Robot Compact PRO User manual

Compact PRO, Optimum Flow PRO, District Heating PRO, LT,
Wilo Para Pump
MANIFOLD MANUAL

Content
Content
p.
1. Introduction 01
1.1 Manufacturer, copyright 01
1.2 Disclaimer 01
2. Warnings/safety measures 02
2.1 Safety instructions 02
2.2 Required personal protection equipment 04
3. Product description/product overview 05
3.1 Compact PRO manifold 05
3.2 Optimum Flow PRO manifold 08
3.3 District heating PRO manifold 10
3.4 LT manifold 12
3.5 Setting of the PRO-valve 13
3.6 Pumps 14
3.6.1 Wilo Para HU 25/6-43/SCU 14
4. Storage and transport 15
4.1 Storage 15
4.2 Transport 15
5. Mounting preparation 16
5.1 Mounting conditions 16
5.2 Tools overview 17
6. Installing/mounting 18
6.1 Installation of a manifold 18
6.2 Connecting the manifold to the central heating system 20
 6.3 Connectingtheunderoorheatingpipetothemanifold  20
 6.4 Fillingandventingtheunderoorheatingsystem   22
7. Commissioning/decommissioning 24
7.1 Putting into operation/setting the manifold 24
7.2 Setting of the PRO-valve on Standard and 25
Optimum Flow manifolds
8. Maintenance & service 26
9. Failures 27
9.1 Troubleshooting 27
10. Environment/waste disposal 28
11. Guarantee 28
12. Contact 28
Appendices
Notes
Publication: 2020

1. Introduction
This manual provides the key and essential information on the system and maintenance of the
following manifolds: Compact PRO, District Heating, Optimum Flow PRO, LT and the Wilo Para
pump. The 5 group manifold “Compact PRO” is used as an example for installation/mounting
in this manual. The installation/mounting of the other manifolds is done in an equivalent way.
The main differences will be further explained. Read the manual thoroughly so that you are fully
aware of the contents of this manual. Follow the instructions in the manual carefully. Perform the
operations in the correct order. Store this manual in a safe and dry place for future consultation!
If the manual should go missing, you can ask Robot Vloerverwarming B.V. for a new copy.
1.1 Manufacturer, copyright
Manufacturer:
Robot Vloerverwarming B.V. Tel.: [phone]
Kelvinring 56a E-mail: [email protected]
2952 BG Alblasserdam, NL
Copyright:
All rights reserved. Any copying, multiplying or transferring of this manual to third parties,
including storage and usage on optical and electronic data carriers, other than the usage by the
owner for training purposes and operations, is only permitted with the written permission of the
manufacturer.
1.2 Disclaimer
Robot Vloerverwarming B.V. is not liable for accidents or damage due to ignoring the warnings
or regulations set out in this manual, including:
• Inexpert or incorrect transportation, mounting, usage or maintenance.
• Use for other applications or under circumstances other than those indicated in this
manual.
• The use of other components than prescribed.
• Repairs and adjustments without the permission of the manufacturer.
Robot Vloerverwarming B.V. is not liable for direct and indirect damage as a result of failures or
defects to the manifolds, such as interruptions of operations, delays, etc.
Robot Vloerverwarming B.V. disclaims all responsibilities for damage or injury caused by
not following the instructions in this manual carefully and not exercising due care during
transportation, mounting, usage and maintenance. As a result of our continuous striving for
improvement, the product may differ in detail from what is described in this manual. For this
reason, the instructions given serve as a guideline for the installation/mounting of the product
referred to in this manual only. This manual has been compiled with great care, however,
Robot Vloerverwarming B.V. cannot accept any liability for any errors in this manual or the
consequences thereof.
Introduction
Manifolds Manual 01

2. Safety measures & warnings
Safety measures
2.1 Safety instructions
Important:
Please read the safety measures and warnings before you start mounting the manifolds. When
mounting, follow the instructions and guidelines as set out in this manual carefully. Never change
the order of the operations to be performed. Please contact Robot Vloerverwarming B.V. if
anything is unclear about the mounting work.
• Mounting/commissioningmustonlybedonebyexpertstaff(qualiedinstallers),
otherwise the guarantee will cease to apply.
• Manifolds of Robot Vloerverwarming B.V. may be used only for their intended
purpose.
Mounting:
•You must comply with the valid standards and legal regulations.
• Immediately check the delivery upon receipt. In the event of damages or incomplete
delivery, we ask you to immediately contact Robot Vloerverwarming B.V.
• The materials must be stored in a dry, ventilated area and not be exposed to
direct sunlight.
• Open the package carefully. Ensure that you do not damage the product.
• Place the components on a soft and clean surface to avoid damaging your
manifold.
• The manifolds may be installed and operated only in an undamaged condition.
• Mark off the mounting area with safety tape to keep unauthorised people away.
• Keep the workplace clean and free from obstacles when mounting and
performing maintenance.
• Ensurethatthereissufcientambientlightingwhenmountingandperforming
maintenance.
• Mountthemanifoldsonaatnon-combustible/heat-resistantsurfacewithsufcient
carrying capacity. Ensure that the surface is clean and dry and that the manifold is
leveled.
!
02 Manifolds Manual

• Always mount the manifold with the supplied rubber silencers to limit noise/vibrations as
much as possible.
• Ensure that all fasteners are properly tightened. Check if all fasteners are in the right place.
PLEASE NOTE: Not using fasteners will have adverse effects.
• To guarantee the correct operation of the system, you are only allowed to use the
manufacturer’s replacement components.
•Itisimportantthatthecorrectpipingisused(bothprimaryandsecondary)forinstallations
to guarantee the correct performance of the manifold.
•PLEASE NOTE: The temperature of the water in the manifold can go up to 55°C. Avoid your
skin coming into contact with the water at all times.
• PLEASE NOTE: Whenthesystemisrstputintooperation,theheatmustgraduallybe
broughtintotheoorbecauseofthelinearexpansionofthescreedandtheriskofcracking.
• PLEASE NOTE:Disablethepumpwhenllingandventingthesystem.Takeouttheplugfrom
the earthed wall socket.
• PLEASE NOTE: THE PUMP MUST BE RUNNING WHEN THE SYSTEM IS FILLED.*
Additives
• PLEASE NOTE: Theadditionofchemicals(waterdescalersordetergentsetc.)canadversely
affect the lifetime of the system or even damage it. An exception to this is mono-ethylene
Glycol(rateofmaximum30%Glycol).Thisadditiveisusediftheunderoorheatingismount-
ed outside or in cold-storage areas.
Warning
This product may be used by children of 8 years and upwards and by persons with reduced
physical, sensory or mental capacities, or with lack of experience with the product, provided
they are supervised or have received clear instructions for the safe use of the product. They must
also understand what hazards are involved in using the product. Never let children play with the
product. It is not allowed to have the system cleaned or maintained by children or people with
reduced physical, sensory or mental capacities without appropriate supervision.
Robot Vloerverwarming B.V. accepts no liability for damage or injury caused by not strictly
observing the safety regulations and instructions set out in this manual or due to negligence
when performing mounting work, usage and maintenance of the product or any accessories.
Robot Vloerverwarming B.V. is not responsible for any form of damage.
*This will prevent damage to the pump, which will invalidate the guarantee.
Safety measures
!
!
!
!
Manifolds Manual 03

Safety measures
2.2 Required personal protection equipment
Always wear the right personal protection equipment when carrying out the work:
Protective clothing Safety gloves Safety shoes
Safety helmet Eye protectionHearing protection
04 Manifolds Manual

Product description
3. Product description/product overview
Manifolds Manual 05
This manual is written for all steel manifolds of Robot Climate Comfort systems. To get a clear
impression of the differences between the manifolds, we prepared an overview. All parts of
thespecictypeofmanifoldcanbefoundhere.Italsodescribesboththeapplicationas
well as the functioning.

Product description
3.1 Compact manifold
3.1.1 Partslist/functionaloverviewandspecications
A. Circulationpump,A-label(WiloParaHU25/6-43/SCU)
B. Thermostaticcontrolofsupplywaterforboiler(adjustable)
B1. Double adjustable thermostatic valve for supply water for boiler
C. Adjustable return valve for return water for central heating
D. Temperature safety stat, with set temperature of 55°C +/- 5°K
E. Temperaturegaugeforunderoorsupplywater
F. Robotpressure/temperaturegauge0-8bar/0-60°Cforunderoorreturnwater
G. Euroconeconnectionforunderoorsupplywater
H. Thermostaticvalve(M30x1.5),doubleadjustable,euroconeconnection,forunder-
 oorreturnwater
I. Manual air bleed valve
J. Fill and drain tap
K. PRO Valve for adjustment
3.1.2 Application Compact PRO
Underoorheating,highandlowtemperaturesystem:minimum40°C-70°Csupply(primary),
suitable for main or auxiliary heating. Maximum 6 bar pressure. In combination with this steel
manifold, only use diffusion-tight pipes according to DIN 4726. The manifold is supplied
hydraulically neutral.
Toelichting op de afbeelding:
A. Wilo Para HU 25/6 pomp
B. Thermostatisch regelelement 20-50 °C met dompelvoeler en dompelbuis
B1.Dubbel instelbaar thermostaatventiel CV aanvoer
C. Instelbaar retourventiel
D. Maximaalbeveiliging met vaste temperatuursinstelling 60°C +/- 5K
E. Insteek thermometer ten behoeve van vloer-retourwater
F. Insteek mano/thermometer 63 mm 0-8 bar/0-60°C voor vloer-aanvoerwater
G. Aansluiting ten behoeve van vloer-aanvoerwater ¾" euroconus
H. Groepsafsluiter (M30 x 1,5), dubbel instelbaar, met ¾" euroconus aansluiting, ten behoeve van vloer-retourwater
I. Ontluchter ½", draaibaar en handbediend
J. Vul – en aftapkraan
K. Instelschroef t.b.v. regelen flow/temperatuur
J
F
C
B
H
I
G
E
A
D
B1
K
06 Manifolds Manual

Manifolds Manual 07
Product description
3.1.3 General Compact PRO manifold
PRO manifolds, suitable for connection to both high and low temperature boilers. When
connectedtoalowtemperatureheatingsource,themassowshouldbeenlargedprimarilyto
providesufcientheatingpower.ThePROmanifoldsareequippedwithaLTVcontrolvalvewhich
makesitpossibletoregulatethereturnwaterow.

3.2 District Heating PRO manifold
3.2.1 Partslist/functionaloverviewandspecications
A. Circulationpump,A-label(WiloParaHU25/6-43/SCU)
B. Thermostaticcontrolofsupplywaterfordistrictheating(adjustable)
B1. Double adjustable thermostatic valve for district heating supply water.
C. Adjustable return water valve for district heating.
D. Temperaturesafetystat,withsettemperature(55°C+/-5K)
E. Robotpressure/temperaturegauge0-8barforunderoorreturnwater
F. Temperaturegaugeforunderoorsupplywaterwater
G. Euroconeconnectionforunderoorsupplywater
H. Thermostaticvalve(M30x1.5),doubleadjustable,euroconeconnection,forunder-
 oorreturnwater
I. Manual air bleed valve
J. Fill and drain tap
L. Internalcheckvalvetopreventowwatertomixwithreturnwater(primary)
M. Return control valve 20-50 °C
B
I
G
L
A
D
H
E
C
B1
M
F
J
08 Manifolds Manual
Product description

3.2.2 Application
Underoor heating, high-temperature system: 70°C supply (primary)/40°C return (primary),
suitableforunderoorheating.Combinedwiththissteelmanifold,onlyuseaunderoorheating
pipe, in accordance with DIN 4726. Maximum pressure 6 bar on the manifold.
3.2.3 General
Becauseof possible transport damage,theadjustablereturn valve (C)andthereturn control
(M),arepackedasawholeandsuppliedseparately(theowvalveandreturnwaterthermostatic
valvemustremainconnectedatalltimes).
The district heating manifolds are equipped with a check valve (L), ensuring that the supply
water(primary)isalwayspumpedthroughtheunderoorheatingpipingtothereturnpipeinthe
districtheatingnet.Thispreventsthewaterfromowingdirectlyfromthesupplytothereturn
valve of the district heating net.
Manifolds Manual 09
Product description

3.3 Optimum Flow PRO manifold
3.3.1 Partslist/functionaloverviewandspecications
A. Circulationpump,A-label(WiloParaHU25/6-43/SCU)
B. Thermostaticcontrolofsupplywaterforboilers(adjustable)
B1. Double adjustable thermostatic valve for supply water for boilers
C. Adjustable return valve for return water for boilers
D. Temperature safety stat, with temperature set at 55°C +/- 5°K
E. Temperaturegaugeforunderoorsupplywater
F. Robotpressure/temperaturegauge0-8bar/0-60°Cforunderoorreturnwater
G. Singleadjustableowvalve
H. Thermostaticvalve(M30x1.5),doubleadjustable,euroconeconnection,forunder
 oorreturnwater
I. Manual air bleed valve
J. Fill and drain tap
K. Robotowmeter(½”x¾”eurocone)
L. PRO Valve for adjustment the return
3.3.2 Application Optimum Flow Pro
Underoorheating, high and low temperaturesystem:approx.40°C-70°Csupply(primary),
suitable for main or auxiliary heating. Maximum 6 bar pressure. In combination with this steel
manifold, only use diffusion-tight pipe in accordance with DIN 4726. The manifold is supplied
hydraulically neutral.
10 Manifolds Manual
Toelichting op de afbeelding:
A. Wilo Para HU 25/6
B. Thermostatisch regelelement 20-50 °C met dompelvoeler en dompelbuis
B1.Dubbel instelbaar thermostaatventiel CV aanvoer
C. Instelbaar retourventiel
D. Maximaalbeveiliging met vaste temperatuursinstelling 60°C +/- 5K
E. Insteek thermometer ten behoeve van vloer-retourwater
F. Insteek mano/thermometer 63 mm 0-8 bar/0-60°C voor vloer-aanvoerwater
G. Aansluiting ten behoeve van vloer-aanvoerwater voorzien van enkel instelbaar voetventiel +
regelbare koppeling met ½" (doorlaat) x ¾" euroconus (aansluiting)
H. Groepsafsluiter (M30 x 1,5), dubbel instelbaar, met ¾" euroconus aansluiting, ten behoeve van vloer-
retourwater
I. Ontluchter ½", draaibaar en handbediend
J. Vul- aftapkraan
K. Flowmeter ½" (doorlaat) x ¾" euroconus (aansluiting) vernikkeld
L. Instelschroef t.b.v. regelen flow/temperatuur
F
B
A
H
K
I
B1
G
C
D
E
L
J
Product description

3.3.3 General Optimum Flow PRO
PRO manifolds, suitable for connection to both high and low temperature heating source. When
connectedtoalowtemperatureheatingsource,themassowshouldbeprimarilyenlargedto
providesufcientheatingpower.ThePROmanifoldsareequippedwithanLTVcontrolvalve,
whichmakesitpossibletoregulatereturnwaterow.
Withtheowmetersthenumberoflitersperminuteareeasilymonitored.Thesingleadjustable
owvalves(G)helptolltheunderoorheatingsystemefciently.
Product description
Manifolds Manual 11

3.4 LT manifold
3.4.1 Partslist/functionaloverviewandspecications
A. Inserttemperaturegaugeforunderoorreturnwater
B. Robotpressure/temperaturegauge0-8bar/0-60°Cforunderoorsupplywater
C. Thermostaticvalve(M30x1.5),doubleadjustable,euroconeconnection,forunder
 oorreturnwater
D. Robotsingleadjustableowvalve(½”x¾”eurocone)
E. Manual air bleed valve
F. Manual air bleed valve
G. Blanking cap
3.4.2 Application
The Robot LT manifold, without a pump, is a steel manifold that is suitable for systems with a low
temperature supply where a central pump is present.
• Suitable for heat pumps and boilers with limited temperature setting, with an
external pump if required
• Low-temperaturesystem:upto50°Csupply(primary)
• Available 2-20 groups
• Available with connection on both left and right (can be changed into cross-
 connection)
G
C
B
E
F
D
A
G
12 Manifolds Manual
Product description

3.5 Setting of the PRO-valve on Standard & Optimum Flow manifolds
Setting of the PRO-valve on Standard and Optimum Flow manifolds
Whenfullyclosed(clockwise)therewillbenomixtureofowand(underoor)returnwater.This
setting can be used for sourcetemperatures to about
40°C. *
When fully open (counterclockwise in factorysetting)
there will be mixture of the ow and (underoor)
returnwater. This setting can be used for
sourcetemperatures from 55 – 80°C.
The setting is done by means of an Allan-key. The
more you close the valve in this way, the less mixture
there will be, hence the lower the sourcetemperature
can be.
*We recommend to leave the PRO valve a bit open to be sure of circulation. (One rotation is
enough)
Manifolds Manual 13
Product description

3.6 Pumps
Pay attention:
The pump must always be plugged into the power** outlet (grounded wall
socket)ifthemanifoldiscompletelylled.Thisalsoappliesifthemanifoldis
primarilynotyetconnected(forexampletotheboiler).
3.6.1 Wilo Para HU 25/6-43/SCU
The manifolds of Robot Vloerverwarming B.V. are equipped with a composite Wilo* pump
house. The pump housing is mounted stress-free on the manifold to avoid annoying pump noise.
* See the appendix for the Wilo Para HU 25/6-43/SCU manual.
** THIS WILL PREVENT DAMAGE TO THE PUMP, WHICH WILL VALIDATE THE GUARANTEE.
14 Manifolds Manual
Product description

Storage and transport
4. Storage and transport
4.1 Storage
Keep the manifolds in their original packaging until installation is started.
The manifolds must be stored safely in a dry, ventilated area and not be exposed to direct
sunlight. The packaging is not weather-resistant.
The manifolds must be stored frost-free.
4.2 Transport
Ensure that the manifold in its packaging is exposed to vibrations as little as possible during
transport. Transport/move the packaging carefully.
PLEASE NOTE the ergonomic conditions such as lifting, bending, reaching, etc. when working
with the manifolds.
Manifolds Manual 15

5. Mounting preparation
Mounting preparation
5.1 Mounting conditions
5.1.1 Requirements for the mounting area of the manifold
The mounting area must meet the following conditions:
1. Proper access to the system components
2. Room around the manifold to carry out work
3. The mounting area is frost-free
4. Themountingareaisprovidedwithawaterllingpoint
5. The mounting area is provided with a lighting point
6. The mounting area is provided with an earthed wall socket.
7. The mounting area is provided with a water outlet
Location of the manifold
• Place the manifold in a dry, well-vented, centrally located area in the house.
• PLEASE NOTE: The manifold should not be placed in the fuse box.
• If the manifold is equipped with a pump, it should not be placed in or against the
wall of a bedroom or living room. When the pump is operational, it might cause a
small vibration noise. A good location for the control unit could be the hall, pantry
or garage.
• Do not place the manifold onto a partition of a light construction.
• Place the manifold in an easily accessible place because of possible maintenance
work.
The location of the manifold must be:
• Dry and Dust- and frost-free
• Free from vibrations
• Adequately lit
• Free from combustible materials
• Free from explosive gases.
Installation of the manifold
•Placethemanifold50to60cmabovetheoorsothatthepipingcanbeeasilyconnected.
PLEASE NOTE:Thedistancefromthebottomofthemanifoldtothetopofthenishedoor
must be at least 30 cm.
•Mountthemanifoldatasufcientheighttobeableto‘gradually’benttowardsormountto/
onthemanifoldtopreventthepipefrombuckling.Itisrecommendedtouseoorbends.
•Mountthemanifoldsonaatnon-combustible/heat-resistantwallwithsufcientcarryingca-
pacity. Ensure that the surface is clean and dry.
16 Manifolds Manual

• When performing mounting work below the surface to be heated, the manifold must always
be placed above the level of the to be heated surface for venting purposes.
• The manifold must be mounted to the wall in a level position so that the venting point can be
used optimally.
• Always mount the manifold with the supplied rubber silencers to limit noise/vibrations as
much as possible.
• The manifold is exclusively intended for mounting on a wall with the help of the supplied
bolts and plugs. The manifold can also be mounted on a console.
• Ensure that all fasteners are properly tightened. Check if all fasteners are in the right place.
5.2 Tools overview
Tools required for mounting the manifold and the piping:
Mounting preparation
Manifolds Manual 17
Tape measure Pencil / marker Level Brush
Drilling machine Drill Open-end wrench Screwdrivers
Stanley knife
Pipe cutter
copper/steel
Hammer ClothPipe cutter
Allenkey(4mm)

6. Installing/mounting
Installing/mounting
6.1 Mounting of manifold
1. Position the manifold level against the wall
ataheightofapprox.50cmfromtheoor.
2. Mark the positions of the mounting holes of
themanifoldwithapencil/markerontheoor.
3. Drill the mounting holes in the wall. 4. Place the plugs in the mounting holes.
18 Manifolds Manual
ca. 50 cm
Ø10 mm