
used more efficiently.
The return temperatures are low and the stratification in
the buffer tank is maintained.
3.2.1 3-temperature mixing valve [specialist]
The 3-temperature mixing valve, 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. It is equipped
with a second flow connection (C-3) on the back side. This connection allows to withdraw water with a
lower flow temperature from the intermediate part of the tank, f. ex. of a buffer tank.
K35: A check valve is integrated in this second flow connection to avoid unwanted circulation in the
mixing valve. This check valve is designed for heating pumps with a maximum head of 7 m. If you
want to use a more powerful pump, an additional check valve may be necessary in the feed line.
MC45: A non-return valve (D-1) prevents unwanted circulation.
3 Product description
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Rear view of mixing valve with flow on the right
Expl. K35: Front view of mixing valve with flow on the
right
Position 0-5:
The flow temperature is reached by mixing
return water and water from the
intermediate part of the tank.
Position 5:
100% supply from the intermediate part of
the tank
Position 5-10:
The flow temperature is reached by mixing
water from the intermediate part and the
upper part of the tank.
3.2.2 Change of the flow line [specialist]
Dismounting of the mixing valve
1. Take off the thermometer handles (A-2, F-2) and remove the insulating front shell.
2. Take the group of fittings out of the insulating back shell.
3. Dismount the mixing valve (C).
3 Product description
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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 (4).
5. Loosen the two screws (5).
6. Remove the front plate (6).
7. Extract the sealing bush (7) with the cock plug (8) from the housing of the mixing valve.
8. Loosen the screws (10) on the back side of the mixing valve and take off the cover (9).
9. Pull the sealing plug (11) to the front by using pliers. Remove the flow-reducing plate (12) by
pushing from front to back.
10. Turn the housing of the mixing valve by 180°.
11. Mount the flow-reducing plate (12) on the back side and the sealing plug (11) on the front side.
3 Product description
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12. Mount the cover (9) on the back side of the mixing valve. The letters on the cover indicate the
correct assembly position:
flow on the left: L points upwards flow on the right: R points upwards
Assembly position for mixing valve with flow on
the left
Assembly position for mixing valve with
flow on the right
13. Fix the cover (9) by using the screws (10).
14. Insert the sealing bush (7) with the cock plug (8) into the channel of the mixing valve.
15. Screw down the front plate (6) using the screws (5).
Mixing valve with flow on the right Mixing valve with flow on the left
16. 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.
17. Fix the cover plate (4) by using the screws (3).
18. Put the rotary knob (2) onto the cock rod.
19. Fix the rotary knob (2) on the cock plug (8) by using the screw (1).
3 Product description
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Retrofitting and commissioning of the heating circuit
1. Interchange the return pipe (D) and the flow pipe with the pump (B).
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. Dismount and interchange the ball valves.
3. Mount the HeatBloC® and connect it to the installation.
4. Check all union nuts before commissioning and firmly tighten them if necessary.
5. Mount the insulation only after having carried out a pressure test. Mount the thermometer
handles (A-2, F-2) in a final step.
3.2.3 Check valve and non-return valve [specialist]
The HeatBloC® is equipped with a check valve (D-1, opening pressure 200 mm wc) in the return pipe
and with a non-return valve (C-4, opening pressure 50 mm wc) in the return of the mixing valve. The
valves can be opened. An additional check valve is integrated in the connection C-3 (low-temperature
flow).
This check valve cannot be opened!
3 Product description
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Operation During operation, the markings must point to "Z".
●The check valve and the non-return valve are closed.
●Flow only in the direction of the arrow.
Filling, draining, venting For filling, draining and venting, the markings must be directed
to "A".
●The check valve and the non-return valve are closed.
●Flow in both directions.
3 Product description
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3.3 Accessories: Actuator (optional)
The PAW actuator for weather-compensated control is available as an accessory.
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 - flow on the right:
If the PAW actuator has been purchased as an optional
accessory, the mixing valve contains a metal plate. To
mount the PAW actuator on the mixing valve, proceed as
follows:
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. Mount the rotation lock / the stop bolt in the left
opening of the metal plate. The actuator is fixed on a
stop bolt.
5. Put the PAW actuator on the rotary knob of the mixing
valve and mount the actuator on the stop bolts. The
PAW actuator must be mounted in a horizontal
position.
6. Set the actuator to automatic mode.
3 Product description
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4 Mounting and installation [specialist]]
The HeatBloC® K35 can be mounted on a PAW modular distribution manifold or on a wall bracket. The
modular distribution manifold and the wall bracket are optional accessories and are thus not included
in the scope of delivery.
The distance between the pipe axis of the HeatBloC® and the wall must be at least 10 cm, as the
connection C-3 is on the back side of the mixing valve.
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 Mounting and installation [specialist]]
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4.1 Accessories: Cutting-ring compression fitting (not included in the scope of delivery)
The connection to the heating installation can be carried out fast, pressure-proof and without
soldering if you use the optionally available compression fittings.
1. Push the union nut ②and the cutting ring ③
onto the copper pipe ①. The pipe must protrude
at least 3 mm from the cutting ring in order to
ensure the force transmission and the sealing.
2. Insert the support sleeve ④into the copper pipe.
3. Insert the copper pipe with the plugged-on
individual parts ②, ③and ④as far as possible
into the body of the compression fitting ⑤.
4. First, screw the union nut ②manually.
5. Tighten the union nut ②by rotating one full
turn. Secure the body of the compression fitting
⑤against distort in order to avoid damaging the
sealing ring.
Not included in the scope of delivery!
4 Mounting and installation [specialist]]
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4.2 Mounting of the HeatBloC®
1. Mount the wall bracket with mounting plate.
2. Take off the thermometer handles and remove
the insulating front shell of the HeatBloC®.
3. Unscrew the nuts on the lower connections of
the HeatBloC® and take out the sealing rings.
If a PAW modular distribution manifold or
transition connection is used:
4. Put the two nuts over the flanges.
5. Insert the sealing rings into the nuts.
6. Put the HeatBloC® onto the two nuts.
7. Tighten the nuts. Make sure that the nuts do
not get jammed and that the sealing rings do
not slip.
4 Mounting and installation [specialist]]
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8. Connect the HeatBloC® to the installation by
using the pipes. The installation to the piping
must be carried out without any tension.
①- Flow from the upper part of the storage
tank
②- Return to the storage tank
③- Flow from the intermediate part of the
storage tank (connection on the back of the
mixing valve)
④- Return from the consumer
⑤- Flow to the consumer
9. Connect the pump.
10. Carry out a pressure test and check all thread
connections.
11. Mount the insulating front shell and the
thermometer handles.
Note:
If the K35 is mounted on a distribution manifold, the insulating back shell in the pipe axis of the
connection on the back of the mixing valve ③should be cut. The back shell of the distribution
manifold is thus easier to mount.
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 Scope of delivery [specialist]
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Position Spare part Item number
1 Thermometer ball valve DN 25, flange 1" x 1" int. thread N00244
2 Thermometer handle for thermometer ball valve 1" N00248
3 Dial thermometer, red scale, d = 50 mm, 0-120 °C N00242
4 Dial thermometer, blue scale, d = 50 mm, 0-120 °C N00243
5 Union nut G 1½" N00269
6 Gasket 1" for threaded connection 1½" N00131
7 Pump see following table
8 Insulation for HeatBloC® DN 25 N00016
9 Actuator 5 Nm, 230 V, 50 Hz 705001
10 Brass pipe DN 25, 2 x 1½" ext. thread, 180 mm, with check valve N00018
Item no. heating circuit* Pump Item no. pump EEI
36093(M)WP6 Wilo Para SC 25/6-43 N00259 < 0.20
36093(M)WP8 Wilo Para SC 25/8-60/O N00271 < 0.20
36093(M)WN06 Wilo Yonos PICO 25/1-6 N00214 < 0.20
36093(M)GL9 Grundfos UPML 25-95 Auto N00396 < 0.23
36093(M)GM6 Grundfos UPM3 Auto L 25-70 PP3 N00237 < 0.20
36093(M)GH6 Grundfos Alpha2.1 25-60 N00236 < 0.17
*Heating circuits with an actuator additionally contain a M in the item number, f. ex. 36093MWH6
(without actuator = 36063WH6)
5 Scope of delivery [specialist]
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6 Technical data
HeatBloC® K35 DN 25 (1")
Dimensions
Centre distance (1) 125 mm
Width insulation (2) 250 mm
Height insulation (3) 383 mm
Installation length (4) 340 mm
Connections
Upper connections (A-1, F-1) 1" internal thread
Lower connections (C-1, C-2) 1½" external threads, flat-sealing
Rear connection (C-3) 1" external thread
Operating data
Max. pressure 6 bars
Max. temperature 110 °C
Opening pressure check valve (D-1) 200 mm wc, can be opened
Opening pressure non-return valve (C-4) 50 mm wc, can be opened
6 Technical data
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HeatBloC® K35 DN 25 (1")
Materials
Valves and fittings Brass
Gaskets EPDM
Insulation EPP
6.1 Pressure drop and pump characteristic curves
(1) 100% return, KVSvalue = 5.1
(2) 100% low-temperature flow, KVSvalue = 4.1
(3) 100% high-temperature flow, KVSvalue = 4.7
6 Technical data
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