Watts HKF 8180 User manual

HKF 8180
Operating instructions
Version 1.0en /Edition 05/2013
EN

Contents
1 Important basic information........................................................................................................................3
1.1 Limitation of liability........................................................................................................................................3
1.2 Operator's responsibilities..............................................................................................................................3
1.3 Documentation...............................................................................................................................................3
1.3.1 Content and structure...........................................................................................................................3
1.3.2 Notation concept used in the documentation.......................................................................................4
1.4 Target group...................................................................................................................................................4
1.5 Replacing wear parts......................................................................................................................................4
2 Safety.............................................................................................................................................................5
2.1 Important safety information...........................................................................................................................5
2.2 Correct use.....................................................................................................................................................5
2.2.1 Area of use...........................................................................................................................................5
2.2.2 Safety-related environmental conditions..............................................................................................5
2.3 Compliance with the operating instructions....................................................................................................6
2.4 Residual hazards and safety measures.........................................................................................................6
3 Overview of components.............................................................................................................................7
4 Functional description.................................................................................................................................8
5 Installationandrstcommissioning..........................................................................................................9
5.1 Safety.............................................................................................................................................................9
5.2 Installation......................................................................................................................................................10
5.3 First commissioning........................................................................................................................................11
6 Maintenance..................................................................................................................................................12
6.1 Safety.............................................................................................................................................................12
6.2 Recommended maintenance intervals...........................................................................................................12
6.3 Maintenance work..........................................................................................................................................13
6.3.1 Dismantling the circulating pump.........................................................................................................13
6.3.2 Fitting the circulating pump..................................................................................................................14
6.3.3 Dismantling the thermal mixer valve with temperature setting.............................................................15
6.3.4 Fitting the thermal mixer valve with temperature setting......................................................................16
6.3.5 Swapping the supply and return lines..................................................................................................17
7 Technical data...............................................................................................................................................18
8 Decommissioning, recommissioning.........................................................................................................20
8.1 Decommissioning...........................................................................................................................................20
8.2 Recommissioning...........................................................................................................................................20
9 Dismantling...................................................................................................................................................21
10 Disposal ........................................................................................................................................................21
10.1 Safety.............................................................................................................................................................21
10.2 Disposal..........................................................................................................................................................21
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1 Important basic information
1.1 Limitation of liability
The contents of these operating instructions have been created in accordance with applicable laws and standards.
The device has been developed in line with the state of the technological art.1
The manufacturer accepts no liability for damage resulting from:
XFailure to observe / comply with the operating instructions
XDeliberate misuse
XIncorrect use
XUse of untrained specialist personnel (for maintenance and repair work, etc.)
XTechnical modications to the device that have not been discussed with the manufacturer
XUse of spare parts that have not been approved by the manufacturer
1.2 Operator's responsibilities
The safety, accident prevention and environmental protection regulations applicable to the domain of the device's
use must be complied with.
This particularly includes:
XThe operator must ensure that these operating instructions are available throughout the HKF 8180's lifetime.
XThe operator must ensure that the maintenance intervals described in these operating instructions are
complied with.
XThe operator must regularly arrange a check of the functionality and intactness of all safety equipment.
note
Installation and operation of the HKF 8180 must comply with country-specic standards and
guidelines.
1.3 Documentation
1.3.1 Content and structure
These operating instructions are part of this device. They contain instructions and information regarding the safe
use of the device and must be made available to all users for the device's entire life cycle.
These operating instructions are designed for use by trained professionals.
1 We reserve the right to make technical changes!

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1.3.2 Notation concept used in the documentation
The following types of notication are used:
Typeofnotication Illustration Meaning
Acute danger of death
danger
Dangerous situation that is certain to cause serious
injury or death if it is not avoided
Danger of death and serious
injury warning
Dangerous situation that could cause serious injury or
death if it is not avoided
Danger of mild to moderate
injury caution
Dangerous situation that could cause mild to
moderate injury if it is not avoided
Information, easier operation
note
Refers to information that does not relate to physical
injury, e.g. reference to material damage
$Alerts the user to an instruction regarding general safety
■Alerts the user to an instruction regarding action to be taken
@Alerts the user to the consequences of an action
1.4 Target group
These operating instructions are designed for use by trained professionals.
The operator of this device must ensure suitable and safe conditions in line with the requirements of these
operating instructions.
Professionals – trained professionals who are aware of the dangers of the HKF 8180 and who are familiar with
the technology used in the device. Professionals are trained and capable of installing, maintaining and repairing the
device.
1.5 Replacing wear parts
Be aware that the HKF 8180 contains parts which, depending on how frequently and how much they are used, will
be subject to technology-related wear and tear, even if they are cared for and maintained properly. This particularly
relates to mechanical parts and parts that come into contact with hot water and steam, such as hoses, gaskets,
valves, etc.
Wear-related defects naturally do not represent faulty workmanship and are therefore not covered by the warranty
or any guarantee; regardless of this, faults and malfunctions must only ever be rectied by trained professionals.
Contact your dealer for more information.

2 Safety
2.1 Important safety information
$Read these operating instructions carefully before use.
$Only connect the HKF 8180 to an energy supply with a suitable mains voltage.
$The energy supply to the HKF 8180 must be disconnected before any maintenance, cleaning or repair work is
carried out.
$Maintenance, cleaning and repair work must only be carried by trained professionals.
$In the event of damage to the HKF 8180 or if its function becomes impaired, the HKF 8180 must no longer be
used. In this instance, contact your dealer immediately.
$Note the maintenance instructions and intervals.
$Protect the HKF 8180 against the effects of weather.
$Never use the HKF 8180 outdoors.
$For your own safety and to ensure the HKF 8180's long service life, only use original spare parts.
$The device must only be used in accordance with the descriptions set out in the section entitled Correct use.
2.2 Correct use
2.2.1 Area of use
The HKF 8180 has been built in accordance with the state of the technological art and in line with recognised
safety technology regulations. No liability is accepted for any damage caused by misuse, incorrect use, incorrect
connections or inadequate maintenance / repair not carried out by trained professionals. All warranty services will
also be rendered null and void in such situations.
The HKF 8180 is used to distribute hot water in heating systems.
HKF 8180 is fully pre-assembled and designed for wall-mounting.
The HKF 8180 is not intended for use by individuals (including children) who have limited physical, sensory or
mental capacities or who lack the technical knowledge and/or experience to do so.
2.2.2 Safety-related environmental conditions
yThe HKF 8180 must not be installed and operated outdoors.
yThe components are not UV resistant.
yThe installation site of the HKF 8180 must be chosen so that maintenance and repair work can be carried out
when required.
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2.3 Compliance with the operating instructions
note
Read the operating instructions carefully before use.
In addition to the instructions contained in these operating instructions, regional requirements
(e.g. accident prevention guidelines) also apply to the safe operation of this device. The operator of
the device must make this information available.
2.4 Residual hazards and safety measures
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
warning
Hot water!
Severe scalding possible.
hAllow the HKF 8180 to cool down rst before carrying out any maintenance, cleaning or
repair work.
hWhen ushing, lling and draining the HKF 8180, do not touch the hot water.
warning
Hot surfaces!
Severe scalding possible.
hDo not touch any pipes or components during operation.
hAllow the HKF 8180 to cool down rst before carrying out any maintenance, cleaning or
repair work.
hWear heat-resistant safety gloves when carrying out work on hot components.
caution
Working on the device by inadequately trained specialist personnel!
Potential physical and material damage.
hMaintenance, cleaning and repair work must only be carried by trained professionals.
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3 Overview of components
BA
DC
1 Ball valve with thermometer (return) and gravity brake
2 Ball valve with thermometer (supply) and gravity brake
3Circulating pump (wet-running circulating pump with integrated
electronic differential pressure-managed power control.
4 Thermal mixer valve with temperature setting from 20 to 43 °C
A Return inlet
B Supply outlet
C Supply inlet
D Return outlet
Fig. 1: Overview of components – dimensions [mm]
130 130
40
125
300
355
243
Fig. 2: Dimensions [mm]
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4 Functional description
Setting the supply temperature
While the HKF 8180 is operational, you can set the desired supply temperature using the hand wheel on the
thermostatic valve. The target value is checked using the supply thermometer.
Fig. 3: Setting the supply temperature

5 Installationandrstcommissioning
5.1 Safety
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
caution
Danger of material damage!
The HKF 8180 is not spray- or drip-roof.
hOnly install the HKF 8180 in a dry location.
caution
Material damage caused by pressure shocks!
Development of pressure shocks caused by opening the shut-off valves too quickly.
hAlways open the shut-off valves slowly and in a controlled manner.
note
HKF 8180 must only be installed and commissioned by a qualied professional.
Installation and operation of the HKF 8180 must comply with country-specic standards and
guidelines!
Do not make any modications to components (e.g. pumps, valves, etc.), supply or return lines
and / or safety equipment that could impair the operational safety of the HKF 8180.
Ensure that the HKF 8180's energy supply is always freely accessible.
note
Wear personal safety equipment when carrying out maintenance, cleaning or repair work.
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5.2 Installation
note
Install the HKF 8180 so that it is positioned at eye level.
■Remove the front cover on the HKF 8180.
Fig. 4: Removing the front cover
■Draw on the drilling points for installing the HKF 8180.
130 40
12
130
Fig. 5: Drilling dimensions [mm]
■Drill the holes in accordance with the screw and dowel size.
■Insert the dowels.
■Place the HKF 8180 on top.
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■Screw the screws into the dowels.
■Attach the supply and return lines (system connections, see Fig. 1 on page 7).
■Check all screw connections to ensure they are secure.
5.3 First commissioning
Essential
yHKF 8180 is fully installed.
Connecting the energy supply
■Connect the HKF 8180's energy supply.
note
The electrical installation of HKF 8180 must only be performed by a qualied professional.
@The HKF 8180 switches on automatically once the power supply has been connected.
■Vent the heating system.
note
Switch the circulating pump off during the venting process.
Thermometer handle settings
ABC
Fig. 6: Thermometer handle settings
A Operation setting: gravity brake ready for operation; ball valve open
B Drain setting: gravity break open
C Service setting: ball valve closed

6 Maintenance
6.1 Safety
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
hBefore carrying out any maintenance, cleaning or repair work, disconnect the energy supply to
the HKF 8180 and ensure it cannot be switched back on.
warning
Hot water!
Severe scalding possible.
hAllow the HKF 8180 to cool down rst before carrying out any maintenance, cleaning or
repair work.
hWhen ushing, lling and draining the HKF 8180, do not touch the hot water.
warning
Hot surfaces!
Severe scalding possible.
hDo not touch any pipes or components during maintenance, cleaning or repair work.
hAllow the HKF 8180 to cool down rst before carrying out any maintenance, cleaning or
repair work.
hWear heat-resistant safety gloves when carrying out work on hot components.
6.2 Recommended maintenance intervals
Task Interval
Check the shut-off valve and ball valve for clearance Annually
Check for noisy pump operation Annually
Check HKF 8180 for leaks (visual inspection) Annually
Check the hand wheel is functioning properly Annually
Check the actuator is functioning properly Annually
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6.3 Maintenance work
6.3.1 Dismantling the circulating pump
■Disconnect the energy supply to the HKF 8180 and ensure it cannot be switched back on.
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
hBefore carrying out any maintenance, cleaning or repair work, disconnect the energy supply to
the HKF 8180 and ensure it cannot be switched back on.
■Remove the front cover on the HKF 8180 (see Fig. 4 on page 10).
■ Close the ball valves (multi-function ttings, pos. A) by turning the thermometer handle (see “Thermometer
handle settings” on page 11).
■Remove the lower insulation (pos. B), the supply and return thermometer handles (pos. A) and the upper
insulation (pos. C) in that order.
C
B
AA
Fig. 7: Dismantling the insulation
■Disconnect the circulating pump's wiring.

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■Loosen the nuts (pos. A) and dismantle the circulating pump (pos. B).
warning
Hot water!
Severe scalding possible.
hAllow the HKF 8180 to cool down rst before carrying out any maintenance, cleaning or
repair work.
hWhen draining the HKF 8180, do not touch the hot water.
A
B
Fig. 8: Dismantling the circulating pump
6.3.2 Fitting the circulating pump
■Replace damaged or faulty gaskets if necessary.
■ Insert the circulating pump and tighten the nuts (for tightening torques, see “Technical data” on page 18).
■Connect the wiring to the circulating pump as per the electrical wiring diagram.
■Slowly open the ball valves (multi-function ttings, pos. A, Fig. 9 on page 15) by turning the thermometer
handle (see “Thermometer handle settings” on page 11).
■Prime the HKF 8180 slowly with pressure and vent the system, if necessary.
note
Switch the circulating pump off during the venting process.

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■Check the HKF 8180 to ensure there are no leaks.
■Restore the energy supply to the HKF 8180.
■Dismantle the thermometer handles.
■Fit the interim insulation, the thermometer handles and the front cover.
6.3.3 Dismantling the thermal mixer valve with temperature setting
■Disconnect the energy supply to the HKF 8180 and ensure it cannot be switched back on.
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
hBefore carrying out any maintenance, cleaning or repair work, disconnect the energy supply to
the HKF 8180 and ensure it cannot be switched back on.
■Remove the front cover on the HKF 8180 (see Fig. 4 on page 10).
■ Close the ball valves (multi-function ttings, pos. A) by turning the thermometer handle (see “Thermometer
handle settings” on page 11).
■Dismantle the lower insulation (see pos. B, Fig. 7 on page 13).
■Dismantle the thermal mixer valve with temperature setting (pos. A) by loosening the union nuts (pos. B).
B
A
Fig. 9: Dismantling the thermal mixer valve with temperature setting

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6.3.4 Fitting the thermal mixer valve with temperature setting
■Replace the seals on the screw connections.
■Insert the thermal mixer valve and tighten the nuts (pos. B, Fig. 9 on page 15) (for tightening torques, see
“Technical data” on page 18).
note
When installing the control valve, check that it is installed in the correct position.
■Slowly open the shut-off valves on the supply and return lines.
■Prime the heating system slowly with pressure and vent it, if necessary.
note
Switch the circulating pump off during the venting process.
■Check the HKF 8180 to ensure there are no leaks.
■Restore the energy supply to the HKF 8180.
■Fit the lower insulation and the front cover.

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6.3.5 Swapping the supply and return lines
1234
5678
Fig. 10: Swapping the supply and return lines

7 Technical data
General
Dimensions (W x H x D) 300 x 355 x 243 mm
Weight 8.5 kg
Maximum operating pressure 10 bar
Maximum permissible operating temperature 90 °C (note pump specication)
Circulating pump
The technical data for the circulating pumps can be found in the respective pump documentation.
Mixer valve
Model (type) Thermal mixer valve
Function Thermostatic
Temperature range 20–43 °C
Kvs value 4.2
Materials
Fittings Brass Ms 58 (CW614N)
Pipe components Steel pipe, coated
Plastics Impact- and temperature-resistant
Flat gaskets AFM 34 or EPDM
O-rings EPDM
Tightening torque for screw connections with Reinz AFM 34 seals
3/4“35 Nm
1“ 55 Nm
11/4“90 Nm
11/2“130 Nm
2“ 190 Nm
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Characteristic curves
1
10
100
1000
10 100 1000 10000
Pressure drop [mbar]
Flow [l/h]
Pressure drop

8 Decommissioning, recommissioning
8.1 Decommissioning
■Disconnect the energy supply to the HKF 8180 and ensure it cannot be switched back on.
danger
Electrical energy!
Danger of death by electric shock!
hDo not touch any voltage-carrying cables or components with wet hands.
hWhen handling electrical current, always comply with accident prevention guidelines.
hBefore carrying out any maintenance, cleaning or repair work, disconnect the energy supply to
the HKF 8180 and ensure it cannot be switched back on.
■Remove the front cover on the HKF 8180 (see Fig. 4 on page 10).
■Close all of the shut-off valves on the water connections.
For longer periods of decommissioning:
■Depressurise the HKF 8180 (for example by opening a bleeder screw).
note
During the depressurisation of the HKF 8180, water can leak out.
8.2 Recommissioning
■Slowly open all of the shut-off valves on the water connections.
■Prime the HKF 8180 slowly with pressure and vent it, if necessary.
■Restore the energy supply to the HKF 8180.
■Fit the front cover on the pump assembly.
■Separate the components of the HKF 8180 into recyclable materials, hazardous materials and operating
materials.
■Dispose of the HKF 8180 components or recycle them.
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