PAW K36E Owner's manual

Installation and Operation Instructions
HeatBloC® K36E
DN 25 / DN 32
DN 25 DN 32
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
3.3 Thermo controller.......................................................................................................8
3.4 Check valve................................................................................................................. 11
4 Mounting and installation [specialist]].....................................................................12
4.1 Installation and commissioning of the HeatBloC®...................................................12
4.2 Accessories: Cutting-ring compression fitting (not included in the scope of
delivery).......................................................................................................................15
5 Scope of delivery [specialist]..................................................................................... 16
5.1 Spare parts DN 25....................................................................................................... 16
5.2 Spare parts DN 32....................................................................................................... 18
6 Technical data............................................................................................................. 20
6.1 Pressure drop and pump characteristic curves DN 25.............................................22
6.2 Pressure drop and pump characteristic curves DN 32.............................................22
7 Disposal....................................................................................................................... 23
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, function and the operation of the
HeatBloC® K36E DN 25 and DN 32.
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 HeatBloC® K36E (boiler charging set) is a preassembled fitting group for boiler circuits. The pump
can be isolated by means of the ball valves and maintenance work on the pump can thus be carried
out without draining the boiler circuit.
You can mount the PAW HeatBloC® directly onto a wall bracket or under/on a PAW modular
distribution manifold. With transition connections, PAW HeatBloC®s can also be mounted under/on
PAW modular distribution manifolds of other dimensions.
3.1 Equipment
A-1 Return from the consumer circuit
A-2 Thermo controller with adjustable overflow
valve
B Heating pump
C-1 Return to the heat generator
C-2 Full metal thermometer integrated in the ball
valve (return, blue)
D-1 Flow from the heat generator
D-2 Full metal thermometer integrated in the ball
valve (flow, red)
E Flow pipe
F Design insulation with optimised function
G-1 Flow to the consumer circuit
G-2 Check valve, can be opened
G-3 Coupling piece for overhead installation
3 Product description
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3.2 Function
Boiler charging set for the return flow temperature
maintenance of solid fuel boilers, wood firing and
stove heating systems
The boiler charging set prevents the temperature in the
boiler from falling under the dew point, thus reducing the
contamination of the boiler.
Application ranges:
●The boiler charging set can be mounted to a buffer
tank or to a hydraulic separator. If the opening
temperature of 45 °C or 60 °C is reached in the
boiler circuit, the performance of the boiler can be
used to charge the tank or the hydraulic separator.
The following figure shows the adjustments necessary for
this system.
3 Product description
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●The boiler charging set can be mounted under/on
a distribution manifold. In this system the pump
exerts a pressure on the entire installation. When
the overflow valve in the thermo controller is open,
the pressure can be reduced via the valve.
Undesired circulation, which could lead to
overcharging of the domestic water tank, can thus
be prevented.
The following figure shows the adjustments necessary for
this system.
3 Product description
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3.3 Thermo controller
The thermo controller is equipped with an overflow valve and a thermal control valve.
Overflow valve
In systems with a distribution manifold, the pump of the boiler charging set exerts an initial pressure
on the entire installation. If the overflow valve of the thermo controller is open, the pressure can be
reduced via the valve. Undesired circulation, which could lead to an overcharging of the domestic hot
water tank, can thus be prevented.
Overflow valve open
close
Overflow valve closed
open
3 Product description
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Thermal control valve
The thermal control valve serves as a bypass in the startup phase.
1. If the water temperature in the boiler circuit is lower than the
opening temperature of the thermal control valve, this valve is
closed and thus also the line to the consumers. The water
circulates in the boiler circuit via the completely open bypass.
2. As soon as the water in the boiler circuit has reached the
opening temperature (+/- 3 K), the thermal control valve starts
opening the line from/to the consumers. This enables the
circulation in the consumer circuit. The cold water from the
consumer return line is mixed with the hot water from the
bypass at the control valve. Depending on the temperature and
the flow rate of the water from the return line, the thermal
control valve shuts or opens the line to the consumers. Thus, the
return to the boiler always remains at a certain temperature
level.
3. With increasing temperature in the return line of the consumers,
the thermal control valve completely opens the line to the
consumers. During operation, the temperature of the return of
the boiler remains nearly constant (+/ -3 K), until the buffer tank
is completely charged.
3 Product description
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Change of the flow line [specialist]
1. Take off the thermometer handles (C-2, D-2) and
remove the insulating front shells.
2. Take the group of fittings out of the insulating
back shell.
3. Loosen the union nuts at the thermo
controller (A-2).
4. Dismount the thermo controller and turn it
by 180° around the vertical axis.
Retrofitting and commissioning of the heating
circuit
1. Interchange the flow line with the return line and
the pump (B).
2. Re-install the thermo controller and tighten the
union nuts.
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.
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 (C-2, D-2) in a final step.
3 Product description
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3.4 Check valve
The HeatBloC® is equipped with a check valve (G-2) in the housing of the thermo controller (A-2). The
check valve can be opened manually.
Operation During operation, the marking must be directed to "Z".
●The check valve is closed.
●Flow only in the direction of the arrow.
Filling, draining, venting For filling, draining and venting the installation, the marking must
be directed to "A".
●The check valve is open.
●Flow in both directions.
3 Product description
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4 Mounting and installation [specialist]]
The HeatBloC® K36E can be mounted under/on a PAW modular distribution manifold or on a wall
bracket. The K36E is prepared for assembly under a PAW distribution manifold DN 25 when it is
delivered. If you want to mount the K36E on a PAW modular distribution manifold, remove the
coupling piece for overhead installation (G-3). The modular distribution manifold and the wall bracket
are optional accessories and are thus 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 and commissioning of the HeatBloC®
The HeatBloC® can be mounted
Option 1:
directly to the wall with a mounting bracket (item no. 34722)
4 Mounting and installation [specialist]]
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Option 2:
under a PAW modular distribution manifold
Option 3:
directly on a wall bracket
Please observe the separate and respectively corresponding instructions regarding the installation of
the distribution manifold, of the mounting bracket and of the wall bracket.
4 Mounting and installation [specialist]]
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Assembly with mounting bracket
- Fix the mounting bracket to the wall with the
enclosed screws and washers.
- Screw the HeatBloC® with the coupling piece for
overhead installation (G-3) to the mounting
bracket.
Assembly with wall bracket
- Fix the wall bracket to the wall with the
enclosed screws and washers.
- Insert the clip springs in the lower ball
valves.
- First insert the back part of the
insulation and then the valves and
fittings on the wall bracket.
Only for the assembly under a modular
distribution manifold
- Mount the modular distribution manifold with the
PAW mounting brackets. You can mount the
HeatBloC® K36E directly on the connections of the
modular distribution manifold. Remove the plugs
in the pipe connections of the modular
distribution manifold if necessary.
Piping
1. Connect the HeatBloC® to the installation by
using the pipes. The hydraulic schemes for both
assembly versions can be found in chapter 3.2.
The installation to the pipes must be carried out
without any tension.
2. Connect the pump.
3. Carry out a pressure test and check all thread
connections.
4. After commissioning, mount first the front
insulating elements and then the ball valve
handles with thermometer.
4 Mounting and installation [specialist]]
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4.2 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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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 DN 25
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 Thermo controller K36E DN 25, flange 1“ G 1½" N00228
Item no. heating circuit Pump Item no. pump EEI
45 °C 60 °C
360343WP6 360373WP6 Wilo Para SC 25/6-43 N00259 < 0.20
360343WP8 360373WP8 Wilo Para SC 25/8-60/O N00271 < 0.20
360343WN06 360373WN06 Wilo Yonos PICO 25/1-6 N00214 < 0.20
360343GL9 360373GL9 Grundfos UPML 25-95 Auto N00396 < 0.23
360343GM6 360373GM6 Grundfos UPM3 Auto L 25-70 PP3 N00237 < 0.20
360343GH6 360373GH6 Grundfos Alpha2.1 25-60 N00236 < 0.17
360343 360373 without pump / /
5 Scope of delivery [specialist]
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5.2 Spare parts DN 32
5 Scope of delivery [specialist]
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Position Spare part Item number
1 Thermometer ball valve DN 32, flange 1¼" x 1¼" int. thread N00245
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 2" N00121
6 Gasket 1¼", for threaded connection 2" N00133
7 Pump see following table
Item no. heating circuit Pump Item no. pump EEI
45 °C 60 °C
390343WP6 390373WP6 Wilo Para SC 30/6-43 N00261 < 0.20
390343WN06 390373WN06 Wilo Yonos PICO 30/1-6 N00313 < 0.20
390343WY10 390373WY10 Wilo-Yonos PARA HF 30/0.5-10 E12361510 < 0.24
390343GM6 390373GM6 Grundfos UPM3 Auto L 32-70 PP3 N00240 < 0.20
390343GH6 390373GH6 Grundfos Alpha2.1 32-60 N00239 < 0.17
390343GL9 390373GL9 Grundfos UPML 32-95 Auto N00344 < 0.23
390343 390373 without pump / /
5 Scope of delivery [specialist]
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6 Technical data
HeatBloC® K36E DN 25 (1") DN 32 (1¼")
Dimensions
Centre distance (1) 125 mm 125 mm
Width insulation (2) 250 mm 250 mm
Height insulation (3) 383 mm 441 mm
Installation length (4) 408 mm 465 mm
Connections
Outlet (A-1, G-1) 1½" int. thread
(union nut)
2" int. thread
(union nut)
Inlet (C-1, D-1) 1" int. thread 1¼" int. thread
Operating data
Max. pressure 6 bars 6 bars
Max. temperature 110 °C 110 °C
KVSvalue [m3/h] 5.9 9.7
Opening pressure check valve (G-2) 200 mm wc, can be opened
Opening pressure thermovalve 45 °C / 60 °C
6 Technical data
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