Swegon TBXZ-3-42 User manual

GB.TBXZ342.130915
Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 1
Installation Instructions for the
TBXZ-3-42 Pipework Package, GOLD SD/GOLD CX 100/120
1. General
The pipework package is used for circulating a mixture of
water and glycol between two interconnected heat recov-
ery coils in a closed system.
The supply includes the following: The pipework package
is supplied complete with insulated sheet-metal casing,
pump, control valve with actuator, expansion vessel,
safety valve, manometer and shut-off cocks, thermom-
eters, filling valve and air purging valve.
Basic circuit diagram
M
1
2
3
4
5
7
6
8
8
6
10
11
8
9
8
6
10 1 Air purging valve
2 Manometer
3 Safety valve
4 Filling valve
5 Expansion vessel
6 Shut-off valve
7 Pump
8 Thermometer
9 Control valve with actuator
10 Adjustment valve
11 Temperature sensor

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Registered design. The company reserves the right to make changes without prior notice.
2 www.swegon.com
2. Installation
2.1 Pipework Package.
1. Install the pipework package at a suitable location in
the fan room.
Wall mounting
Remove the wall mounting bracket from the pipework
package and secure it to a suitable place on a wall. In
order to reach and unfasten the wall mounting bracket,
you must first dismantle the front panel of the sheet-metal
casing.
Floor mounting
A stand for floor mounting, TBXZ-2-43, is available as an
accessory, see illustration to the right. Secure the stand to
a suitable spot on the floor. In order to reach the pipework
package and secure it to the stand with screws, you must
first dismantle the front panel of the sheet-metal casing.
2. Mount the pipework package onto the wall mounting
bracket/floor stand.
3. Fit the pump to the pipework package. Give careful
attention to the direction of flow. See the label on the
front of the pipework package and the illustration to the
right. It may be necessary to dismantle the drive side of
the pump and turn it so that the electrical terminal box
will be positioned upward. This can be done after remov-
ing four socket head cap screws.
4. Mount the shut-off valve + pipes onto the pump.
5. Mount the pressure expansion vessel and accessories.
2.2 Control unit.
The control unit is designed for wall mounting should be
mounted at an appropriate location. Make sure that you
position the safety isolating switch on the control unit 0.6
– 1.9 metres above floor level.
2.3 Installing the pipework
The pipework between the heat exchanger coils and the
pipework package should be installed and insulated in a
professional manner by a ventilation and sanitation fitter,
according to customary trade standards and regulations.
Connect the heat exchanger coils for counter-flow cir-
culation according to the arrows on the coil connection
branches. Incorrect connection may cause a reduction in
efficiency. Make sure that the pipework package and the
connecting pipework do not block inspection of the other
functional sections.
Check that the deadweight of the pipework and/or the
expansion forces will not be applied to liquid connections.
Use an appropriate sealing/jointing compound for sealing
the threads on the heat exchanger connections.
Connect the safety valve, appropriately using a hose, to a
collecting vessel (not supplied by Swegon ).
M
Supply air Extract air
The height from
floor level to the
thermometers on
the installed pipe-
work package is
1480 mm.
2.4 Temperature sensor
A type strap-on temperature sensor is supplied with the
pipework package. Secure the sensor onto the return
pipe, as shown in the basic circuit diagram on page 1, for
instance by means of a bundling strap. The sensor is used
as a limiting sensor to counteract freezing.
Wire the temperature sensor leads to terminals 107-108 in
the control unit of the pipework package.

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3. Dimensions
M
B
H
C
Wall
Pipework Package
GOLD
Size
TBXZ-42
Size
Coil heat
exchanger
connections
Pipework
package con-
nections
12, 14, 20 20 DN 32 DN 32
25, 30 30 DN 40 DN 40
35, 40 40 DN 40 DN 50
50, 60 60 DN 40 DN 50
70, 80 80 DN 50 DN 50
100, 120 120 DN 65 DN 65 Flange
GOLD
Size
TBXZ-42
Size
B H
12, 14, 20 20 600 415
25, 30 30 770 530
35, 40 40 770 530
50, 60 60 770 530
70, 80 80 770 530
100, 120 120 840 640
GOLD
Size
TBXZ-42
Size
C
12, 14, 20 20 100
25, 30 30 120
35, 40 40 120
50, 60 60 120
70, 80 80 120
100, 120 120 165

GB.TBXZ342.130915
Registered design. The company reserves the right to make changes without prior notice.
4 www.swegon.com
105
106
107
108
101
N
104
107
102
106
108
103 105
F1
K1
A
101
N
104
107
102
106
108
103 105
NN
4
5
6
7
8
9
A
B
C
D
E
F
0
1
2
3
P1
COM POWER
IQlogic+
1234 5678 9101112
-+-+ -++--S-S
C
13
NO
14
C
15
NO
16
+
17
-
18
+
19
-
20
G
21
G0
22
Com 1Heat/Cool Com 2
103
3. Electrical Connections
The electrical connections are to be wired by a qualified
electrician in accordance with local electrical safety regula-
tions.
Connect the cable between the GOLD unit and the control
unit for the pipework package from terminal to terminal,
i.e. from Terminal No. 1 in the GOLD unit to Terminal No.
1 in the control unit for the pipework package. See the
fig. to the left.
The cable between units is not included in the supply.
Twisted-pair cables are recommended. Use one cable pair
for 24 V and the other cable pair for bus communication.
Terminals, Cable
adapter - Control
unit for the pipe-
work package
Terminal No. 1 = -24 V DC
Terminal No. 2 = +24 V DC
Terminal No. 3 = EIA-485 B BUS
Terminal No. 4 = EIA 485 A BUS
1
2
3
4
1
2
3
4
Max permissible cable length: 100 metres
Terminals – Cable adapter, GOLD air handling unit.
GOLD SD: Cable adapter in the supply air or
extract air handling unit.
GOLD CX 100/120: Cable adapter marked EIA-485
in the upper electrical equipment cubicle.
Pump, 3x400 V
Pump TP
(thermostatic contacts)
Control valve, actuator
Temp. sensor
Bus communication
Power supply: 3x400 V,
5-wire cable or 1x230
V*, 3-wire cable. Wire
to a safety isolating
switch. Rec. fuse: 10 A.
Brown Black Grey Blue
Brown Black Grey Blue
The function selector
switch must be set to
position 1.
Bus contacts
Wiring
terminals
Cable adapter
Control unit for the pipework package
L1 L2 L3
Pump,
3 x 400 V
Safety isolating switch
Pump, TP
Pump, TP
24 V AC/GO
24 V AC/G
0-10 V DC/Y
0-10 V DC/U
TEMP/GND (Brown)
TEMP/DTA (White)
Violet
Orange
Yellow
Yellow
L1 L2 L3
Pump,
1 x 230 V
* If 1x230 V is supplied, con-
nect the phase wire to L3 on the
safety isolating switch.

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Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 5
4. Commissioning
1. The height of lift for the control valve is automatically
calibrated the first time it is commissioned.
2. Check the pre-pressure by measuring the level dif-
ference from the centre of the expansion vessel to the
highest point of the pipe connection system. Convert the
level difference to bar (1 metre = 0.1 bar). Add another
0.3 bar (for the coil) to this figure to obtain the pre-pres-
sure.
The safety valve must be sized to withstand at least 1 bar
above the pre-pressure. The safety valve supplied is sized
to withstand 2.5 bar.
Example:
Measured level difference of 2 metres = 0.2 bar
Pre-pressure = 0.2 bar + 0.3 bar (coil) = 0.5 bar
Min. permissible safety valve pressure = 0.5 bar + 1 bar =
1.5 bar
This figure is well below the max. limit of the safety valve
supplied, which is 2.5 bar.
Equipped with the safety valve supplied, the pipe connec-
tion system will manage a level difference of 12 metres (=
1.2 bar).
If the level difference is more than 12 metres, you will
either have to move the expansion vessel with accessories
to a higher position or replace the safety valve. Since the
expansion vessel manages max. 5 bar, a safety valve sized
for a max permissible pressure of 5 bar must be used.
The expansion vessel is factory-rated for a pre-pressure of
0.5 bar, which also is the minimum limit. If the pre-pres-
sure of the expansion vessel threatens to drop below 0.5
bar, fill more air through the nipple on the underside of
the expansion vessel.
3. Preset the adjustable red pointer on the manometer, to
the corrected pre-pressure in the expansion vessel.
4. Open "the cap" on the automatic air purging valve.
5. Fill the system with water (usually water mixed with
glycol). Please note that if glycol is used, it must be meant
for cooling medium systems, not motor vehicles. Fill the
system slowly. Vent the liquid circuit at the air purging
points as you fill it.
6. Adjust (fill / drain) the system so that the pressure in the
system will conform to the corrected pre-pressure reading
(see the red pointer on the manometer).
7. The system is now ready to be commissioned. Under
normal operating conditions, the pressure in the system
must not drop below the corrected pre-pressure preset on
the manometer (see the red pointer on the manometer) or
exceed the red mark.
Sizing diagram
EVOPLUS B 150/250,40
For the GOLD SD, sizes 12-40
5. Circulation pumps, wet motor
Survey – Pump data
Temperature range, liquid: -10°C – +110°C
Max. perm. operating pressure: 16 bar
Size of pipe connections: DN40
Max. permissible static pressure: PN 16
Enclosure class: IP44
Weight: 16 kg
Electrical data
Frequency: 50 Hz
Rated voltage: 1 x 230 V
Output: 610 W
Nominal current: 2.9 A
Motor protection: Integrated
Head
Power input P1
Total eciency
v7
62,6%
Tot. e.
8 m
4 m
v7
8 m
4 m
v7
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
[m]
0
0,1
0,2
0,3
0,4
0,5
0,6
[kW]
0
10
20
30
40
50
[%]
0 4 8 12 16 20 24 [m³/h]

GB.TBXZ342.130915
Registered design. The company reserves the right to make changes without prior notice.
6 www.swegon.com
Sizing diagram
EVOPLUS B 150/280.50
For the GOLD SD, sizes 50-60
Sizing diagram
EVOPLUS B 150/340.65
For the GOLD SD, sizes 70-120,
GOLD CX, sizes 100/120
Survey – Pump data
Temperature range, liquid: -10°C – +110°C
Max. perm. operating pressure: 16 bar
Size of pipe connections: DN50
Max. permissible static pressure: PN 16
Enclosure class: IP44
Weight: 18 kg
Electrical data
Frequency: 50 Hz
Rated voltage: 1 x 230 V
Output: 640 W
Nominal current: 3 A
Motor protection: Integrated
Head
Power input P1
Total eciency
v6
64,5%
Tot. e.
12 m
8 m
4 m
v6
12 m
8 m
4 m
v6
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
[m]
0
0,1
0,2
0,3
0,4
0,5
0,6
[kW]
0
10
20
30
40
50
60
[%]
0 5 10 15 20 25 30 [m³/h]
Survey – Pump data
Temperature range, liquid: -10°C – +110°C
Max. perm. operating pressure: 16 bar
Size of pipe connections: DN65
Max. permissible static pressure: PN 16
Enclosure class: IP44
Weight: 20 kg
Electrical data
Frequency: 50 Hz
Rated voltage: 1 x 230 V
Output: 1210 W
Nominal current: 5.5 A
Motor protection: Integrated
Head
Power input P1
Total eciency
v5
70,3%
Tot. e.
10 m
5 m
v5
10 m
5 m
v5
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
[m]
0
0,2
0,4
0,6
0,8
1
0
10
20
30
40
50
60
[%]
010 20 30 40 [m³/h]

GB.TBXZ342.130915
Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 7
6. Adjustment valve, 9505/9555P
General
Draining
The valves without drain nipple have a cover sleeve. This
cover sleeve can be exchanged for a set of drain fittings
available as accessories.
Measurement tappings
The measurement tappings are self sealing. For measure-
ments, remove the cover. Then insert the measurement
needle through the self-sealing measurement tapping.
Technical Description
Range of Application
Heating and cooling systems. Tap water installations.
Function
Commissioning, pressure drop and flow measurements,
shut off and drainage.
The valve can regulate the flow when you turn the handle
to change the setting. There are 40 (9505) or 80 (9555P)
different positions on the handle.
The valve can stop the flow and on a restart there is a
memory function that returns the valve back to the previ-
ous setting.
The valve can be used for measuring the flow across the
valve by measuring the pressure in the two measurement
points.
Pressure class
9505:
PN 20. (PN 25 at max. permissible operating temperature,
100°C)
9555P:
PN 16.
Temperature
Max. permissible operating temperature: 130°C.
Min. permissible operating temperature: - 10°C.
Kv values
The values or chart on the next page can be used for cal-
culating the pipe system.
1 21,9
1,5 26,4
2 31,1
2,5 35,7
3 40,1
3,5 44,4
4 49,3
4,5 53,2
5 57,7
5,5 64,4
6 71,8
6,5 76,6
7 80,4
7,5 84,1
8 88,8
Commissioning valve 9505
65
DN
Turns
Commissioning valve 9555P
0,5 0,09 0,37 0,4 1,4 1,4 2,7 3,9
1 0,19 0,55 0,7 2 3,3 3,5 7,8
1,5 0,33 0,75 0,9 2,6 4,1 4,5 10,6
2 0,5 0,94 1,2 3,5 5,1 6,1 14,8
2,5 0,66 1,18 1,5 4,8 7,6 10 19,9
3 0,81 1,75 2,2 5,5 10,4 14,1 23,9
3,5 0,92 2,44 3,4 6 11,2 17,6 27,2
4 0,97 2,67 4,1 6,4 12 19,5 29,8
10 15 20 25 32 40 50
DN
Turns

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Registered design. The company reserves the right to make changes without prior notice.
8 www.swegon.com
Presetting
The valve can be preset by means of the appropriate flow
diagram for the relevant valve size. The presetting of the
valve can be read in the "main" and "secondary" scale on
the handle. Double zeros indicate that the valve is closed.
- The primary valve setting (main) is shown in the lower
window, where the values move in a vertical direction.
Each number indicates one whole turn.
- The secondary valve setting (secondary) is shown in the
upper window, where the values move in a horizontal
direction. Each number indicates one tenth of a turn.
To set a valve to a certain pressure drop setting that e.g. is
equivalent to 2.3 turns in the diagram, proceed as follows:
1. Close the valve completely.
2. Open the valve 2.3 turns.
3. The memory stop can be set as follows:
- Remove the plastic cover on the handle using a small
tool:
- Insert the 3 mm Allen key supplied into the hole in the
center. Make sure that the topset® is in its required posi-
tion and tighten the inner screw clockwise until it stops.
Do not tighten it too hard.
- Replace the plastic cover. You can prevent unauthorized
persons from changing the setting by security sealing the
cover of the handle's upper section. This can be done by
using a special wire with a security seal that you insert
through the existing grooves.
The valve can now be closed, and thus influence the flow
at anytime. When the valve is opened again the memory
stop will return to the previous setting.
4. The valve is now set.
To check the presetting, close the valve. The setting indi-
cated should then be 0.0. After that, open it to stop. The
presetting will then be indicated, in this case: 2.3.
Diagrams that indicate the pressure drop at various set-
tings and flows for each size of valve are provided for
guidance in determining the correct valve size and preset-
ting (pressure drop).
A fully open valve corresponds to 4 turns (9505) or 8
turns (9555P). Opening the valve additional turns will not
increase its capacity.

GB.TBXZ342.130915
Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 9
Important!
If the flow is outside the chart, it can be read as follows:
Assume the example above that reads 10 kPa, Kv=5 and a
flow of 1.6 m3/h. For 10 kPa and Kv=0.5 you read a flow
of 0.16 m3/h and for Kv=50 you read 16 m3/h. Therefore,
for every given pressure drop you can read 0.1 or 10 times
the flow and Kv.
Example
This chart shows the pressure drop across the valve. A
straight line that interconnects the scales for flow – Kv
- pressure drop constitute the relationship between the
different readings.
7. Chart
The position for each valve size can be obtained by plot-
ting a horizontal line from the value intersected on the Kv
scale.
Sought
Presetting for DN 25 and required 1.6 m flow 3/h and pres-
sure drop of 10 kPa.
Solution
Plot a line between 1.6 m3/h and 10 kPa. This intersects
the Kv scale at KV=5. Then plot a horizontal line from Kv 5
to the DN 25 scale where you read 2.75 turns.
7.1 DN 32 – 50 (GOLD SD 12-80)

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Registered design. The company reserves the right to make changes without prior notice.
10 www.swegon.com
Important!
If the flow is outside the chart, it can be read as follows:
Assume the example above that reads 25 kPa, Kv=53 and
a flow of 27 m3/h. For 25 kPa and Kv=5,3 you read a flow
of 2,7 m3/h and for Kv=53 you read 270 m3/h. Therefore,
for every given pressure drop you can read 0.1 or 10 times
the flow and Kv.
Example
This chart shows the pressure drop across the valve. A
straight line that interconnects the scales for flow – Kv
- pressure drop constitute the relationship between the
different readings.
The position for each valve size can be obtained by plot-
ting a horizontal line from the value intersected on the Kv
scale.
Sought
Presetting for DN 65 and required 27 m flow 3/h and pres-
sure drop of 25 kPa.
Solution
Plot a line between 27 m3/h and 25 kPa. This intersects the
Kv scale at KV=53. Then plot a horizontal line from Kv 53
to the DN 65 scale where you read 4,5 turns.
7.2 DN 65 (GOLD SD 100/120, GOLD CX 100/120)