2012 Hydronics Handbook

Transcript

REV-1 2012 Hydro 10 Industrial Parkway Woburn, MA 01801 cs Tel. 781-721-0303 Fax 781-721-9119 www.CapcoSupply.com Application Drawings Buderus 2 GB 142 Boilers with DHW on System Side of Hydro Separator…………………... 1 Wiring G142 Boiler with DHW on System Side as Set point………………………… 2 Lochinvar 2 WHNs with DHW with Buffer Tank & DHW on System Side………….……....... 3 Wiring for 2 WHNs Cascading with Lochinvar Smart Control ………………………. 4 2 KBNs with DHW on System Side of Hydro Separator……………………………... 5 Wiring for 2 KBNs with Tekmar 275 Control………………………………………… 6 Taco iRadiant 3-Way Mixing Piping & Wiring…………………………………………… 7 Tekmar Basic Radiant with Tekmar 360….…………………………………………………... tN2 with Tekmar 402 House Control………………………………………………... tN2 with Tekmar 406 Geothermal control…………………………………………… 260 Basic Boiler Reset with DHW Priority………………………………………….. 664 Snowmelt with Tekmar 040…………………………….……………………...... 8 9 10-11 12 13 Viessmann Vitotronic 200 with Taco SR & ZVC Controls………………………………............ WB2B with Combustion Air Controls………………………………………………. Vitodens WB1B DHW Priority using Relay Boxes…….…………………….……… WB2B Wiring for 50:1 Coding………………………………………………………. 14 15 16 17 Wilo Stratos Pump with Relay………………………………………………………......... Stratos Pump Using Ext Off Module..………….…………………………………… Dual Pump Wiring…………………………………………………………….…….. Delta T Application with T775R Control………..………………………………….. Honeywell T775R Instruction Sheet………………………………………………… Stratos 0-10V with Honeywell 775M Control………………………………………. Top S Wiring “Optional Internal Protection”………………………………………… 18 19 20 21 22 23 24 Reference Drawings Raywal Hydro-Separator Support……………………………………………………. 25 Basic Snowmelt/Axiom………………………………………………………........... 26 Basic Snowmelt Wiring with TK150 & SM97…….…………………………........... 27 Wiring Diagram for 2-stage Heat using RIB Relay……………………..……........... 28-29 Multiple Chiller Piping & Wiring Using T775 Chiller Staging Control with Buffer..... 30 Solar Retrofit with DHW …………………………….……………………….......... 31 Product Specifications AIC Heat Exchanger Specifications & Sizing……………………………................ Caleffi Hydro Separator Series 548.………...……………………………................ Caleffi DirtCal Series 5462.………...…………….………………………................ Centrotherm Flexible Chimney Liner……………………………………................. Grundfos UPS 15-55/ Alpha Pump Chart………………………………..…………. Grundfos UPS 32-100/ Magna Pump Chart………………..……………………….. Grundfos UPS 15-58FC Pump Chart…………………………………….................. Grundfos UPS 26-99FC/Superbrute Pump Chart………………………................... Grundfos UPS 26-150 and 43-100/Superbrute Pump Chart…………………………. HBX HYD 0100/ HydroBloc w/Pump Chart………………………………………. Lochinvar Squire Buffer Tank SBT………………………………………………… Lochinvar Squire StorageTank SIT………………………………………………… Lochinvar WHN Specification……….…………………………………................... PAW Pumping, Mixing, and Manifold……………………………………………… SunReports Apollo 1 Energy Monitor ……………………………………………… SunReports Apollo 2 Energy Monitor ……………………………………………… SunReports Apollo 2 Quick Reference Sheet ……………………………………… Taco Pump Curves……………………………………………………...................... Taco I Series Radiant Mixing Valve……………………………………................... Tekmar 3-Way Mixing Valves Sizing……………………………………................ Tekmar 710A Mixing Valve Repair........................................................................... Tekmar 710B Mixing Valve Repair............................................................................ Turbomax Product Specifications............................................................................... Viega Tech Data……….............................................................................................. Viega Pressure Drop………………............................................................................ Viega System Design Water/Glycol Mixture…………………….…………............. Viega Snowmelt Tube Spacing & Water Temperature……………….……............. Viega Stainless Manifold w/ Balancing Valves.......................................................... Viessmann WB2B Pressure Drop Chart……………………………………………. Webstone Hydro-Core piping kits………………………………………………….. Wilo Eco Pump Specifications……………………………………………………... Wilo Stratos Pump Specifications…………………………………………………… Wilo Stratos D Pump Specifications………………………………………………… Wilo Top S Pump Specifications…………………………………………………… 32-36 37 38 39 40 41 42 43 44 45-46 47-48 49-51 52 53-55 56-57 58-59 60-61 62 63-64 65-66 67 68 69 70 71 72 73 74 75 76-77 78 79 80-81 82 Quick Sheets Buderus AM10 Quick Sheet...................................................................................... Bosch Combi FW200 Control Quick Start Guide………………………………… Lockinvar Knight Quick Set-Up................................................................................ Tekmar 275 Modulation Sheet………....................................................................... Viessmann WB2B Quick Start-up Sheet................................................................... Wilo Stratos Quick Start Guide……………………………………………………. Expansion Tank Sizing............................................................................................... Pipe Volumes…………….………………………………………………………… Conversion Factors..................................................................................................... 83-84 85-86 87-88 89 90-93 94-95 96-98 99 100 1 DHW Tank 1 1/2" NPT 3/4" FNPT Pipe Reverse Return for Even Flow Through Low-loss Header 3/4" FNPT 1" FNPT 1 1/2" NPT DHW SUPPLY 1" FNPT 1" FNPT 1" FNPT DHW RETURN DHW RETURN BUDERUS GB-142 DHW SUPPLY BUDERUS GB-142 FAX 781-721-9119 10 INDUSTRIAL PARKWAY WOBURN MA 01801 WWW.CAPCOSUPPLY.COM 2 GB 142's PIPED WITH DHW NLC ON THE SYSTEM SIDE OF LOW-LOSS 2.24.10 HEADER THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 781-721-0303 ENERGY SUPPLY, INC. To Mixed Zones CA P C O To space heating Piping Example for (2) GB-142's and DHW on system side of the Low-loss Header M 1 2 1 1 WA T 1 2 FW Lt Gray DHW Sensor 4 N/C 4 N/O 6 N/O 6 N/C 2 5 Factory Installed Jumper 1 EV Red Safety Limit ** This wiring diagram is intended to illustrate the ** general wiring connections on one GB 142 Boiler with the DHW piped on the system side of the piping arrangement just like the heating zones, rather than using the manifold piping tee’s to pipe the DHW that come with the GB 142. The same wiring may be used for anything other than DHW which would require a set-point such as a pool or spa, or snowmelt. INSTRUCTIONS JUMPER N H 3 1 ZONE SWITCHING RELAY T 2 Lt Green T T Connection SR501 2 Blue FA Orange RC Outdoor Sensor Low Voltage RC 1 2 White 1 FA Blue 2 PS Outdoor sensor DHW Pump Piped as a zone White connector on black cable from boiler wiring harness TT 1 2 Red AM 10 Module **AM10 Gets installed in boiler ** PK 63 24 NO C NC N L N L Line voltage 120 Volts Line voltage 120 Volts 2.19.09 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR GB142 With AM10, ZVC Control and DHW as a Setpoint piped off of System Piping ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM Space Heating Pump Please see Capco Hydronics Book 2009 index for Complete internal/external wiring of the ZVC Control 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 ES ! 14 FW Lt Gray 120V Power In Don’t Use 13 PZ Lt Green DHW Recirc THREE ZONE ZONE VALVE CONTROL 25 PS Blue DHW Pump Boiler Pump 61 PK Orange Boiler Pump 5 Amp Max Wiring for a Single GB142 Boiler with DHW as Setpoint Demand with AM10 reset & Taco ZVC Control RC 10 / 20 DHW Aquastat Line voltage 120 Volts 2 3 7.19.11 GP Viega STADLER Viega STADLER THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 2-WHNs with Buffer Tank WWW.CAPCOSUPPLY.COM ENERGY SUPPLY, INC. FAX 781-721-9119 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 Mix 1 P3 Mix Sensor Radiant P2 AH-1 P1 AH-2 SS SIT119 SBT050 DHW AH-3 AH-4 BP2 WHN 285 BP1 WHN 285 4 120 V (ac) N P3 Boiler Mixing Power Sys Demand L N Pmp N THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 1 2 3 Opn Cls Com C R R C Opn Cls 7 8 9 10 11 Powered Output 1 2 3 4 5 6 10A 2 wire PH 2 wire PH 7.19.11 GP T T ZONE 4 360 4 wire PH ZONE 4 1 2 3 4 MS BS OS UnOCom Boil Mix Com Out Indr Sw 12 13 14 15 16 17 18 Do not apply power 4 wire PH ZONE 3 1 2 3 4 ON ZONE 4 PRIORITY OF F FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY ZONE 2 1 2 3 4 WWW.CAPCOSUPPLY.COM 2-WHNs with Buffer Tank Cascading Controls T T ZONE 3 ZVC 404 T T ZONE 2 ZONE 1 1 2 3 4 3 A F U S E T T ZONE 1 10A MODERESE NORMAL T EXTRA N/O COM N/C E S ZONE 4 RELAY ENERGY SUPPLY, INC. MAIN ES POWER IN Radiant Zones FAX 781-721-9119 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 Class 2 Transformer 24V (ac) R C FACTORY INSTALLED TRANSFORM ER L T STAT 1 VALVE 1 T STAT 2 VALVE 2 T STAT 3 VALVE 3 T STAT 4 VALVE 4 POWER Boiler 2 FACTORY INSTALLED TRANSFORM ER P2 MAIN ES Dhw SS OS EXTR A ES POWER IN N/O COM N/ ZONE C 4 RELAY T T ZONE 3 ZVC 404 T T ZONE 2 T T ZONE 4 4 wire ZV Boiler 1 2 wire PH ZONE 2 1 2 3 4 P1 4 wire PH ZONE 3 1 2 3 4 1 3 T STAT 1 VALVE 1 T STAT 2 VALVE 2 T STAT 3 VALVE 3 T STAT 4 VALVE 4 POWER 120 v 120 v 3 wire ZV 2 Boiler 2 BP2 Boiler 1 BP1 ZONE 4 1 2 3 4 ON ZONE 4 PRIORITY OF F FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY ZONE 1 1 2 3 4 T T ZONE 1 Boiler 1 3 A F U S E MODERESE NORMAL T Hydro Air Zones 5 or DHW sensor Squire tank Typical boiler zones P3 S1 C A L E F F I P1 GP 2/16/11 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 2 KBNs TK275 DHW on System Side of Caleffi WWW.CAPCOSUPPLY.COM ENERGY SUPPLY, INC. FAX 781-721-9119 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 P2 6 Set to 9.8V 120v Supply Boiler 1 Boiler Pump Boiler Maximum Modulation Setting in Adjust Menu 5 Com DHW Bret/ 6 + Mod2 9 120v Supply 8 Boiler 2 Boiler Pump + Mod1 7 Do not apply power S1 DHW Sup + 4 Boil 3 Out OAS 2 Com 1 tN4 Tekmar programming: The TK275 can use either a DHW sensor or an Aquastat but not both. + + Mod4 5A 5A 5A 5A 5A 1 Relay 2 Relay 4 Relay Boiler 1 Boiler 2 3 Relay Alert C.A. / P3 / P2 DHW P1 Prim L Power N /Setp DHW Dem Com L N R C 120V (ac) Class II Transformer 24V (ac) End switch or thermostat heat call Pr. Dem 781-721-0303 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR GP 2/16/11 WWW.CAPCOSUPPLY.COM 2 KBNs TK275 DHW on System Side of Caleffi FAX 781-721-9119 ENERGY SUPPLY, INC. Lochinvar programming: Parameter Setting Demand Boiler 27 28 29 30 31 10 INDUSTRIAL PARKWAY WOBURN MA 01801 275 13 14 15 16 17 18 19 20 21 22 23 24 25 26 5A * Note: Boiler pumps must be powered out of Lochinvar control. KBN081-286 boilers have powered pump outputs. KBN400 and larger boilers have “dry” pump contacts and must be powered. Boiler 1 Boiler 2 Mod3 10 11 12 5A N L 7 H PRIMARY PUMP P1 N 120 VAC INPUT 3 SR501 1 ZONE SWITCHING RELAY 6 N/C MIX PUMP P2 4 N/C 4 T T N/O W R T 24 5 P1 Boiler N/O 6 COM VAC SUPPLY SENSOR (MIX) OAS A C R L R 120V (ac) B P2 A C 24 VAC POWER INPUT N C Class II Transformer 24V (ac) A or B can be supply from the boiler. Rotate wiring terminal end of valve over Supply port. C must be “Mix Supply”. B SENSOR COMMON NLC 3.07.09 Viega STADLER THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR i-Series 3-way valve piping/wiring ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 C i-Series Radiant BOILER SUPPLY (MIX) OUTDOOR The Boiler Sensor is used for boiler protection and goes on the boiler return piping. This sensor can be left out if the area of radiant is small relative to the overall capacity of the boiler or if the boiler does not need protection. i-radiant 8 20V (ac) L R Class II Transformer 24V (ac) N C R Relay Box End Switch or T-stat W Mixing P1 2 Demand 1 Power Sys 5 Pmp P2 N 4 EXISTING SUPPLIES L 3 10A N 6 Boiler 8 Boiler 7 10A C Com 3 C 11 13 Com P2 Sw UnO 12 EXISTING RETURNS Mixing Valve 2 Cls 1 Opn Cls R 10 Powered Output Opn R 9 Boil Mix 15 Out 17 Indr 18 MV S2 = OUTDOOR SENSOR S1 = MIX SUPPLY SENSOR NEW SYSTEM PUMP S2 S1 Com 16 Do not apply power 14 360 4 WAY VALVE 3 WAY VALVE SPRING CHECK ZONE VALVE PUMP BALL VALVE NLC 1.04.07 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TK360 Basic Radiant Add ENERGY SUPPLY, INC. FAX 781-272-0514 WWW.CAPCOSUPPLY.COM 10 Industrial Parkway Woburn, MA 781-272-0020 P1 NEW RADIANT PUMP S1 Single Boiler, 2 Boiler Zones, DHW, 3 Way Mix, 4 Mix Zones A402-2 Description: The House Control 402 operates a modulating boiler with indirect Domestic Hot Water. Mixing is performed with a three-way floating action mixing valve, which supplies a reset water temperature to four mix temperature hydronic zones. Two boiler water temperature zones shown are operated by a Wiring Center through the tN4 Boil Expansion terminals. tekmarNet ®2 Thermostats S3 070 313 tekmarNet ®2 Thermostats 402 Z1 P2 Z2 Z3 Z4 S4 S1 P1 P3 S2 tekmarNet ®2 Thermostats Com Open Close Mix Sensor (S2) Zone 3 C Vlv Stage 2 Mod dc/mA Boil Exp. Mix Exp. + tN4 C tN4 C Stage 1 Zone Valves (Z1 to Z4) Back of House Control 402 (black) (P1) Boil (P2) DHW Mix System Pump (black) Boil System Pump (black) DHW Pump (red) Pump Power L L (blue) Variable Speed Pump to pump grounds L NG 115 V (ac) © 2010 D 402 - 09/10 tN4 Boil Expansion Modulating Boiler 313 tekmarNet ®4 Expansion to Wiring Centers, Timers, or User Switch Zone 4 Input Power Use at least 167°F C Vlv C R (75°C) conductors C Mix tN4 Mix Expansion 1 R (P3) + Zone 2 C Vlv — H8007B Zone 1 C Vlv tN4 DHW Call House Control 402 C Item tN4 Menu C Setpoint Call DHW Sensor (S4) Sensors - No Power Outdoor Sensor (S3) Made in Canada tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2 C Opn Cls Zone 1 Zone 2 Zone 3 Zone 4 Floating Action Mix Com Boil Out Com DHW Boiler Sensor (S1) 9 Strip wires 1/2 inch (13 mm). Installed wires are not removable. 12-18 AWG L N 24 V (ac) Transformer 009 Mechanical A406-4 Description: The House Control 406 operates a two stage water source heat pump in heating or cooling mode to supply an outdoor reset water temperature to 4 on board tank temperature zones. The 406 also operates an on/off boiler to supply an outdoor reset water temperature to 4 boiler zones connected to the Boil expansion terminals with a Wiring Center 314. The boiler supplies backup heat to the tank loop using the variable speed pump P1. To allow the heat pump to operate for some amount of time before the variable speed pump starts adding heat to the tank loop, use the backup delay setting in the adjust menu. This ensures the heat pump is being used to its full potential before backup is allowed. A non-condensing boiler may be used since P1 provides boiler return protection, preventing flue gas condensation. Tank zones can have fan-coils, air handling units, chilled beams, or chilled panels as their terminal units depending on the type of tekmarNet thermostat selected. Legend Application Settings P1 Variable Speed Pump WATER TEMP T+B (tank + boiler) P2 HP Loop Pump ZONES 1-4 TANK P3 Boiler System Pump BACKUP VAR (variable speed pump) P4 Tank System Pump BOIL TYPE 1STG (1 stage) P6 DHW Pump HP LOOP INT S1 Outdoor Sensor HP TYPE 2STG S2 HP Return Sensor DHW MODE 2 S3 Boiler Sensor S4 Tank Sensor S5 DHW Sensor 314 tekmarNet 2 Thermostats ® 406 tekmarNet ®2 Thermostats S1 DHW S5 Z5 Backup: On/Off Boiler Z6 Z7 Z8 P6 S3 P3 P1 Z1 Two Stage Water to Water Heat Pump P4 Z2 Z3 Z4 S4 Geo Field S2 Expansion Tank P2 10 © 2011 D 406 - 12/11 Electrical A406-4 tekmarNet ®2 Thermostats tN2 tN2 DHW Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 R Y1 Y2 O Two Stage Water to Water Heat Pump Tank Sensor (S4) Boiler Sensor (S3) Backup DHW Call H8009B Zone 2 C Vlv Zone 3 C Vlv T (Z3) L N (Z4) Back of House Control 406 (P4) Tank Sys (black) (P3) Boil Sys (black) HP Sys (P2) (black) (red) Tank Sys Pump Mix Sys Pump Boil Sys Pump DHW Pump HP Loop Pmp Transfer Pump Pump Power (L) Pump Power (L) L (P1) N (blue) Variable Speed On/Off Boiler Zone 4 Input Power C Vlv C R C (Z2) 314 T R (Z1) tN4 Boil Expansion Rc2 Y2 Item House Control 406 Zone 1 C Vlv tN4 Setpoint Call Menu C Outdoor Sensor (S1) Sensors - No Power Tank Com Boil HPRt Com Out Heat Pump Return Sensor (S2) Mod dc/mA Boil / Mix Tank + tN4 C tN4 C Mix/DHW tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2 Rc1 Y1 O/B No Power Zone 1 Zone 2 Zone 3 Zone 4 24 V (ac) Transformer 009 (black) (black) DHW (P6) (black) (red) L Variable Speed Pump N to pump grounds to pump grounds L1 N1 G G N2 L2 115 V (ac) 115 V (ac) © 2011 D 406 - 12/11 11 12 24 VAC POWE R SLAVE MASTER FUSE 1 AMP FACTORY INSTALLED TRANSFORMER X END SWITCH X RESET ZC ZR NORMAL PLUG IN CARDS ZONE 1 ZONE 2 ZONE 3 ZONE 2 ZONE 3 EXISTING CIRCULATORS 120 VOLT CIRCULATORS ZONE 1 120 VAC INPUT POWER THREE ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY SR 503 EXP OFF ZONE 3 PRIORITY ON POWER ZONE 1 ZONE 2 ZONE 3 N 7 P1 Boil 10A Pmp/Vlv DHW Boiler Boiler 9 10 11 12 DHW PUMP N 8 10A 260 Sw UnO Com Out Com Indr OUTDOOR BOILER SUPPLY Boil 13 14 15 16 17 18 Do not apply power 3.2.10 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TK260 Basic Boiler Reset W/DHW ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 120 VAC L 6 Power 5 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 DHW AQUA STAT Demand 4 Demand 3 DHW 2 Boiler 1 10A 13 C R 24V (AC) 120V AC M Tekmar 090 Snow/Ice Sensor Slab Mix Pwr 4 5A Cls 5 741 4 1 5 6 7 3 Opn Cls Aux Aux Com 2 C Opn Cls limit limit Sw Sw Var Opn/ 4-20 mA - 2 1 + 3 max 1k 2.4A Blu 8 Mix Supply Com Blk / 7 Mix Return Red 6 Yel 9 P3 Slab1 Brn / Com 4 040 no Power 3 tN2 Com 2 Slab Ret Mix Mix Sup Com Boil M 5A 5A 5A 5A 5A Boiler Boiler 1 Stage Boiler 2 Stage 1 Zn P1 Zn Com 2 Zn L N 120V AC Power P2 Boiler Pumps wired directly into boilers P3 P1 Sys THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR ENERGY SUPPLY, INC. 781-721-0303 FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL 664 Snowmelt PARKWAY NLC 6.10.08 with Tekmar 040 WOBURN MA 01801 Demand Melt/Idle Com 19 20 21 22 23 24 25 26 27 28 29 30 Boiler Supply Out Mix Return Mix Supply Outdoor tN2 10 11 12 13 14 15 16 17 18 664 N 14 NO COM NC Zone Pump ES RESET 3 A F U S E T T ZONE 2 T T ZONE 3 PH PH ZONE 1 1 2 3 4 Two Wire Zone Valve ZONE 2 1 2 3 4 Taco Zone Valve ZONE 3 1 2 3 4 THREE ZONE ZONE VALVE CONTROL T T ZONE 1 Viessmann WB2B Power Pump Module POWER IN FACTORY INSTALLED TRANSFORMER MASTER T STAT 1 VALVE 1 T STAT 2 VALVE 2 T STAT 3 VALVE 3 POWER FUSE 1 AMP 24 VAC SLAVE FACTORY INSTALLED TRANSFORMER ZC ZR T T ZONE 3 T T ZONE 4 SIX ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY T T ZONE 2 T T ZONE 6 SR 506-EXP T T ZONE 5 OFF ON ZONE 6 PRIORITY POWER ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 3.3.10 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR WB2B Power Pump Module ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 Zone Pumps ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 POWER 120 VOLT CIRCULATORS INPUT NORMAL T T ZONE 1 Remove jumper and wire Primary Pump Contact to ZC terminal for DHW priority and WWSD. X X E. S. RESET PLUG-IN CARDS For more information on the WB2B Control, please refer to “Quick Set-up Guide” in the back or this book. 15 16 17 120 Power In G L * Must Use Low Loss Header Sensor in this application Boiler Pump N MAIN END SWITCH L G N EXTRA END SWITCH POWER IN NORMAL N/O COM T 2 3 ZONE 1 4 N T ZONE 2 T ZVC 404 T ZONE 3 T T L 2 3 ZONE 2 4 1 2 3 ZONE 3 4 T 1 2 3 ZONE 4 ZONE 4 T T 4 ON OFF ZONE 4 PRIORITY WB2B WIRING FOR 50:1 CODING 1.20.10 NLC ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM G 1 FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 1 ZONE 1 T T THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR ZONE 4 RELAY N/C RESET FUSE (3 AMP MAX) MODE T THIS DIAGRAM SHOWS THE STRATOS PUMP WIRED WITH 230V THROUGH A 20AMP RELAY. YOU NEED TO MATCH THE PUMP CALL’S VOLTAGE TO THE RELAY COIL VOLTAGE RATING. IN THIS EXAMPLE, A PUMP CALL WITH 120V IS SHOWN. THIS WOULD BE THE TYPICAL WIRING WHEN USING A PUMP RELAY BOX. IN THIS APPLICATION, THE PUMP LCD SCREEN POWERS UP AND DOWN WITH EACH PUMP CALL. RIB01S2 Relay In a Box Close Open Auto Powered Pump Call White/Black White/Black Coil 120 Vac Orange (Common) Orange (N.O.) Contacts Brown (Common) Brown (N.O.) WILO STRATOS PUMP L1 L2 230 V Circuit 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 WILO STRATOS PUMP WITH RIB RELAY 3.07.09 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 18 THIS DIAGRAM SHOWS THE STRATOS PUMP WIRED DIRECTLY WITH 230V AND CONTROLLED BY THE “EXTERNAL OFF MODULE”. THIS MODULE ONLY NEEDS A SET OF “DRY CONTACTS” TO OPERATE THE PUMP. IF THE PUMP CALL IS ALREADY POWERED, AN ISOLATION RELAY IS NEEDED WITH A MATCHING COIL RATING TO THE PUMP CALL’S VOLTAGE RATING. IN THIS EXAMPLE, A PUMP CALL WITH 120V IS SHOWN. IN THIS APPLICATION, THE LCD SCREEN REMAINS ON EVEN IN PUMP OFF CYCLES. RIBU1C Relay In a Box White/Blue (10 - 30 VAC/DC) White/Yellow (Common) COIL Powered Pump Call White/Black (120 VAC) Blue (N.C.) CONTACTS Yellow (Common) Orange (N.O.) External Off 0-10v dc DP Dual Pump EXTERNAL OFF MODULE WILO STRATOS PUMP L1 L2 230v 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 WILO PUMP WITH EXT OFF MODULE/120V RELAY 12.29.08 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 19 WHEN PIPING 2 STRATOS PUMPS IN PARALLEL, THE EXTERNAL OFF MODULE ALLOWS FOR DUAL PUMP CONTROL. THE PUMPS CAN BE PROGRAMMED TO BE “MASTER/SLAVE” OR “STANDBY/DUTY”. IN THE MASTER/SLAVE MODE, THE PUMPS ROTATE EVERY 24 HOURS OF RUN TIME AND IF A PUMP GOES INTO ERROR, THE OTHER PUMPS COMES ON. IN THE STANDBY/DUTY MODE, THE OPERATING PUMP WILL BRING ON THE OTHER PUMP WHENEVER THE LOGIC DETERMINES THAT TWO PUMPS RUNNING AT A LOWER SPEED WOULD USE LESS WATTS THAN ONLY ONE RUNNING AT A HIGHER SPEED. RIBU1C Relay In a Box COIL White/Blue (10 - 30 VAC/DC) White/Yellow (Common) Powered Pump Call White/Black (120 VAC) Blue (N.C.) CONTACTS Yellow (Common) Orange (N.O.) L1 L2 230v WILO STRATOS PUMP (MASTER) External Off External Off 0-10v dc 0-10v dc DP Dual Pump DP Dual Pump WILO STRATOS PUMP (SLAVE) EXTERNAL OFF MODULES 781-721-0303 L1 L2 230v ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 WILO STRATOS PUMPS USING DUAL PUMP FEATURE 3.07.09 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 20 THIS DIAGRAM SHOWS THE STRATOS PUMP WIRED DIRECTLY WITH 230V AND CONTROLLED BY THE “EXTERNAL OFF MODULE”. THIS MODULE ONLY NEEDS A SET OF “DRY CONTACTS” TO OPERATE THE PUMP. IF THE PUMP CALL IS ALREADY POWERED, AN ISOLATION RELAY IS NEEDED WITH A MATCHING COIL RATING TO THE PUMP CALL’S VOLTAGE RATING. IN THIS EXAMPLE, A PUMP CALL WITH 120V IS SHOWN. IN THIS APPLICATION, THE LCD SCREEN REMAINS ON EVEN IN PUMP OFF CYCLES. A 0-10VDC SIGNAL IS GENERATED BY THE DELTA-T CONTROL TO OPERATE THE PUMP BASED ON A SET DELTA-T. RIBU1C Relay In a Box White/Blue (10 - 30 VAC/DC) White/Yellow (Common) COIL Powered Pump Call From Controller White/Black (120 VAC) Blue (N.C.) CONTACTS Yellow (Common) Orange (N.O.) Supply Sensor Honeywell T775R Delta-T Control External Off 0-10v dc Return Sensor 24v c - Ground to conduit clamp + DP Dual Pump WILO STRATOS PUMP L1 L2 230v 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 WILO PUMP WITH EXT OFF MODULE DELTA-T 12.15.09 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 21 200 F 180 F 10 F -10 F 22 MOD 1 Settings are suggested starting points. Field testing of system performance is needed to verify and adjust as needed is required. RIBU1C Relay In a Box T775M programing MOD 2 a. 0-10vdc a. 0-10vdc b. Set Point = 65 F b. Set Point = 40 F c. Throttling Range =30F (80F-50F) c. Throttling Range =30F (55F-35F) d. Control Reaction = Cool e. Integral Constant = 0 Seconds d. Control Reaction = Heat Relay 1 Relay 2 e. Integral Constant = 0 Seconds a. Set Point = 51F a. Set Point = 49F b. Differential = 1F b. Differential = 1F c. Control Reaction = Cool c. Control Reaction = Heat Powered Pump Call From Controller White/Blue (10 - 30 VAC/DC) White/Yellow (Common) COIL White/Black (120 VAC) Blue (N.C.) CONTACTS Return Sensor Yellow (Common) Orange (N.O.) External Off 0-10v dc Honeywell T775M Delta-T Control 24v c + Ground to conduit clamp DP Dual Pump WILO STRATOS PUMP L1 L2 VFD 230v S1 To/ From units S1 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 Closed loop Honeywell T775M operarting 010 Vdc pump 02.08.11 GWP THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 23 L1 FOR 115 VOLT PUMPS N G P1 L1 FOR 230 VOLT 1 PH PUMPS Do Not Apply Power Directly to P1 P2 P2 N P1 L L2 G P2 N THERMAL OVERLOAD SWITCH L THERMAL OVERLOAD SWITCH 250 Vac 1 amp NC contact 250 Vac 1 amp NC contact MOTOR 115 V 1PH MOTOR 230 V 1PH L1 N G P1 For internal overload protection add contactor or relay as shown 781-721-0303 Wilo Top S wiring N L THERMAL OVERLOAD SWITCH ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 P2 250 Vac 1 amp NC contact GP 2.17.11 MOTOR THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 24 Raywal Support System for Hydro Separators Using 12" WM2 Cantilever Arms, you can support the weight in lbs. shown in the chart. The Length measurement is taken from the Slide Nut and threaded rod to the wall. Smaller hydraulic separators will have less of a distance off of the wall than larger separators. ** Please use 4 brackets for 3" and larger hydro separators. 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 Raywal Support For Hydro-separator 3.4.10 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 25 26 SX40V The Axiom Feeder is not suitable for use as a transfer pump. You will need to fill system with a proper transfer pump before putting feeder into use. P1 Fill and Purge Points 24 VAC iVALVE-S SENSOR POWER COMMON INPUT C R B A C P2 Basic Snowmelt/Axiom 3.07.09 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 See Basic Snowmelt Wiring on the next page for control details. Snowmelt Manifold ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM Taco i-Series Valve Setpoint Model Axiom MF-200 Glycol Feeder BOILER SUPPLY SETBACK Panel Circuit Breaker OFF Place Sensor Outdoors This will serve as a tighter Warm Weather Shut Down than provided by the SM97. Set for 34 F S1 SM 97 Black Yellow 1 2 3 4 8A On Power Off C - R + Com N/O PWM Yellow 27 White 150 TIMER N/C Sensor 5 6 7 No Power Basic Wiring for Snowmelt SR501 5 P-2 Boiler T T Connection 6 N/O 6 N/C COM 24 VAC POWER T STAT Michael D. Fox 02/21/2007 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR Basic Snowmelt Wiring ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM P-1 4 N/C 4 R W T T N/O 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 JUMPER N H 3 120 VAC INPUT 24V 1 ZONE SWITCHING RELAY 2-Stage Heat Wiring Hydronic / Fan-coil 2-Stage Thermostat Typical 1st Company Fan-coil R W Y G C R Rc W1 W2 Y G P P RIBU1C Relay In a Box White/Blue (10 - 30 VAC/DC) White/Yellow (Common) White/Black (120 VAC) Blue (N.C.) Typical wiring where 1st - Stage heat is hydronic and 2nd - stage heat is from a fan-coil unit. Thermostat gets it’s 24v from the fan-coil. W1 needs to be isolated from thermostat voltage because TT on zone control has it’s own voltage. PLUG-IN CARDS 1 2 3 4 SLAVE MODE RESET ENDSW B PUMP NORMAL N/O COM N/C ZONE 4 RELAY T T ZONE 1 EXPANSION T T ZONE 2 T T ZONE 4 ZONE 4 PRIORITY ON OFF ZVC 404-EXP MASTER ENDSW A BOILER T T ZONE 3 FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY ZONE 1 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 1 2 3 4 2nd Stage Heat Call for hot water flow SR506 X POWER CONTROLS FUSE 7 AMP MAX POWER IN Yellow (Common) Orange (N.O.) Notice W2 goes to W on fan-coil. X END SWITCH 24 VAC POWER CONTROL INPUTS ZC ZR ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 SIX ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY ZONE6 ZONE1 ZONE2 ZONE3 ZONE4 ZONE5 120 VOLT CIRCULATORS ZONE6 ZONE 6 PRIORITY ON OFF POWER INPUT FUSE 1 AMP 1st Stage Heat Call 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 2-Stage T-stat Wiring 10.18.08 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 28 2-Stage Heat Wiring Using 2 Powered Zone Relays 2-Stage Thermostat Rc Rh W2 W1 C Y RIBU1C Relay In a Box White/Blue (10 - 30 VAC/DC) White/Yellow (Common) White/Black (120 VAC) CONTROL INPUTS Blue (N.C.) POWER IN Yellow (Common) Orange (N.O.) T T ZONE 1 FUSE (5 AMP MAX) END SWITCH N/O COM N/C T T ZONE 2 T T ZONE 3 ZVC 403 THREE ZONE ZONE VALVE CONTROL ZONE 1 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 1ST Stage Heat Call SLAVE ZONE 3 PRIORITY ON PLUG-IN CARDS MASTER 1 2 3 4 EXPANSION POWER CONTROL INTERFACE RESET NORMAL 24V C X X END SWITCH 24 VAC POWER ZONE1 ZONE2 ZONE3 OFF THREE ZONE SWITCHING RELAY SR503-EXP WITH OPTIONAL PRIORITY ZC ZR ZONE1 ZONE2 ZONE3 120 VOLT CIRCULATORS This example shows a 2-stage thermostat controlling 2 zone boxes with powered TT terminals. Notice the power for the thermostat and the W1 and W2 come from the right-hand terminal on the 2nd-stage zone box. This terminal always has power. Also notice the common from the thermostat and the relay coil needs to come back to the common on the transformer that supplied 24v to the thermostat. POWER INPUT FUSE 1 AMP 2nd Stage Heat Call 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 2-Stage T-stat Wiring With 2 Zone Boxes 3.4.10 NLC THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 29 N C ZV4 L R C N.C. C N.O. N.C. N.C. C N.O. C C N.O. 24V S1 T775B 2040 ZV3 Multiple Chiller Piping and Staging ZV1 On Power Off C - R + Com N/O ZV2 2.16.10 GP 8A 1 2 3 4 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 120V (ac) 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 To Chiller Stage 2 To Chiller Stage 1 Class 2 Transformer 24V (ac) S1 SUPPLY TEMP SENSOR S1 ENDSW B PUMP NORMAL SLAVE ZONE 6 RELAY N/O COM N/C MODE POWER CONTROLS RESET POWER IN Glycol Feed Tank ZONE 1 1 2 3 4 PLUG-IN CARDS T T ZONE 2 ZVC 406-EXP T T ZONE 3 T T ZONE 4 T T ZONE 5 ZONE 3 1 2 3 4 ZONE 5 1 2 3 4 Chiller Purge Valve ZONE 4 1 2 3 4 Zone Valve Wired through Airhandler ZONE 2 1 2 3 4 SIX ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY T T ZONE 1 Zone Valve Wired Directly ENDSW A BOILER MASTER EXPANSION Calls for Zone Valves 1 2 3 4 Balancing Valve Buffer Tank Set to ## OAS VFD N/C Sensor 5 6 7 No Power 150 Outdoor Temp Enable/Disable FUSE 7 AMP MAX STAGING CONTROLLER Digital In PWM THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 30 ZONE 6 PRIORITY ON OFF ZONE 6 1 2 3 4 T T ZONE 6 Chiller Dirt Separator 31 SYSTEM FILL EXISTING HYDRONIC SYSTEM SX40V The Solar portion of work would remain the same. The Hot Out of the Solar Tank would be the Cold In on the existing tank. This example shows a hydronic system heating the existing domestic hot water. The retrofit application would work with any type of DHW heater. It could be electric, oil-fired or gas-fired. To heat zones Existing DHW Tank Hot Out Fill & Purge Valve Solar Storage Tank S1 Cold In o r C S1 la o ll e c r S2 to THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 2.21.08 NLC WWW.CAPCOSUPPLY.COM Thermal Solar Retrofit FAX 781-721-9119 10 INDUSTRIAL PARKWAY WOBURN MA 01801 781-721-0303 ENERGY SUPPLY, INC. S C A P C O S2 32 Model No. of Plates Boiler water Domestic water Hot Side Cold Side 9.3 1.8 LB31‐20 20 10.0 2.0 LB31‐20 20 12.9 2.5 LB31‐20 20 14.4 2.8 LB31‐20 20 15.5 3.0 LB31‐20 20 25.7 5.0 LB31‐40 40 30.9 6.0 LB31‐40 40 36 1 36.1 7.0 70 LB31‐60 LB31 60 60 46.4 9.0 LB31‐80 80 All units with plate dimensions of 5" x 12" Flow (gpm) Hot side Cold side Domestic Water 90,000 100,000 125,000 140,000 150,000 250,000 300,000 350,000 350 000 400,000 BTU/h 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" 1" FNPT FNPT 1" FNPT Connections Cold Side 0.22 0.27 0.4 0.5 0.57 0.39 0.54 0 0.36 36 0.38 Dimensions (in.) Dim. A 12 Dim. B 5 Dim. C 9.8 Dim. D 2.8 Dim. F 0.49+0.09NP Area (sq. ft.) 0.34 NP = number of plates Hot Side 3.06 3.71 6.5 8.1 7.85 6.16 8.62 6 6.29 29 6.99 Pressure Drop (psi) 180*F to 160*F 40*F to 140*F 33 Model No. of Plates BTU/h 90,000 100,000 125,000 200,000 300,000 400,000 Boiler water Radiant floor water Hot Side Cold Side 9.3 9.1 LB31‐20 20 10.3 10.1 LB31‐20 20 12.9 12.6 LB31‐20 20 20.6 20.2 LB31‐40 40 30.9 30.3 LB31‐60 60 41.2 40.4 LB31‐80 80 All units with plate dimensions of 5" x 12" All units with plate dimensions of 5  x 12 Flow (gpm) Hot side Cold side Radiant Floor 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT Connections Cold Side 4.04 4.89 7.34 4.77 5.24 6.04 Dim. A 12 Dim. B 5 Dim. C 9.8 Dim. D 2.8 Dim. F 0.49+0.09NP Area (sq. ft.) 0.34 NP = number of plates Dimensions (in.) Hot Side 3.06 3.71 5.57 4.09 4.72 5.6 Pressure Drop (psi) 180*F to 160*F 100*F to 120*F 34 90,000 100,000 125,000 140,000 250,000 350,000 400,000 400 000 Model Hot Side Cold Side 6.2 6.7 LB31‐20 20 6.9 7.4 LB31‐20 20 8.6 9.3 LB31‐20 20 9.6 10.4 LB31‐20 20 17.2 18.6 LB31‐40 40 24.1 26.0 LB31‐60 60 27.5 27 5 29.7 29 7 LB31‐80 LB31 80 80 All units with plate dimensions of 5" x 12" Flow (gpm) BTU/h Boiler water 40% Ethylene glycol No. of Plates Hot side Cold side Snow Melt 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT 1" FNPT Connections Dimensions (in.) Dim. A 12 Dim. B 5 Dim. C 9.8 Dim. D 2.8 Dim. F 0.49+0.09NP Area (sq. ft.) 0.34 NP = number of plates Hot Side Cold Side 1.47 2.83 1.78 3.43 2.68 5.15 3.29 6.33 2.94 4.96 2.97 4.72 2.62 2 62 4.00 4 00 Pressure Drop (psi) 180*F to 160*F 100*F to 130*F 35 Boiler water Model HTA (sq. ft.) Length (in.) Shell OD (in.) Tube Conn. Shell Conn. M‐180 4.7 15.3 4.1 1" NPT 1.5" NPT M‐300 9.0 25.1 4.1 1" NPT 1.5" NPT M‐500 16.8 42.9 4.1 1" NPT 1.5" NPT Pool Capacity Boiler Output 1*F/hr Heat Rise Pressure Drop (psi) Gallons Btu/hr Model Hot Side Cold Side 16,000 133,000 M‐180 0.14 0.72 18,000 150,000 M‐180 0.17 0.92 20,000 167,000 M‐180 0.21 1.14 32,000 267,000 M‐300 0.86 0.88 34,000 284,000 M‐300 0.97 0.99 36,000 300,000 M‐300 1.07 1.11 38,000 317,000 M‐500 2.07 2.14 40,000 40 000 334,000 334 000 M‐500 M 500 2.28 2 28 2.37 2 37 42,000 350,000 M‐500 2.49 2.61 44,000 368,000 M‐500 2.73 2.88 Applications requiring two heat exchangers shall be piped in parallel Hot side Pool side Pool Heating Boiler Output Btu/hr 266,000 300,000 334,000 534,000 568,000 600,000 634,000 668,000 668 000 700,000 736,000 2*F/hr Heat Rise Model M‐300 M‐300 M‐500 2x M‐300 2x M‐300 2x M‐300 2x M‐500 2x M‐500 2 M 500 2x M‐500 2x M‐500 Pressure Drop (psi) Hot Side Cold Side 0.86 0.88 1.07 1.11 2.28 2.37 0.86 0.88 0.97 0.99 1.07 1.11 2.07 2.14 2.28 2 28 2.37 2 37 2.49 2.61 2.73 2.88 180*F to 160*F 85*F to 100*F 36 88 146 M 300 M 500 500,000 300,000 180,000 Btu/Hr 1.3 0.9 0.4 PSIG Hot Water 14.53 10.57 7.93 USGPM Water Flow PRESSURE 150 PSI (1.03MPa) 406°F (208°C) TUBES 1.56 M 500 Design Parameters 0.84 M 300 TEMPERATURE 0.44 m2 150 PSI (1.03MPa) 406°F (208°C) SHELL 16.8 9 4.7 ft2 Heat Transfer Area M 180 Model 1-1/2" 1-1/2" 1-1/2" in Connection Shell 1" 1" 1" in Connection Tubes Nominal values are based on 60°C (140°F) temperature difference between incoming heating and heated water 53 kW Nominal Capacity M 180 Model 2899 Portland Drive Oakville, ON L6H 5S4 Tel (905) 829 4666 Fax: (905) 829 4646 3.2 2.5 1.1 PSIG Cold Water 95.1 79.25 55.48 USGPM tech brochure 01076 548 Hydro Separator Hydronic Separator Hydronic separator. Epoxy resin coated steel body. With pre-formed insulation. Sweat & threaded union connections. Complete with: automatic air vent valve with automatic check valve, drain valve. Max. working pressure: 150 psi. Working temperature range: 32 - 210°F. Working temp. without insulation: 32 - 250°F. Code 548006A 548096A 548007A 548097A 548008A 548009A Description 1" NPT unions 1' sweat unions 1-1/4" NPT unions 1-1/4" sweat unions 1-1/2" NPT unions 2" NPT unions Pk 1 1 1 1 1 1 The hydronic separator creates a zone with a low pressure loss, which enables the primary and secondary circuits connected to it to be hydraulically independent of each other; the flow in one circuit does not create a flow in the other. Lbs 12.5 12.5 16.5 16.5 25.1 27.1 Maximum recommended flow rates in GPM and volume capacity in gallons. Size GPM Volume 548 tech brochure 01076 Hydro Separator Hydronic separator. Epoxy resin coated steel body. With pre-formed insulation. ANSI flanged connections. Complete with: automatic air vent valve with shutoff valve, drain valve. Max. working pressure: 150 psi. Working temperature range: 32 - 220°F. Working temp. without insulation: 32 - 250°F. FLOW CAPACITY - UNION CONNECTIONS 1" 1 1/4" 1 1/2" 2" 11 18 26 37 0.7 1.3 3.5 0.5 FLOW CAPACITY - FLANGED CONNECTIONS Size GPM Vol. 2 40 4.0 2 1/2" 80 4.0 3 124 8.0 4" 247 8.0 5" 330 22.5 6" 485 23.2 8" 792 95 10" 1320 175 12" 1850 255 548 tech brochure 01076 Hydro Separator ASME Hydronic separator. Epoxy resin coated steel body. Without insulation. Complete with: automatic air vent valve with shutoff valve, drain valve. ANSI flanged connections. Max. working pressure: 150 psi. Working temperature range: 32 - 250°F. ASME tagged and registered with the National Board of Boiler and Pressure Vessel Inspectors. Code 548052A 548062A 548082A 548102A Description 2" flanged 2-1/2" flanged 3" flanged 4" flanged Pk 1 1 1 1 Lbs 75.0 81.5 112.4 117.0 Code NA548052A NA548062A NA548082A NA548102A Description 2" flanged ASME 2-1/2" flanged ASME 3" flanged ASME 4" flanged ASME Pk 1 1 1 1 Lbs 75.0 81.5 112.4 117.0 Code NA548120A NA548150A NA548200A NA548250A NA548300A *NA prefix indicates ASME tagged and registered with the National Board of Boiler and Pressure Vessel Inspectors. 37 Description 5" flanged ASME 6" flanged ASME 8" flanged ASME 10" flanged ASME 12" flanged ASME Pk 1 1 1 1 1 Lbs 220.0 231.0 520.0 725.0 1,100 5462 tech brochure 01137 Dirt separator. Brass body. 1/2" NPT top thread with plug. NPT connections. Max. working pressure: 150 psi. Working temperature range: 250°F. Code 546205A 546206A 546207A 546208A 546209A Description 3/4" NPT 1" NPT 1-1/4" NPT 1-1/2" NPT 2" NPT Pk 1 1 1 1 1 5462 Geometric structure and large dirt collection chamber The geometrical structure of DIRTCAL means that inside it the velocity is reduced to help separate the particles of impurities. The dirt collection chamber has the following features: - It is located at the bottom of the device at such a distance from the connections that the collected impurities are not affected by the swirl of the flow through the screen. - It has enough capacity to increase the amount of sludge stored and therefore decreases the frequency of emptying/discharging it (on the contrary to filters that need to be frequently cleaned). - It is easily inspected by unscrewing it from the valve body for servicing the internal element in the event of an obstruction from large debris. Lbs 3.8 3.8 4.9 4.9 5.5 tech brochure 01137 Dirt separator. Brass body. 1/2" NPT top thread with plug. Sweat connections. Max. working pressure: 150 psi. Working temperature range: 250°F. Particle separation capacity - Dirt separator efficiency Efficiency (%) ( Separated quantity Initial quantity Efficiency 50 passages ( 2 f/s) .100%) Efficiency 50 passages ( 4 f/s) 100 Lbs 3.8 3.8 80 60 40 Low head losses and performance maintained over time The separating action performed by the dirt separator is based on using the internal element with concentric surfaces in place of the ordinary filter. The element, by its nature, offers little resistance to the flow of medium while ensuring separation. This occurs due to the particles colliding with the concentric surfaces and then settling, and not by filtration; an action by which the filter, over time, gets progressively clogged by the sludge it removes. All this is to the benefit of performance; that is the high capacity to separate impurities and the low head losses that remain unaltered over time. Micro particle size (Pm) 20 1000 500 210 250 150 105 50 63 35 20 16 0 5 Pk 1 1 10 Description 1" sweat 1-1/4" sweat 0 Code 546228A 546235A WORKING ZONE DI RTCAL CARTRIDGE FILTERS SPECIAL STRAINERS Size GPM Cv 3/4" 6.0 18.8 FLOW CAPACITY 1 1/4" 1' 1 1/2" 9.3 15.3 23.9 32.6 56.6 73.3 2" 36.0 81.0 Y-STRAINERS 38 39 Fix the Wall Plate (sold separately). Continue with rigid wall Vent Lengths and Elbows to appliance. 9 Install Vent Length (sold separately) with Connector into Base Support. Insert Flex End Pipe into Chimney Cover, screwing in tight. Attach top of Chimney Cover. Cut Flex Pipe at top of Flex End Pipe Locking Ring at recess in corrugations. Snap on Flex End Pipe Locking Ring to Flex Pipe. Fit Chimney Cover over Flex Pipe and attach to chimney with masonry screws provided. The male part Cut the Flex Pipe (just under male part) at the length of the chimney. Attach spacers. Pull Flex Vent Length through chimney inserting male end into Base Support. Ensure that Connector is installed. Mount metal section Base Support in base of chimney. 8 7 6 5 4 3 2 1 Installation Centrotherm Eco Systems, LLC • 418 South Pearl Street, Albany, NY 12202 • 518 434-3400 • Fax 518 618-3166 • [email protected] • www.centrotherm.us.com Centrocin Base support Connector Spacer Flexible vent length (25' or 35') Flex end pipe with locking ring Chimney cover with cap Contents of the kit FLEXIBLE Updated: 11/17/10 3° IFCK0325 / IFCK0335 / IFCK0425 / IFCK0435 Mounting instruction for kit | Horizontal chimney connection INNOFLUE® Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence Performance Curve: Technical Data: Flow Range: 0 to 21 GPM Head Range: 0 to 19 Feet Motor: 1X115V Min. Fluid Temperature: 36°F (2°C) Max. Fluid Temperature: 230°F (110°C) Max. Working Pressure: 150 PSI Watts: 5-45W Amps: 0.65A Description Part Number ALPHA 15-55 F/LC 59896832 ALPHA 15-55 FR/LC 59896833 ALPHA 15-55 SF/LC 59896834 Service Kit - Line cord 91130247 H [ft] 18 16 14 12 10 8 6 4 2 0 0 2 4 6 8 10 12 14 16 18 20 22 24 Q [US GPM] Orange: AUTOADAPT™ Range Red: 3 Constant Pressure Settings Black: 3 Fixed Speed Settings A B C D E F G 6-1/2 6-3/16 4-15/16 3-13/16 2-3/8 3-7/16 4-1/8 U.S.A. GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: (913) 227-3400 Telefax: (913) 227-3500 Canada GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: (905) 829-9533 Telefax: (905) 829-9512 Mexico Bombas GRUNDFOS de Mexico S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto C.P. 66600 Apodaca, N.L. Mexico Phone: 011-52-81-8144 4000 Telefax: 011-52-81-8144 4010 www.grundfos.com 40 L-AL-SL-001 4/09 (US) Dimensional Drawing: Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence Performance Curve: Technical Data: Flow Range: 0 to 52 GPM Head Range: 0 to 34 Feet Motor: 1X230V Min. Fluid Temperature: 35°F (2°C) Max. Fluid Temperature: 200°F (95°C) Max. Working Pressure: 145 PSI Watts: 10-180W Max. Amps: 1.23A AUTOADAPT™ Range Product Offering: Model Description Part Number MAGNA 32-100 Cast iron flange with line cord 97751849 Geni Module External Control/Bus Communicaton for MAGNA 32-100 96236335 Relay Module Signal Relay for MAGNA 32-100 96239336 Dimensional Drawing: C G F E I H J A L-MAG-SL-02 1/11 (US) B D A B C D E F G H I J 6-1/2 2-3/8 3-3/8 2-3/8 1-1/4 6-1/8 7-3/8 1-1/4 2-1/4 3-7/8 U.S.A. GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: (913) 227-3400 Telefax: (913) 227-3500 Canada GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: (905) 829-9533 Telefax: (905) 829-9512 Mexico Bombas GRUNDFOS de Mexico S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto C.P. 66600 Apodaca, N.L. Mexico Phone: 011-52-81-8144 4000 Telefax: 011-52-81-8144 4010 www.grundfos.com 41 TECHNICAL DATA GRUNDFOS SERIES UP UPS 15-58FC/FRC SUPERBRUTE 20 18 Without Check Valve HI With Check Valve 16 MED 14 Head (ft.) 12 10 LOW 8 6 4 2 0 0 2 4 6 8 10 12 14 16 18 Flow (GPM) Flow range: Head range: Motors: Maximum fluid temperature: Min. fluid temperature: Maximum working pressure: UPS15-58FC/FRC 115V Spd. 3 Spd. 2 Spd. 1 0 - 17.5 U.S. GPM 0 - 19 FEET 2 Pole, Single Phase 230°F (110°C) 36°F (2°C) 145 PSI AMPS 0.75 0.66 0.55 WATTS 87 80 60 HP 1/25 1/25 1/25 B C A CAPACITOR 10mF/180V 10mF/180V 10mF/180V 42 E D F GENERAL DATA GRUNDFOS SERIES UP UPS 26-99FC/BFC SUPERBRUTE 30 Without Check Valve HI 25 With Check Valve MED Head (ft.) 20 15 LOW 10 5 0 0 5 10 15 20 25 30 35 Flow (GPM) Flow range: Head range: Motors: Maximum fluid temperature: Min. fluid temperature: Maximum working pressure: 0 - 34 U.S. GPM 0 - 30 FEET 2 Pole, Single Phase 230°F (110°C) 36°F (2°C) 145 PSI B C A MODEL 115V 230V VOLTS Spd. 3 Spd. 2 Spd. 1 Spd. 3 Spd. 2 Spd. 1 Model Type UPS26-99FC/BFC AMPS 1.8 1.5 1.3 0.9 0.8 0.7 A 6 1/2 B 6 WATTS 197 179 150 196 179 150 C 4 7/8 HP 1/6 1/6 1/6 1/6 1/6 1/6 D 3 1/2 CAPACITOR 20mF/180V 20mF/180V 20mF/180V 5mF/400V 5mF/400V 5mF/400V E 3 7/16 F 3 5/32 43 E D F Approximate Shipping Wt. Connection Type and Size (lbs) GF 15/26 Flange - (2) 1/2" Dia. Bolt Holes 10.3 GRUNDFOS TECHNICAL BULLETIN Page 4 of 6 44 HydroBloc Stand-Alone Mixing The HBX HydroBloc The HBX HydroBloc is designed as a hybrid mixing system with built-in pump and control for full functionality. Outdoor reset technology operates utilizing fully programmable reset curves. Single dial control adds to the convenience of this independent boiler control and mixing tool. Installation time is minimized with trouble-free direct connect fittings and single pump operation. Features include outdoor and boiler sensors, and a multi-color back-lit display which indicates application status. Specifications • 115VAC 50/60 Hz • Wall Mountable • Optional Permanent Heat Demand Feature • Multifunction System Sensor (Temp. & Pressure) HBX HydroBloc • Innovative Hybrid Mixing • Single Dial Programming • Fully Inclusive Mixing Control 45 46 Stainless Steel Hydronic Buffer Tanks Capacities from 30 - 120 Gallons 5 Year Limited Warranty Stainless Steel Buffer Tanks gned to Lochinvar’s Stainless Steel Buffer Tanks are designed eparation provide thermal storage volume and hydraulic separation ibution of the boiler or heat pump and the building distribution on/off ce on/off system. A properly applied buffer tank will reduce cycling (short cycling), which will lead to longer runtimes, runtimes, higher efficiencies and longer equipment life. Squire quire water buffer tanks can be used in geothermal, chilled water ers. applications, and any system with low-mass boilers. Thermal Storage Hydronic buffer tanks are utilized to provide thermal rmal storage volume when the system demand is lesss than than ost the lowest firing rate of the boiler. This occurs most bution often when there are “micro” zones in the distribution ring rate system whose demand is below the minimum firing fires of the boiler. Under these conditions the boiler fires at its minimum rate, which is more energy than can can be absorbed by the distribution system, and shuts off uts off “micro” because of high return temperatures before the “micro” m zone’s call for heat is satisfied. The boiler system The in. The continues to receive a call for heat and fires again. uced by by “micro” zone cannot absorb all the energy produced the boiler, and again the boiler shuts off because e of high high return temperatures. With the volume provided by the by the tank the additional energy not utilized by the “micro” icro” zone can be stored in the buffer tank and used when when there are additional heating demands. Hydraulic Separation Lochinvar’s Squire Buffer tanks also function as hydraulic hydraulic separators, effectively separating the flow in the boiler boiler loop from the flow in the distribution system. This is is system beneficial when the flow rate in the distribution system is different than the flow rate of the boiler system. m. It can be very important when there is a variable speed d pump pump in the distribution system whose flow rate can be e less than that of the boiler pump. L o c h i n v a r .c o m 47 Stainless Steel Hydronic Buffer Tank Dimensions and Specifications SBT Models Model Gallon Number Capacity SBT030 SBT050 SBT080 SBT119 30 50 80 119 A B D E F G Supply/Return Connections Shipping Wt. (lbs.) 39-1/2” 47 69-1/2” 68-1/4” 20 24 24 28 28-3/4” 33-3/4” 55-3/4” 54-3/4” 20-1/4” 24-1/4” 35-1/4” 34-1/4” 11-3/4” 14-3/4” 14-3/4” 15 7-3/4” 8-3/4” 8-3/4” 9 1-1/2” NPT 1-1/2” NPT 2” NPT 2” NPT 70 120 153 198 Standard Features > R-13.4 insulation for minimal heat loss > Textured, impact resistant polymer jacket > Light-weight 316L stainless steel tank construction > Bulbwell > Drain and air vent connections > 5 year tank warranty All models standard with a 5 Year Limited Warranty Against Tank Failure. Lochinvar, LLC • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax: 615-547-1000 www.Lochinvar.com FG-10M-10/11–Printed in U.S.A. SBT-02 (replaces SBT-01 9/10) 48 male Female male 49 Installation & Operation Manual 8 Performance Data (continued) Table 8C First Hour Rating - 180°F Boiler Loop Water (Universal Sizing) First Hour Rating - 180°F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Model Circulator Flow GPM Boiler Heating Capacity Domestic Outlet SIT030 5 8 12 SIT040 16 20 5 8 12 SIT050 16 20 5 8 12 16 20 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 45,000 108 83 108 83 122 97 122 97 135 110 135 110 60,000 136 103 136 103 150 118 150 118 164 131 164 131 75,000 165 123 165 123 179 138 179 138 194 151 194 151 95,000 171 128 191 142 202 150 217 165 217 165 217 165 233 179 233 179 233 179 115,000 171 128 191 142 223 165 240 177 217 165 252 189 252 189 252 189 233 179 268 204 273 207 273 207 140,000 191 142 223 165 240 177 267 196 252 189 267 200 282 211 286 208 268 204 292 221 307 232 322 242 165,000 240 177 267 196 267 200 282 211 286 213 292 221 307 232 334 251 195,000 334 251 225,000 260,000 295,000 MAX BTU INPUT 77008 89165 105532 114761 129676 92998 112972 123331 129574 132764 94115 114116 125111 134044 146207 16 20 First Hour Rating - 180°F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Model Circulator Flow GPM Boiler Heating Capacity Domestic Outlet SIT065 5 8 12 SIT080 16 20 5 8 12 SIT119 16 20 5 8 12 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 45,000 153 128 153 128 163 138 163 138 197 172 197 172 60,000 183 149 183 149 193 159 193 159 226 193 226 193 75,000 213 170 213 170 222 180 222 180 255 213 255 213 95,000 252 197 252 197 252 197 261 207 261 207 261 207 294 241 294 241 294 241 115,000 291 226 291 226 291 226 291 226 300 235 300 235 300 235 300 235 333 268 333 268 333 268 333 268 140,000 305 235 319 245 338 259 338 259 338 259 304 238 347 268 347 268 347 268 347 268 384 302 382 302 382 302 382 302 382 302 165,000 305 235 319 245 356 271 386 293 388 294 304 238 349 270 374 288 395 302 395 302 387 306 429 337 429 337 429 337 429 337 195,000 319 245 356 271 386 293 388 294 349 270 374 288 409 312 424 323 483 375 485 376 485 376 485 376 225,000 356 271 386 293 388 294 374 288 409 312 424 323 501 388 548 421 541 416 260,000 388 294 424 323 573 438 596 454 295,000 MAX BTU INPUT 596 454 118488 129139 146864 163768 167924 115860 139106 50 154002 171229 181544 141419 190161 204795 237649 253504 Installation & Operation Manual 8 Performance Data (continued) How to Properly Size Your Indirect Water Heater Use the First Hour Rating (FHR) to properly size your Indirect Water Heater. The First Hour Rating is the amount of hot water in gallons the heater can supply per hour (starting with a tank full of hot water), depending on tank capacity, source of heat, and the size of the burner. Estimate your peak hour demand as follows: • Determine what time of day (morning, noon, evening) you use the most hot water in your home. Keep in mind the number of people living in your home. • Use the worksheet below to estimate your maximum usage of hot water during this one hour of the day -- this is your peak hour demand. Note: The worksheet does not estimate total daily hot water usage. The worksheet example shows a total peak hour demand of 165 gallons; therefore, this household would need a water heater with a First Hour Rating of no less than 165 gallons. Fixture Count Guide To quickly estimate the minimum gallons of hot water required based on a family size number of baths and hot water appliances the First Hour Rating of the Squire must be equal to or exceed the total first hour requirements. Peak Hour Demand Worksheet Description Fill in the Blank Example 40 Gallons for the first 2 people Gals. 40 Gals. 10 Gallons for each additional person Gals. 20 Gals. Gals. 20 Gals. 10 Gallons if dishwasher is used Gals. 10 Gals. 20 Gallons if clothes washer is used Gals. 20 Gals. TOTAL Gals. 110 Gals. 20 Gallons for each bath after the first (consecutive bath) Heavy Usage Buffer x 1.5 Use if family members take longer than average showers, etc. First Hour Rating x 1.5 Gals. 165 Gals. Proceed to pages 21 – 23 of this manual to locate your Indirect Water Heater and Boiler in the sizing charts. Using the First Hour Rating calculated in this worksheet, locate your Indirect Water Heater and Boiler along with your First Hour Rating. This will also determine the flow needed between the Indirect Water Heater and Boiler. 51 ® Knight Wall-Mount Boiler Dimensions and Specifications ® Knight Heating Boiler Dimensions and Specifications Input Heating NET Model Max. Min. AFUE Capacity I=B=R Number MBH MBH % MBH MBH WHN055 WHN085 WHN110 WHN155 WHN199 WHN285 WHN399 55 85 110 155 199 285 399 11 17 22 31 40 57 80 96 96 96 96 96 96 95** 51 79 102 144 186 265 379 44 69 89 125 162 230 330 A B 33-1/4” 18-1/2” 33-1/4” 18-1/2” 33-1/4” 18-1/2” 33-1/4” 18-1/2” 33-1/4” 18-1/2” 33-1/4” 18-1/2” 35-1/2” 25” C D E F G H I J K L 16” 16” 19” 19” 19” 19” 21-3/4” 11-3/4” 11-3/4” 14-1/2” 14-1/2” 14-1/2” 14-1/2” 17-1/2” 10-1/2” 10-1/2” 10-3/4” 10-3/4” 11-3/4” 11-3/4” 12-1/2” 6-1/2” 6-1/2” 7-3/4” 7-3/4” 8” 8” 9-1/4” 4” 4” 7-3/4” 7-3/4” 8” 8” 9-1/2” 1-1/2” 1-1/2” 2-1/4” 2-1/4” 1-1/4” 1-1/4” 2-1/4” 3” 3” 10” 10” 10” 10” 13-1/4” 14-1/2” 14-1/2” 15-1/2” 15-1/2” 16-3/4” 16-3/4” 21-1/2” 5-3/4” 5-3/4” 5” 5” 4-3/4” 4-3/4” 9” 4” 4” 3-1/4” 3-1/4” 3-1/4” 3-1/4” 4-3/4” M N O 3” 16-1/4” 5” 3” 16-1/4” 5” 3” 16-1/2” 2-3/4” 3” 16-1/2” 2-3/4” 2-3/4” 16-1/2” 3” 2-3/4” 16-1/2” 3” 4” 22-1/2” 3-3/4” Gas Conn. 1/2” 1/2” 1/2” 1/2” 1/2” 1/2” 3/4” Water Air Vent Shipping Conn. Inlet Size Wt. (lbs.) 1” 2” 2” 139 1” 2” 2” 142 1” 3” 3” 159 1” 3” 3” 166 1-1/4” 3” 3” 175 1-1/4” 3” 3” 184 1-1/2” 4” 4” 213 Notes: Indoor installation only. All information subject to change. Change "N" to "L" for LP gas models. **WHN399 value is Thermal Efficiency Smart System Features Standard Features ™ > SMART SYSTEM Digital Operating Control > Multi-Color Graphic LCD Display with Navigation Dial and Soft Keys > Three Boiler Setpoint Temperature Inputs > Plus Domestic Hot Water Prioritization > Built-in Cascading Sequencer for up to 8 Boilers > Lead Lag > Efficiency Optimization > Outdoor Reset Control with Outdoor Air Sensor > Programmable for Three Reset Temperature Inputs > Programmable System Efficiency Optimizers > Night Setback > DHW Night Setback* > Anti-Cycling > Outdoor Air Reset Curve > Ramp Delay > Boost Temperature & Time > Three Pump Control > System Pump with Parameter for Continuous Operation > Boiler Pump with Variable Speed Pump Control* > Domestic Hot Water Pump > Domestic Hot Water Prioritization > DHW tank piped with priority in the boiler loop > DHW tank piped as a zone in the system with the pumps controlled by the Smart System > DHW Modulation Limiting > Separately Adjustable Space Heat/DHW Switching Times* > Building Management System Integration > 0-10 VDC Input to Control Modulation or Set Point > 0-10 VDC Modulation Rate Output > 0-10 VDC Input to Enable/Disable call for heat > Access to BMS Settings through Graphic LCD Display > High-Voltage Terminal Strip > 120 VAC / 60 Hertz / 1 Phase Power Supply > Three Sets of Pump Contacts > Low Voltage Terminal Strip > 24 VAC Device Relay > Proving Switch Contacts > Flow Switch Contacts > Alarm on Any Failure Contacts > Runtime Contacts > DHW Thermostat Contacts > 3 Space Heat Thermostat Contacts > System Sensor Contacts > DHW Tank Sensor Contacts > Outdoor Air Sensor Contacts > Cascade Contacts > 0-10 VDC BMS External Control Contact > 0-10 VDC Boiler Rate Output Contacts > 0-10 VDC Variable Speed System Pump Signal Input* > 0-10 VDC Signal to Control Variable Speed Boiler Pump* > Modbus Contacts > Time Clock > Data Logging > Hours Running, Space Heating > Hours Running, Domestic Hot Water > Ignition Attempts > Last 10 Lockouts > Maintenance Reminder > Custom Maintenance Reminder with Contractor Contact Information > Installer Ability to De-activate Service Reminder > Low-Water Flow Safety Control & Indication > Password Security > Customizable Freeze Protection Parameters § > Energy Star™ Qualified § >96% DOE AFUE Efficiency > Modulating Burner with 5:1 Turndown > Direct-Spark Ignition > Low-NOx Operation > Field Convertible from Natural to LP Gas > ASME Stainless Steel Heat Exchanger > 30 psi ASME Relief Valve > Vertical & Horizontal Direct-Vent > PVC, CPVC or SS Venting up to 100 feet > Factory Supplied Sidewall Vent Termination > Smart System Control > Condensate Trap > Other Features > Automatic Reset High Limit > Adjustable High Limit w/Manual Reset > Boiler Circulating Pump > Wall-Mount Bracket > Zero Clearances to Combustible Materials > 12-Year Limited Warranty (See Warranty for Details) Optional Equipment > Modbus Communication > Flow Switch > Low-Water Cutoff w/Manual Reset & Test > Alarm Bell > Concentric Vent Kit > SMART SYSTEM PC Software > Condensate Neutralization Kit Firing Codes > M9 > M7 Standard Construction California Code * Exclusive feature, available only from Lochinvar § WHN 55-285 only LOC HI ION AT AR CORPOR NV NO SE B A E LE Patent Pending N, TENN ES 3 0 0 M a d d o x S i m p s o n P a r k w a y, L e b a n o n, T N 3 7 0 9 0 | 6 1 5 - 8 8 9 - 8 9 0 0 | f a x : 6 1 5 - 5 4 7 - 1 0 0 0 | w w w . L o c h i n v a r .c o m WHN-01 FG-10M-9/11-Printed in U.S.A. (Reprint WHN-01 6/11) 52 PAW North America, LP r 45 Davis Street r
8FCTUFS
."

r
64"
phone: +1-508-943-4240 r fax: +1-508-943-4141 r [email protected] r www.paw.eu Low temperature zone module K32; residential series with 3-way mixing valve ¾"/DN 20 For heating zones controlled by motorized mixing with reset control USE in closed loop design. Low Temperature Zone Module K32 replaces conventional injection mixing systems. In conjunction with an electronic reset control and a direct drive actuator, the K32 modulates a 3-way valve, diverts and mixes radiant return water with hot water from the boiler. The constant speed system circulator delivers the required water temperature to the radiant loop manifolds. Sizing and piping: The K32 can handle radiant load demands of up to 71,000 BTU‘s. Your current method of zoning the radiant loops (manifolds, zone valves, etc.) does not change with the installation of the K32. Multiple K32 modules can be used to separate the distinctive temperature requirements between manifolds. No special piping, just 2 connections and your installation is complete. Features: All components (except for the circulator) are manufactured from brass. Full port ball valve. Full metal temperature gauges can be pulled off, brass thermowell is integrated in the ball valve. ¾" female connection. Large ball valve handles for easy grip and visible closing position. Pump can be replaced or serviced without draining the system. Function-optimized insulation design made of durable elastic EPP, 100% insulation of the fittings, and air duct to cool the pumps. 3-way mixing valve fully made of brass, ideal linear characteristic (prevents swinging of the regulation). The supply line can be isolated, no draining necessary during pump service. Free access to the pump head by simply pulling off the cover. Flow check valve in return pipe is noise free, low pressure drop, manual opener for faster line drain service, spring-actuated - suited for horizontal, vertical or flow-down assembly. Fully assembled with flat sealing union connections at most joints, including 1" connection nut for the installation on PAWdistribution manifolds. For stand alone assembly, use the conversion kit with wall bracket from the PAW-assembly accessories. Supply on the right = standard If required, the supply and return connections can be simply changed on site. The insulation of the distribution manifold is integrated in the insulation of the zone module. 05/2011 Illustration Pressure drop K32/pump characteristics óPX
SBUF
<64HQN> pressure [ft head] pressure [m water column] TECHNICAL DATA Zone Module K32 Dimension ¾" - DN 20 Materials Fittings Brass Gaskets EPDM/NBR Insulation EPP Technical data Max. pressure 116 psi/8 bar Max. temperature 230 °F/110 °C CV value 3.5 Dimensions Supply/return line to manifold (flat sealing) 1" male Supply/return line to heating zone ¾" female Pipe-centre distance 3 ½"/90 mm Length 255 mm/10" Width insulation 180 mm/7 1/16" Height insulation 385 mm/15 1/8" Recommended High/floating temperature zone application control up to 72 MBH/21 kW at ΔT = 36 °F/20°K flow rate [l/h] Type Information PAW pump Item # K32 ¾" DN 20 Advantages Wilo Star S 21 U-15-130 PAW pump: r
DPNQMFUFMZ
preassembled r
QSFDJTFMZ
JOUFHSBUFE

in the insulation r

QSFTTVSF
UFTUFE r
TFSJBM
OVNCFS r
TQFFE
QVNQ 53 32053WI21NA PAW North America, LP r 45 Davis Street r
8FCTUFS
."

r
64"
phone: +1-508-943-4240 r fax: +1-508-943-4141 r [email protected] r www.paw.eu Low temperature zone module K32; with 3-way mixing valve 1"/DN 25 For heating zones controlled by motorized mixing with reset control USE in closed loop design. Low Temperature Zone Modules K32 are replacing conventional injection mixing systems. In conjunction with an electronic reset control and a direct drive actuator, the K34 modulates a 3-way valve, diverts and mixes radiant return water with hot water from the boiler. The constant speed system circulator delivers the required water temperature to the radiant loop manifolds. Sizing and piping: The K32 can handle radiant load demands of up to 111 MBH. Your current method of zoning the radiant loops (manifolds, zone valves, etc.) does not change with the installation of the K32. Multiple K32 modules can be used to separate the distinctive temperature requirements between manifolds. No special piping, just 2 connections and your installation is complete. Features: All-metal temperature gauges can be pulled off, integrated in the ball valve with an immersion sleeve. 1" NPT female connections. Large ball valve handles Easy handling, visible closing position. Fully assembled with flat gaskets. Design insulation with optimized function made of durable elastic EPP, 100% insulation of the fittings, ventilation openings to cool the pumps. PAW heating circulation pumps - flanged 2-bolt already installed, integrated in the insulation, pressure tested, serial numbered. Check valve in return pipe prevents any noise when electronically controlled pumps are used, manual opener, 200 mm water column, springoperated, thus suitable for horizontal and overhead installation. 3-way mixing valve completely made of brass, characteristic curve prevents variation in temperature, flow pipe can be shut off, thus the pump can be replaced or serviced without draining the system. Supply line on the right or on the left Supply and return line can be changed on site, the mixing valve can be changed without difficulties. Flat sealing 1 ½" male inlet connections Incl. 1 ½" union nut for the installation on PAW modular EJTUSJCVUJPO
NBOJGPMET
6TJOH
1"8
NPVOUJOH
FRVJQNFOU
the heating circuit can be installed with wall brackets. All water-carrying parts are made of brass. 1" - DN 25 Brass EPDM/NBR EPP 116 psi/8 bar 230 °F/110 °C 4.4 1 ½" male 1" NPT F 125 mm/4 21/32" 382 mm/15 1/32" 250 mm/9 27/32" 462 mm/18 3/16" up to 114 MBH /33.5 kW pressure [ft head] Pressure drop K32/pump characteristics óPX
SBUF
<64HQN> pressure [m water column] TECHNICAL DATA Zone Module K32 Dimension Materials Fittings Gaskets Insulation Technical data Max. pressure Max. temperature CV value Dimensions Zone module inlet Zone module outlet Center distance Length Width insulation Height insulation Recommended at ΔT = 36 °F/20 K application BU

64HQN
MI
K32-DN 25 flow rate [l/h] Illustration Information PAW pump K32 1" DN 25 Advantages Wilo Star S 21 FX PAW pump: r
DPNQMFUFMZ
preassembled r
QSFDJTFMZ
JOUFHSBUFE

in the insulation r

QSFTTVSF
UFTUFE r
TFSJBM
OVNCFS r
TQFFE
QVNQ 54 Item # 473605.WI21 NA 05/2011 Type PAW North America, LP r 45 Davis Street r
8FCTUFS
."

r
64"
phone: +1-508-943-4240 r fax: +1-508-943-4141 r [email protected] r www.paw.eu Modular distribution manifold residential series for closed loop design only USE in closed loop design. Modular design distribution manifolds allow parallel connection of multiple Zone Modules in order to customize any installation. Available in 2- to 6-sectional designs, for connection of 2 to 9 heating zones, they simplify installation, extremely shorten assembly time, providing cost and time savings. Union connections make mounting ¾"/DN 20 of Zone Modules to the manifold fast and easy. Supply and return chambers of the manifold are thermally divided. Add-on manifold module allows trouble-free connection of additional heating circuits to an existing system. No special piping, just 2 connections and your installation is complete. Features: Distribution manifold - ¾"/DN 20 modular design, with patented thermal separation of the supply and return chambers, for outputs up to 170 MBH/50 kW (per boiler connection) - completely made of brass - completely pre-assembled - supply and return chambers thermally separated at 95% - manifolds are delivered with insulating caps; the insulation for the manifolds is integrated in the zone module insulation - extremely low resistance, free flow = 1" - up to six pre-assembled manifold modules available - multiple boiler connections are possible, for higher outputs Inside view of modular distribution manifold ¾" supply chamber TECHNICAL DATA Modular Distribution Manifold ¾" - DN 20 Connections For boilers On the side Dimensions Center distance Installation height Height of insulation ¾" - DN 20 Brass EPDM/NBR EPP-shells 116 psi/8 bar 230 °F/110 °C 7.8 ¾" PAW flange for 1" union ¾" female x 1" male flat-sealing (bottom) 2 x for boiler connection, rest plugged ¾" female, plugged for safety group and expansion tank 90 mm/3 17/32" 80 mm/3 5/22" 85 mm/3 11/32" thermal separation return chamber Pressure drop modular distribution manifold DN 20 óPX
SBUF
<64HQN> pressure [ft head] Technical data Fittings Gaskets Insulation Max. pressure Max. temperature CV value For heating modules pressure [m water column] Dimension Materials Width of the distribution manifold incl. insulation see item list below flow rate [m3/h] Illustration Item # DN Options MV DN 20 ¾" MV 2 modular distribution manifold 2-fold 3112 for connection of up to 3 heating circuits Width incl. insulation: L = 440 mm/17 1/3" MV 3 modular distribution manifold 3-fold 3113 for connection of up to 5 heating circuits Width incl. insulation: L = 620 mm/24 3/8" MV 4 modular distribution manifold 4-fold 3114 for connection of up to 7 heating circuits Width incl. insulation: L = 800 mm/31 ½" MV 5 modular distribution manifold 5-fold 3115 05/2011 for connection of up to 9 heating circuits Width incl. insulation: L = 980 mm/38 5/8" MV 6 modular distribution manifold 6-fold for connection of up to 11 heating circuits Width incl. insulation: L = 1.160 mm/45 1/3" 55 3116 DATA SHEET Apollo1 Energy Monitor DEVICE FEATURES x x x x x x x x x x x x Compact Size (5.5”x 4”x 1.4”) Easy to Install – Plug and Play One Unit Monitors Solar Thermal and PV* Modular Sensor Design “ZERO Config” Setup (patent pending) Universal Interface for Solar Thermal Universal Interface for PV* Solar Thermal Sensors: o 3 Temperature Inputs (Tank Input, Tank Output, Top of Tank) o 2 A/C Load Inputs (pump status, reheat coil status) o 1 Grundfos Flow Sensor Adapter Cable o Pressure Switch Input PV Connection via standard Ethernet Cable Standard Ethernet connection to existing router LEDs to indicate local status Interfaces to SunReports Web 2.0 portal WEB PORTAL FEATURES x x x x x x Displays current and past performance Calculates BTU usage Integrates data into one easy to read chart Customer and Installer Portals Configurable Alerts** Summary of System Performance** DESCRIPTION The Apollo1 Energy Monitoring Device provides “performance based” residential energy monitoring for both Solar Electric (PV) and Solar Thermal (HW). The ultra-low-cost solution brings the benefits of web-based monitoring within reach for all customers. With the ‘ZERO-Configuration’ setup, installation is simple and requires no on-site configuration or networking experience. Simply plug in the sensors and connect to an existing router and the unit self-configures to begin sending data immediately. The Apollo1 automatically interfaces to the SunReports Web2.0 portal via standard Ethernet to present realtime and historical data in an easy to understand format. The SunReports design philosophy is to “make energy easy”, easy to install, easy to use, and easy to understand. Installer and Customer web portals are accessible anywhere there is a web-browser and an Internet connection. No application software required. Access SunReports monitoring from home, office, or around the world via any web-enabled desktop computer, laptop, netbook, or smart phone. The same unit is capable of monitoring solar PV, solar Hot Water, and solar Pool Heating systems. Installers can use the Installer Portal to monitor all their installations from one remote location. www.SunReports.com     20070726  56 Apollo1 Energy Monitor INCLUDED x x x x x x x x x InstallerPortal–MapView 1 Apollo1 Device 1 Ethernet Cable 1 Inverter Cable 2 A/C Load Cables (CT1 & CT2) 1 Grundfos Flow Sensor Adapter Cable 1 Triple Temperature Sensor Cable 1 Pressure Switch Cable* 1 A/C Adapter (universal input, US plug) Quick Start Guide * Pressure Switch Sold Separately OPTIONAL ACCESSORIES x x x Communication Package including Power Line Carrier (PLC) network bridge Pressure Switch Grundfos VFS Flow Sensor SPECIFICATIONS Input Power: - 5VDC, 1A AC Adapter Input: - 100-240VAC 50/60Hz AC Adapter Plug - US 2-prong Physical Dimensions: - 5.5 x 4 x 1.4in - (139.7 x 101.6 x 35.6mm) Weight - 1.8lbs (0.82kg) with cables Housing Material: - Flame retardant ABS plastic Housing Rating: - UL 94-5VA Regulatory: - FCC-15 Class A Operating Temperature - 0-40qC (32-104qF) Cable Lengths: - 14’ Ethernet Cable - 14’ Inverter Cable - 5’ A/C Load Cables (CT1 & CT2) - 9’ Triple Temperature Sensor Cable** - 4’ Pressure Switch Cable - 6’ A/C Adapter ** 3’ common plus 6’ for each sensor TargetPerformance SunReports,Inc. 415Ͳ891Ͳ9227 www.SunReports.com [email protected] www.SunReports.com     20070726  57 Apollo2 Energy Monitor Robust and affordable remote monitoring system for Solar Thermal and Solar PV installations DEVICE FEATURES x x x x x x x 6 Temperature Sensors 2 Data Ports o Flow Meter(s) o CT Sensor(s) 1 Pressure Sensor Input Ethernet to Existing Internet Connection Static IP or DHCP Network option Connects Directly to Inverter Monitors Thermal AND PV WEB PORTAL FEATURES x x x x x x x x Separate Secure Login for Installer and User Installer Portal with Integrated Google Maps, Custom Alert Configuration, and Comparative Performance Charts 5 Year Service Model Access Data from Any Web Browser, Anywhere in the World Computer and Mobile Phone, iPhone Compatible View Predicted vs. Actual Performance for kWh and BTU/hr Compare Heat Generated vs. Hot Water Consumed No Software to Install DESCRIPTION The Apollo2 Energy Monitoring System has been engineered for commercial applications and provides “performance based” energy monitoring for both Solar Electric (PV) and Solar Thermal (HW) systems. The affordable Apollo2 solution brings the benefits of web-based monitoring within reach for all customers. With the ‘ZERO Config’ setup, installation is simple and requires no on-site configuration or networking experience. Simply plug in the sensors and connect to an existing router and the unit self-configures to begin sending data immediately. The Apollo2 automatically interfaces to the SunReports Web2.0 portal via standard Ethernet to present real-time and historical data in an easy to understand format. The SunReports design philosophy is to “make energy easy”; easy to install, easy to use, and easy to understand. Installer and Customer web portals are accessible anywhere there is a web-browser and an Internet connection. No application software required. Access SunReports monitoring from the home, office, or around the world via any web-enabled desktop computer, laptop, netbook, or smart phone. The same unit is capable of monitoring solar PV, solar Hot Water, and solar Pool Heating systems. Installers can use the Installer Portal to monitor all their installations from one remote location. www.SunReports.com 58 20100727 Apollo2 Energy Monitor INCLUDED x x x x x x x x x 1 Apollo2 Device 1 Ethernet Cable 1 Inverter Cable 2 A/C Load (CT1 & CT2) 2 Grundfos® VFS Series Flow Sensor Cables 1 Six-Sensor Temperature Cable 1 Pressure Switch Cable 1 A/C Adapter (universal input, US plug) Quick Start Guide(s) OPTIONAL ACCESSORIES x x x Communication Package including Power Line Carrier (PLC) network bridge Pressure Switch Outdoor Mounting Kit SPECIFICATIONS Input Power: - 5VDC, 1A AC Adapter: - 100-240VAC 50/60Hz - UL/CE/CUL/C-Tick/TUV - US 2-prong (others available) Physical Dimensions: - 5.5 x 4 x 1.4in - (139.7 x 101.6 x 35.6mm) Weight - 2.1lbs (0.95kg) with cables Housing Material: - Flame retardant ABS plastic Housing Rating: - UL 94-5VA Regulatory: - FCC-15 Class B - CE Mark - C-Tick Operating Temperature - 0-50qC (32-122qF) Cable Lengths: - 14’ Ethernet Cable - 14’ Inverter Cable - 5’ A/C Load Cables (CT1 & CT2) - 13’ Temperature Sensor Cable - 4’ Pressure Switch Cable - 6’ A/C Adapter Solar Production vs. Auxiliary Heating Product Feature Comparison Apollo1 Feature (Residential) X Modular Sensors X Thermal Monitoring X PV Monitoring X Internet Connectivity X Pump On/Off Detect (AC Detect) X DHCP Network Support X Pressure Switch Compatible X Local LED Indicators X Wall Mount One Flow Meter Compatible 3-Loop Thermal Monitoring Double Thermal Loop Monitoring 6 Temperature Sensors Static IP Network Support On-Line Reporting X Secure Login X Installer Portal X User Portal X Historical and Current Data X Configurable Alerts* X Interactive Google Maps* X Predicted vs. Actual Charts* X Energy Equivalence Display Double BTU Calculation* Contribution to Total Energy Chart* Thermal Loop Comparison Chart* Apollo2 (Commercial) X X X X X X X X X Two X X X X X X X X X X X X X X X * Installer Portal Only CONTACT SunReports,Inc. www.SunReports.com [email protected] www.SunReports.com 59 20100727 60 61 Performance Field Information 60 Hz Performance Field Taco Circulator Pump Curves 60 Hz Performance Field 62 iValve, 3-Way Mixing Working with SR502/503 Switching Relay with DHW Priority T DHW Aquastat Power Input H Outdoor Sensor 24 VAC POWER Z ONE1 SR 503 N N 24 VAC POWER INPUT P Z ONE2 Z ONE3 THREE ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY 24 Volt SENSOR COMMON Transformer BOILER POWER SUPPLY GREEN OUTDOOR T A FUSE 1 AMP BACK OF iVALVE-R MIXING VALVE ACTUATOR Thermostats ZC H X1 X2 ZR Z ONE1 Z ONE2 Z ONE3 C R SENSOR ERROR RED DHW Circ. Supply Sensor iSeries-R C C B B A A Boiler Sensor iValve, 4-Way Mixing Working with Zone Valve Control BACK OF iVALVE-R MIXING VALVE ACTUATOR M 24 Volt Motor End Switch SENSOR ERROR RED M T T ZONE 1 FUSE (5 AMP MAX) Transformer C R POWER IN Power H Input N 24 VAC SENSOR COMMON POWER INPUT E ND SWITCH N/O COM N/C T Thermostats T T ZONE 2 T T ZONE 3 ZVC 403 THREE ZONE ZONE VALVE CONTROL ZONE 1 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 End Switch BOILER POWER SUPPLY GREEN OUTDOOR Factory Installed Transformer T Motor Outdoor Sensor Supply Sensor iSeries-R Boiler Sensor FOR ADDITIONAL WIRING DIAGRAMS, PLEASE SEE www.taco-hvac.com/wiringwizard 63 64 - Data Brochure D 710 3-Way Mixing Valves 710 - 714 05/05 The 3-Way Brass Mixing Valves 710, 711, 712, 713, and 714 are used to mix supply water from a heat source with water returning from a system. They are designed for use in either closed loop or open loop hydronic systems. All valves have standard female NPT threads. The valve provides a maximum leak through rate of 1% to allow for water expansion during temperature changes. The valve position can be manually set using the handle. An Actuating Motor 741 can be used to automatically operate the valve. Sequence of Operation When the flap is in the fully closed position, 100% of the heating system return water is supplied to the system. When the valve flap is in the fully open position, 100% of the boiler supply water enters the heating system. Mixing of the water takes place when the valve flap is in an intermediate position. Installation Check the contents of the package. If any of the items listed below are missing or damaged, please refer to the Limited Warranty and Product Return Procedure on the back of this brochure and contact your wholesaler or local tekmar representative. Types 710 - 714 include • One Mixing Valve & One Data Brochure D 710 return from boiler supply supply supply from boiler from boiler return • Factory postion • No changes required from boiler supply return return • Rotate handle 1/4 turn • Flip face plate over • Rotate handle 1/2 turn • Flip face plate over • Rotate handle 1/4 turn Pointer and flat of shaft should only travel between boiler and system return ports on valve. Thers is No flow against the flat, close off point. Replacement Parts 0 5 7 9 1 3 brass screw 10 The Mixing Valve Handle Kit M3047 contains a replacement manual valve handle, a brass screw, a “C” clip, and a position indicator plate. “C” clip handle indicator plate 65 © 2005 D 710 - 05/05 Technical Data 3-Way Mixing Valves 710 - 714 Brass Literature Maximum Operating Pressure Operating Temperature Range Valve Body and Vane Shaft Seal Main Seal — — — — — — Acceptable Fluid Media D 710 146 psi (10 bar) -20 to 248°F (-28 to 120°C) CW 617N - EN 12165 Brass Viton “O” ring EPDM Perioxide “O” ring — Chilled and hot water with antifreeze and anticorrosive compounds (max 60%), glycol, ethyl alcohol glycol, propylene dichloride alcohol, mono ethyl alcohol, ethyl methyl alcohol, glycerine. Not for use with media based on mineral oil components or chlorinated pool water. W Type Pipe Size CV Value Dimension H Dimension W Packaged Weight 710 711 712 713 714 3/4” 1” 1-1/4” 1-1/2” 2” 7 14 21 32 51 1-1/2” (38 mm) 1-1/2” (38 mm) 1-5/8” (41 mm) 2-3/16” (56 mm) 2-5/16” (60 mm) 3” (76 mm) 3” (76 mm) 3-1/4” (82 mm) 4-3/8” (111 mm) 4-5/8” (119 mm) 1.9 lbs (860 g) 1.6 lbs (730 g) 1.8 lbs (800 g) 6.7 lbs (3020 g) 5.6 lbs (2520 g) 1.5 2 1 710 3 4 Valve Performance 712, 713, 714 m3/h 1.5 1 711 0.4 0.5 m of head 1 0.6 ft of head 0.8 2 0 3 6 9 712 3 Normal Operating Range 1 psi ft of head 3 12 15 713 18 1 714 0.8 Normal Operating Range 1 2 1 0.5 0.6 0.4 0.2 0.2 0 0 0 0 2 4 6 8 10 12 US Gal/min 14 16 18 m3/h m of head Valve Performance 710, 711 0 psi H 0 20 0 0 0 10 20 30 40 50 US Gal/min 60 70 80 Limited Warranty and Product Return Procedure Limited Warranty The liability of tekmar under this warranty is limited. The Purchaser, by taking receipt of any tekmar product (“Product”), acknowledges the terms of the Limited Warranty in effect at the time of such Product sale and acknowledges that it has read and understands same. the Purchaser’s sole responsibility and obligation. Purchaser shall indemnify and hold tekmar harmless from and against any and all claims, liabilities and damages of any kind or nature which arise out of or are related to any such representations or warranties by Purchaser to its customers. The tekmar Limited Warranty to the Purchaser on the Products sold hereunder is a manufacturer’s pass-through warranty which the Purchaser is authorized to pass through to its customers. Under the Limited Warranty, each tekmar Product is warranted against defects in workmanship and materials if the Product is installed and used in compliance with tekmar’s instructions, ordinary wear and tear excepted. The pass-through warranty period is for a period of twenty-four (24) months from the production date if the Product is not installed during that period, or twelve (12) months from the documented date of installation if installed within twenty-four (24) months from the production date. The pass-through Limited Warranty does not apply if the returned Product has been damaged by negligence by persons other than tekmar, accident, fire, Act of God, abuse or misuse; or has been damaged by modifications, alterations or attachments made subsequent to purchase which have not been authorized by tekmar; or if the Product was not installed in compliance with tekmar’s instructions and/or the local codes and ordinances; or if due to defective installation of the Product; or if the Product was not used in compliance with tekmar’s instructions. The liability of tekmar under the Limited Warranty shall be limited to, at tekmar’s sole discretion: the cost of parts and labor provided by tekmar to repair defects in materials and/or workmanship of the defective product; or to the exchange of the defective product for a warranty replacement product; or to the granting of credit limited to the original cost of the defective product, and such repair, exchange or credit shall be the sole remedy available from tekmar, and, without limiting the foregoing in any way, tekmar is not responsible, in contract, tort or strict product liability, for any other losses, costs, expenses, inconveniences, or damages, whether direct, indirect, special, secondary, incidental or consequential, arising from ownership or use of the product, or from defects in workmanship or materials, including any liability for fundamental breach of contract. The pass-through Limited Warranty applies only to those defective Products returned to tekmar during the warranty period. This Limited Warranty does not cover the cost of the parts or labor to remove or transport the defective Product, or to reinstall the repaired or replacement Product, all such costs and expenses being subject to Purchaser’s agreement and warranty with its customers. Any representations or warranties about the Products made by Purchaser to its customers which are different from or in excess of the tekmar Limited Warranty are THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHICH THE GOVERNING LAW ALLOWS PARTIES TO CONTRACTUALLY EXCLUDE, INCLUDING, WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, DURABILITY OR DESCRIPTION OF THE PRODUCT, ITS NON-INFRINGEMENT OF ANY RELEVANT PATENTS OR TRADEMARKS, AND ITS COMPLIANCE WITH OR NONVIOLATION OF ANY APPLICABLE ENVIRONMENTAL, HEALTH OR SAFETY LEGISLATION; THE TERM OF ANY OTHER WARRANTY NOT HEREBY CONTRACTUALLY EXCLUDED IS LIMITED SUCH THAT IT SHALL NOT EXTEND BEYOND TWENTY-FOUR (24) MONTHS FROM THE PRODUCTION DATE, TO THE EXTENT THAT SUCH LIMITATION IS ALLOWED BY THE GOVERNING LAW. Product Warranty Return Procedure All Products that are believed to have defects in workmanship or materials must be returned, together with a written description of the defect, to the tekmar Representative assigned to the territory in which such Product is located. If tekmar receives an inquiry from someone other than a tekmar Representative, including an inquiry from Purchaser (if not a tekmar Representative) or Purchaser’s customers, regarding a potential warranty claim, tekmar’s sole obligation shall be to provide the address and other contact information regarding the appropriate Representative. tekmar Control Systems Ltd., Canada tekmar Control Systems, Inc., U.S.A. Head Office: 5100 Silver Star Road Vernon, B.C. Canada V1B 3K4 (250) 545-7749 Fax. (250) 545-0650 Web Site: www.tekmarcontrols.com Product design, software and literature are Copyright © 2005 by: tekmar Control Systems Ltd. and tekmar Control Systems, Inc. 66 All specifications are subject to change without notice. Printed in Canada. D 710 - 05/05. - Data Brochure Addendum D710A Replacement O-Rings for 3/4 to 1-1/4” Brass Valves (M3056) This seal replacement kit is for tekmar Brass Valve models 710, 711, 712, 720, 721 and 722. The kit includes a small o-ring, a medium o-ring indicated with a white paint mark, and a large o-ring. All o-rings are lubricated with silicone grease. Repair procedure: 1. 07/07 Screw Blue Handle Remove screw attaching blue handle. If an actuator motor is installed, remove hand wheel and screw. 2. Pull blue handle or actuator motor off of valve assembly. C-Clip 3. Insert flat blade screwdriver into either rear slot of c-clip. Twist screwdriver to pry off clip. 4. Mark the indicator plate position for later reference. Remove metal indicator plate. 5. Insert small flat blade screwdriver into notch in valve body and pry out metal retainer clip. Indicator Plate Retainer Clip 6. Remove valve flap assembly by pulling on shaft. 7. Remove white plastic washer, if present. White Plastic Washer 8. Remove metal o-ring housing from valve flap. Small O-Ring 9. Remove medium o-ring and clean surface on valve flap using steel wool. Install medium o-ring (with white mark) on valve flap. 10. Remove small and large o-rings and clean surface on o-ring housing using steel wool. Install small and large o-rings on o-ring housing. O-Ring Housing 11. Re-install o-ring housing onto valve flap. Large O-Ring 12. Re-install valve flap assembly into valve body. 13. Re-install metal retainer clip into valve body. Make sure it is snapped all the way around. Medium O-Ring (has white marking) 14. Use your finger to push the small o-ring down between the valve flap shaft and o-ring housing. 15. Re-install white plastic washer over shaft, if present. Valve Flap 16. Re-install indicator plate. 17. Re-install c-clip onto valve shaft. 18. Re-install blue handle and screw or actuator motor, screw and handwheel. 19. Rotate handle through its full motion both ways. It should be smooth and stop at the ends of the range indicated on the plate. 67 Valve Body D 710A - 07/07 - Data Brochure Addendum D710B Replacement O-Rings for 1-1/2 to 2” Brass Valves (M3057) 07/07 This seal replacement kit is for tekmar Brass Valve models 713, 714, 723 and 724. The kit includes a small o-ring, a medium o-ring indicated with a white paint mark, and a large o-ring. All o-rings are lubricated with silicone grease. Screw Bottom Cover Removal Tool Assembly To remove the bottom cover of the valve, a special tool can be assembled using the following: Blue Handle • One 1/2” NC x 2” long bolt with 3/4” hex head • Two 1/2” NC nuts C-Clip Thread both nuts onto the bolt. Then thread the first nut backwards to lock against the second nut. Indicator Plate Repair procedure: 1. Remove screw attaching blue handle. If an actuator motor is installed, remove hand wheel and screw. Small O-Ring 2. Pull blue handle or actuator motor off of valve assembly. 3. Insert flat blade screwdriver into either rear slot of c-clip. Twist screwdriver to pry off clip. 4. Mark the indicator plate position for later reference. Remove metal indicator plate. Valve Body 5. Turn valve assembly over and use special tool to unscrew bottom cover. 6. Push valve flap assembly out through bottom of valve body. 7. Remove small o-ring from top of valve body. Medium O-Ring (has white marking) 8. Clean top of valve body using steel wool. 9. Remove medium o-ring from shaft of valve flap. 10. Clean the shaft of valve flap using steel wool and install new medium o-ring (with white mark) on shaft of valve flap. 11. Re-install valve flap assembly into valve body. Valve Flap 12. Remove the large o-ring from the bottom cover. 13. Clean the bottom cover using steel wool and replace the large o-ring. 14. Re-install bottom cover using special tool. 15. Install new small o-ring onto shaft of valve flap. Use your finger to push the o-ring down between the valve body and shaft. Large O-Ring 16. Re-install indicator plate. 17. Re-install c-clip onto valve shaft. 18. Re-install blue handle and screw or actuator motor, screw and handwheel. 19. Rotate handle through its full motion both ways. It should be smooth and stop at the ends of the range indicated on the plate. 68 Bottom Cover D 710B - 07/07 TURBOMAX INDIRECT WATER HEATERS ® TURBOMAX ® 109 TURBOMAX ® 65 Domestic hot water produced per hour in U.S. gallons† Domestic hot water produced per hour in U.S. gallons† Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 400 000 117 807 531 363 687 483 346 200 000 59 416 270 183 344 241 173 500 000 146 979 651 450 859 603 436 250 000 73 501 331 227 429 302 216 600 000 176 1151 772 536 1031 724 516 300 000 88 587 391 270 515 362 260 700 000 205 1323 893 1202 845 350 000 103 673 451 601 422 800 000 234 1494 1013 1374 965 400 000 117 759 512 687 483 900 000 264 1666 450 000 132 845 572 773 543 500 000 146 931 1546 TURBOMAX ® 45 Standard Equipment Boiler supply Domestic hot water produced per hour in U.S. gallons† kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 200 000 59 392 261 180 344 241 173 Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 250 000 73 477 321 223 429 302 216 50 000 15 134 80 50 86 60 43 300 000 88 563 381 266 515 362 260 100 000 29 220 140 93 172 121 87 350 000 103 649 442 601 422 150 000 44 306 200 137 258 181 130 400 000 117 735 502 687 483 200 000 59 392 261 180 344 241 173 450 000 132 821 562 773 543 250 000 73 477 321 223 429 302 216 500 000 146 907 300 000 88 563 381 515 362 350 000 103 649 442 601 422 TURBOMAX 34 400 000 117 735 Domestic hot water produced per hour in U.S. gallons† TURBOMAX ® 33 859 ® Fiberglass insulation kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 50 000 15 126 76 49 88 60 43 100 000 29 211 137 92 172 121 87 Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 150 000 44 297 197 135 258 181 130 50 000 15 126 76 49 86 60 43 200 000 59 383 257 179 344 241 173 100 000 29 211 137 92 172 121 87 250 000 73 469 318 222 429 302 216 150 000 44 297 197 135 258 181 130 300 000 88 555 378 515 362 200 000 59 383 257 179 344 241 350 000 103 641 438 601 422 250 000 73 469 318 222 429 302 400 000 117 727 300 000 88 555 378 687 Drain valve Domestic hot water produced per hour in U.S. gallons† Domestic hot water produced per hour in U.S. gallons† Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F Net BTUH kW First hour Continuous 110°F 140°F 180°F 110°F 140°F 180°F 50 000 15 112 71 47 88 60 43 50 000 15 112 71 47 86 60 43 100 000 29 198 131 90 172 121 87 100 000 29 198 131 90 172 121 87 150 000 44 284 192 134 258 181 130 150 000 44 284 192 134 258 181 130 200 000 59 370 252 177 344 241 173 200 000 59 370 252 344 241 250 000 73 455 312 220 429 302 216 250 000 73 456 312 429 302 300 000 88 542 373 515 362 300 000 88 542 350 000 103 628 433 601 422 400 000 117 714 515 Model Tank volume Shell Max. Allowed ASME = 150 PSI at 250°F Working Pressure Adjustable feet for levelling Copyright © 2007 Thermo 2000 Inc. All rights reserved. TURBOMAX is a trademark of Thermo 2000 Inc. Thermo 2000 Inc. reserves the right to modify at any time and without notice colors, components, materials, specifications or models described in or shown in this brochure. Heat transfer Utility area (sq.ft.) connection TURBOMAX 109 119 US gal. 58.9 ft2 Tube Max. Allowed ASME = 150 PSI at 250°F Working Pressure Boiler return Specifications † Based on ASHRAE (D.O.E.) test method performed by CRIQ. Technical Information Domestic cold water inlet 515 TURBOMAX ® 23 Domestic cold water at 40°F and boiler water at 180°F. Steel jacket painted with durable epoxy Domestic hot water produced per hour in U.S. gallons† TURBOMAX ® 24 687 Copper heat exchanger inside high quality carbon steel tank Aquastat prewired for 120 or 24V 687 Net BTUH Output Temperature up to 200°F Temperature/pressure gauge 859 Net BTUH Heat Transfer Efficiency = 99% Pressure relief valve set at 30 psi TURBOMAX ® 44 Domestic hot water produced per hour in U.S. gallons† Standby loss <1/2°F per hour Domestic hot water outlet Boiler connection Hgt. Diam. Shipping weight 2’’ Sweat M 2’’ NPTM 74’’ 29’’ 555 lbs TURBOMAX 65 72 US gal. 32.7 ft2 1 1/2’’ Sweat M 1 1/2’’ NPTM 67’’ 24’’ 250 lbs TURBOMAX 45 48 US gal. 32.7 ft2 1 1/2’’ Sweat M 1 1/4’’ NPTM 55’’ 22’’ 235 lbs TURBOMAX 44 48 US gal. 26.2 ft2 1 1/2’’ Sweat M 1 1/4’’ NPTM 55’’ 22’’ 210 lbs TURBOMAX 34 36 US gal. 26.2 ft2 1 1/2’’ Sweat M 1 1/4’’ NPTM 65’’ 18’’ 195 lbs TURBOMAX 33 36 US gal. 19.6 ft2 1 1/4’’ Sweat M 1 1/4’’ NPTM 65’’ 18’’ 170 lbs TURBOMAX 24 26 US gal. 26.2 ft2 1 1/2’’ Sweat M 1 1/4’’ NPTM 49’’ 18’’ 175 lbs TURBOMAX 23 26 US gal. 19.6 ft2 1 1/4’’ Sweat M 1 1/4’ NPTM 49’’ 18’’ 150 lbs Boiler connection Hgt. Diam. Shipping weight ASME Models Specifications Model Tank volume Heat transfer Utility area (sq.ft.) connection TURBOMAX 109A 110 US gal. 58.9 ft2 TURBOMAX 65A 70 US gal. 32.7 ft2 69 21/2’’ Sweat M 2’’ NPTM 74’’ 29’’ 755 lbs 2’’ Sweat M 11/2’’ NPTM 67’’ 24’’ 340 lbs TechData PRODUCT SPECIFICATION SHEET PRESSURE DROP TABLE ViegaPEX Barrier Expressed per/ft. Quality Assurance ViegaPEX Barrier tubing is manufactured and tested to the requirements of ASTM F876 and F877. The degree of cross-linking of finished tubing is determined by method ASTM D2765. Certifications - tested for health effects to ANSI/NSF 61 and performance to ANSI/NSF standard 14. When tube spacing is less than minimum bend dimension. When the tube spacing is less than the minimum recommended bending dimension, the loop ends should be swept out to at least the dimensions shown. Otherwise, if tube spacing is equal or greater than “X”, a standard loop may be used. 5/16” 3/8” GPM PSI Head Loss PSI Head Loss .1 .2 .3 .4 .5 .6 .7 .8 .9 1 1.5 2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 .002 .009 .018 .031 .047 .066 .088 .001 .001 .004 .008 .008 .017 .013 .030 .020 .045 .027 .063 .036 .084 .047 .108 .058 .134 .070 .1626 .005 .021 .042 .072 .109 .152 .203 1/2” SIZE 5/8” 3/4” PSI Head Loss PSI Head Loss PSI Head Loss PSI Head PSI Head PSI Head Loss Loss Loss .001 .002 .002 .002 .003 .006 .011 .023 .039 .082 .140 .211 .296 .001 .002 .003 .007 .011 .024 .041 .062 .087 .001 .002 .003 .004 .006 .008 .011 .013 .016 .034 .058 .002 .004 .007 .010 .014 .019 .024 .030 .037 .078 .133 .001 .001 .002 .003 .003 .004 .005 .007 .014 .024 .050 .085 .181 .002 .002 .004 .006 .008 .010 .012 .015 .032 .055 .116 .197 .417 1” .003 .004 .005 .006 .007 .015 .025 .052 .089 .189 .322 .487 .683 1-1/4” .002 .004 .007 .015 .026 .056 .095 .143 .023 .054 .201 .032 .075 .042 .098 .053 .123 .065 .151 .078 .182 .093 .217 .108 .252 1-1/2” .022 .052 .027 .063 .033 .077 .039 .091 .045 .105 .052 .121 .060 .140 .067 .156 .075 .175 SDR-9 PEX Tubing ASTM F876/F877/CTS-OD SDR-9 ViegaPEX Barrier Oxygen Dimension X Tubing Size With the Coil Permeation: 5/16” 7” 3/8" 1/2" 5/8" 3/4" 1" 1-1/4” 1-1/2” 8” 10” 12” 14” 18” 22” 26” All sizes have less than 0.1 grams/m3/day Note: ViegaPEX Barrier tubing meets DIN 4726 requirement for oxygen tight pipes. TUBING SIZE 5/16” 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" O.D. .430±.003 .500±.003 .625±.004 .750±.004 .875±.004 1.125±.005 1.375±.005 1.625±.006 WALL THICKNESS .064+.010 .070+.010 .070+.010 .083+.010 .097+.010 .125+.010 .153+.015 .181+.019 NOM. I.D. 0.292 0.350 0.475 0.574 0.671 0.863 1.053 1.243 WEIGHT VOLUME (GAL)/ PER FT 100 ft .0340 0.34 .0413 0.50 .0535 0.92 .0752 1.34 .1023 1.82 .1689 3.04 .2523 4.52 .3536 6.30 NOTE: Dimensions are in English units. Tolerances shown are ASTM requirements. ViegaPEX Barrier is manufactured to within these specifications. ViegaPEX Barrier tubing is available in both straight lengths and coils. VIEGA 301 N. Main, Floor 9 Wichita, KS 67202 Phone: 1-877-VIEGA-NA Fax: 1-800-976-9817 [email protected] www.viega-na.com TD-PRVPB 0507 70 Calculating The Pressure Drop Pex Tubing Data Table In order to select the correct pump size for the system, the pressure drop must be calculated. Use the chart below to calculate the pressure drop. Nominal Size (in.) Outside Diameter (in.) Inside Diameter (in.) Water Content (in.) *5/16 0.430 0.292 0.004 3/8 0.500 0.350 0.005 Procedure: 1. Locate desired flowrate for one circuit on the left. vertical axis (receive circuit flowrate from the Radiant Wizard program). 2. Follow to the right until you reach the selected tubing size. 3. Then move down to the horizontal axis and read the pressure drop in feet of head per foot of tubing. 1/2 0.625 0.475 0.009 5/8 0.750 0.574 0.014 3/4 0.875 0.671 0.018 1 1.125 0.862 0.030 1-1/4 1.375 1.053 0.045 1-1/2 1.625 1.243 0.063 Example: GPM through 5/16” PEX: 0.3 gpm 4. Multiply pressure drop per foot by length of longest circuit. Pressure drop per foot: ~ .05 ft. of head / ft. Total pressure drop: .05 x 250 total ft. = 12.5 ft. of head /2” /4” 1-1 1-1 50 1” 30 3/4” ” 20 5/8 ” 10 1/2 7 ” 3/8 6 ” 4 5/16 3 2 1 /S FT 71 SYSTEM DESIGN - CHAPTER 3 3.6 Water/ Glycol Mixture: Selecting the percentage of Glycol Mixture: Freeze protection is essential to the snow melting system. For typical applications, Viega recommends using 40% Propylene Glycol. Ethylene Glycol is accepted. Use the table to determine the freezing point of the water/ glycol mixture based on % glycol by volume. Note: Automotive antifreeze is not recommended; the silicates in automotive antifreeze can coat and foul heat transfer surfaces and plug the system, reducing energy efficiency. Glycol effects on the system: The material properties change according to the % glycol mixture. Use the table to adjust the flow rate and pressure drop calculated through the tubing (refer to 3.7 and 3.8 for values). Procedure: 1. Use the table to find the % increase multiplier (based on the % glycol mixture). 2. Multiply the flow rate and pressure drop figures by the multiplier. Freezing Point (°F) Glycol Mixture Ethylene Glycol Propylene Glycol 30% 3.7 8.4 40% -12.6 -6.7 50% -35.0 -30.0 Table 3.6A Glycol Effects on the System Flow Rate Pressure Drop % Increase Multiplier % Increase Multiplier Glycol Mixture 30% 5% (1.05) 20% (1.20) 40% 8.5% (1.085) 25% (1.25) 50% 12.5% (1.125) 31% (1.31) Table 3.6B Example: Glycol mixture: 40% Calculated flow rate: 7 gpm Flow rate multiplier: 8.5% (1.085) Adjusted flow rate calculation: 7 gpm x 1.085 = 7.6 gpm Calculated pressure drop: 20 ft of hd Pressure drop multiplier: 25% (1.25) Adjusted pressure drop calculation: 20 ft of hd x 1.25 = 25 ft of hd VIEGA NA 877-VIEGA-NA IM-SNO-09/04 72 SYSTEM DESIGN - CHAPTER 3 3.3 Calculating the Tube Spacing: Decreasing the tube spacing will allow the snow melting system to operate at lower fluid temperatures while meeting the heat output requirements. Use table 3.3 to the right to calculate the proper tube spacing. Procedure: 1. Find the tube size in the first column. 2. Follow to the right and read the recommended tube spacing under the column representing the heat load. Example: Tube size: 5/8” Snow melting load: 200 Btu/h*ft Recommended tube spacing: 9” Recommended Tube Spacing in Concrete Snow Melting Load (Btu/h*ft2) Tube Size Max. Circuit Length 100 150 200 250 300 1/2" 150 ft 9" 9" 6" 6" 6" 5/8" 250 ft 9" 9" 9" 6" 6" 3/4" 400 ft 12" 12" 9" 9" 6" Table 3.3 Notes: • Space tubing 1 inch closer for each inch of concrete cover over 2 inches. • Space tubing 2 inches closer for each additional inch of pavers > 2-3/8” pavers. • Space tubing 1 inch closer for asphalt applications. 3.4 Calculating the Fluid Supply Temperature: Use table 3.4 to calculate the fluid (antifreeze solution) supply temperature. Procedure: 1. Find the snow melting load in the first column. 2. Follow to the right and read the recommended fluid supply temperature under the column representing the selected tube spacing. Example: Snow melting load: 200 Btu/h*ft Tube spacing: 9 inches Fluid supply temperature: 131°F Fluid Supply Temperature (°F)* Snow Melting Load (Btu/h*ft2) 6 9 12 100 100 100 103 150 100 106 128 200 108 131 153 250 133 156 300 158 Tube Spacing (inches) Table 3.4 * Based on a 30 F° temperature drop Note: Fluid supply temperature of 130°F is typical for snow melting applications. VIEGA NA 877-VIEGA-NA IM-SNO-1006 73 Product Instructions Stainless Manifold Shut Off/Balancing/Flow Meters Product Description Stainless manifold is to be used in closed loop hydronic heating, cooling and snow melting systems. These preassembled 1-1/4” diameter stainless supply and return manifolds come attached to two 6-5/8” spacing brackets for compact remote mounting. This stainless manifold provides shut off and balancing valves with flow meters for each circuit. Each flow meter/balancing valve allows graduated flow setting up to 2 gpm, maximum 18 gpm per manifold. The air bleeder and purge valves are connected and factory tested. 1-1/4” Union connections, 1” NPT removable end caps. SVC Circuit connection fittings are sold separately. 1.18” 1.15” Dimensions Height 12.1” Depth 3.6” Manifold Total Width 2 outlets 10.2” 3 outlets 10.2” 4 outlets 12.2” 5 outlets 14.1” 6 outlets 16.1” 7 outlets 18.1” 8 outlets 20.0” 9 outlets 22.0” 10 outlets 24.0” 11 outlets 25.9” 12 outlets 27.9” 5.31” 12.08” 6.63” 11.22” TOTAL WIDTH 3.56” *When extending the manifold, Viega requires using thread sealant paste and Teflon tape on the 1” NPT manifold end connection. Technical Data 1. 1-1/4” 304 Stainless Header Stock 2. Supply Manifold with Balancing valve/flow meter 3. Return Manifold with shut off valves (blue caps) 4. Factory installed air bleeders and purge valves 5. Mounting Brackets The return header is fitted with shut off valves which are suitable to receive optional 24V powerheads for control over each circuit via thermostat. Note: Use new style white cap powerheads with this mainfold (stock code 15 061). 6. Max. operating temperature: 180°F Short periods of 200°F 7. Max. operating pressure: 100 psi VIEGA • One Company... One Partner... Delivering System Solutions. 301 N. Main, Floor 9 • Wichita, KS 67202 • Ph: 877-Viega-NA • Fax: 800-976-9817 • E-Mail: [email protected] • www.viega-na.com PI-PR-15900 0507 518858 74 Waterside Flow Vitodens 200 Heat Exchanger Pressure Drop Waterside Flow (primary circuit) The Vitodens 200-W, WB2B is designed for closed loop, forced circulation hot water heating systems only. Supply head pressure (water) H(ft.) H(m) 8 26 23 7 19.7 6 16.4 5 13.1 4 9.8 3 6.6 2 3.3 1 0 0 Pressure drop (primary circuit) for Vitodens 200-W, WB2B 19, 26, 35 For sizing an on-site circulation system. Max. flow rate: 1400 L/h / 6.2 GPM 0 0 Fig. 11 500 2.2 1000 4.4 1500 6.6 2000 l/h 8.8 GPM Supply head pressure (water) H(ft.) H(m) 20.1 6.1 16.7 5.1 13.4 4.1 10.0 3.1 6.7 2.0 3.4 1.0 0 0 Fig. 12 Pressure drop (primary circuit) for Vitodens 200-W, WB2B 45, 60 For sizing an on-site circulation system. Max. flow rate 3500 L/h / 15.4 USGPM 0 0 500 2.2 1000 4.4 1500 6.6 2000 8.8 3000 13.2 2500 11 H(ft.) H(m) 33.5 10.2 Pressure drop (primary circuit) for Vitodens 200-W, WB2B 80, 105 For sizing an on-site circulation system. Max. flow rate 8000 L/h / 35.2 USGPM 30.1 9.2 Supply head pressure (water) 3500 l/h 15.4 GPM 26.8 8.2 23.4 7.1 20.1 6.1 16.7 5.1 13.4 4.1 10.0 3.1 6.7 2.0 3.4 1.0 0 0 0 1000 4.4 2000 8.8 3000 13.2 4000 17.6 5000 22.0 6000 26.4 7000 30.8 8000 l/h 35.2 GPM Fig. 13 Use standard friction loss method for pipe sizing. Observe boiler maximum and minimum flow rate limitations. If system flow rate exceeds boiler maximum flow rate (as stated above), falls below the minimum flow rate or if system flow rate is unknown, Viessmann strongly recommends the installation of a low-loss header. An alternative method may be used, such as primary secondary piping using closely spaced tees. A low-loss header offers additional benefits not provided by a pair of closely spaced tees. Viessmann therefore strongly recommends and prefers the use of a low-loss header over closely spaced tees. See page 13 for low-loss header information. 75 5369 295 v1.0 0 Box A Box C Box B Box B Box A Box C Box B & Box C combined NBP4-WHN Complete floor mount piping NBP4-080 – Lochinvar KBN 080/081 NBP4-105 – Lochinvar KBN105/106 NBP4-150 – Lochinvar KBN150/151 NBP4-210– Lochinvar KBN210/211 NBP4-WHN – Lochinvar WHN 055-155 76 77 78 WILO Stratos Commercial High-Efficiency Circulators WILO Stratos 10 15 20 25 30 35 40 45 50 Q [m 3 /h] Wilo-Stratos 60 Hz 40 3x 3x 5 35 32x 0 -4 x3 1.5 30 5x3 1.2 3-2 8 3- 3- 30 40 6 4 2 20 x3- 10 1.25 H p-c control mode 10 x 3-35 1.25 20 * Compared to an uncontrolled circulator. 12 x 1.25 30 Up to 80% Energy Savings!* H [m] 5 H [ft] 0 H max 0 Hs 0 40 80 120 200 Q [US gpm] 160 H min Q p-c control mode In this control mode the electronic control will maintain the pumpgenerated head over the permissible flow rate range constant at the preset differential pressure setpoint level HS. p-T control mode Hs Hs max H p-v control mode Hs var. Hs min Hs T min T max T med Q min Q max Q ½ Hs H min Q p-v control mode In this control mode the electronic control will vary the pump-generated head linearly between HS and ½ HS. The differential pressure setpoint level H varies with flow rate Q. WILO USA LLC 1290 N 25th Ave. Melrose Park, IL 60160 1-866-WILO-USA www.WILO-USA.com In this control mode (programmable only with the aid of the IR-Monitor)the electronic control will vary the setpoint level of the pump generated head depending on the measured fluid temperature. This control mode can be applied in conjunction with constant-volume (e.g. one-pipe) systems and variable-flow systems with modulating flow temperature control. The Dp-T control mode supports the condensing boiler technology, provided the pump is installed in the return pipe of the heating system. In addition, with optional Interface Modules the operational setpoints (head or RPM) can be adjusted externally from a 0 – 10V DC signal or a LONworks signal from a BMS system. WILO Canada Inc. Bay #7 - 2915 10th Ave. NE Calgary, Alberta T2A 5L4 1-866-WILO-CDN Www.WILO-CANADA.com 79 0 Submittal Data Sheet 8JMP4USBUPT%)JHI&GÜDJFODZ$JSDVMBUPST Stratos D 2x3-40 Project: Engineer: Contractor: Tag # Submitted By: Date: Approved By: Date: Model # Flow Head Control Mode Cycle Phase Voltage 60Hz 1 230V Stratos D 2x3-40 0 5 10 15 20 H[ft] 25 30 Q [m³/h] Wilo-Stratos-D 2x3-40 1 ~/ 60 Hz + 40 0 5 10 15 20 H[ft] H[m] 14 25 H[m] 14 Wilo-Stratos-D 2x3-40 1 ~/ 60 Hz + 40 12 Q [m³/h] 30 12 Δp Δp -c -v 10 10 30 30 8 ma 20 8 ma x. x. 20 6 6 4 10 4 10 min. 2 0 0 P1[hp] 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0 0 Q [USg.p.m.] 0 0 Q [l/s] 0 Q [m³/h] 0 0 20 0 0 mi 40 60 2 5 80 100 4 10 120 6 15 20 8 25 30 max. 2m 0m 13 16'/1 1 '/8m /6m 32 / 26 / 4 11/ 16' m 19 1/ 8 '/4 13 393/ 8'/1 m 31/ 4 '/1m 20 40 69/ 16'/2 min. 60 80 Max Temperature 0,6 0,4 120 Wilo-Stratos 0,2 2x3-40 0 Q [USg.p.m.] 0 20 40 14°F to 230°F (-10°C to 110 °C) Module 1 Module 2 60 2 80 100 4 5 10 6 15 20 Q [USg.p.m.] 120 Q [l/s] 8 25 Q [m³/h] 30 max. m '/10 6 13 / 1 1/ 4 32 26 0,6 0,4 min. 20 40 60 80 100 120 Wilo-Stratos 0,2 2x3-40 0 Q [USg.p.m.] Applications Module È Heating Systems È Cooling Circuits BACnet / Dual Pump È Air Conditioning È Industrial Circulation LONworks / Dual Pump È Solar Systems È Geothermal Systems 104°F (40°C) Min. Suction Pressure (122°F) 7.1 PSI Min. Suction Pressure (203°F) 17.1 PSI Min. Suction Pressure (230°F) 25.6 PSI SBM Run Signal / Ext. Off / Dual Pump SBM Run Signal / 0-10v / Dual Pump Ext. Min / 0-10v / Dual Pump .BUFSJBMTPG$POTUSVDUJPO Pump Volute P1[kW] 1,0 0,8 '/8m '/6m 11/ 16 19 m 1 8 '/4 13 / P1 *3.PEVMF4FMFDUJPO Technical Data Liquid Temp Range 0,8 P1 100 P1[hp] 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0 0 P1[kW] 1,0 2 n. Ext. Off / 0-10v / Dual Pump Cast Iron (EN-GJL-250) Cataphoresis Coated Impeller Composite (PPS-40% GF) Shaft Stainless Steel (X46Cr13) Bearing Metal Impregnated Carbon Approval Stamp WIL-SDS-STRD001-01-11 80 Submittal Data Sheet 8JMP4USBUPT%)JHI&GÜDJFODZ$JSDVMBUPST Stratos D 3x3-40 Project: Engineer: Contractor: Tag # Submitted By: Date: Approved By: Date: Model # Flow Head Control Mode Stratos D 2x3-40 0 H[ft] 20 40 60 100 Q [m³/h] 80 Wilo-Stratos-D 3x3-40 1 ~/ 60 Hz + Δp 40 -c 0 H[m] 14 H[ft] 12 40 Cycle Phase Voltage 60Hz 1 230V 20 40 60 100Q [m³/h] 80 Wilo-Stratos-D 3x3-40 1 ~/ 60 Hz + 12 Δp -v 10 10 30 30 ma ma x. 8 x. 8 6 20 6 20 4 4 10 min. 10 m 2 0 0 0 0 P1[hp] 200 5 10 20 300 15 40 20 60 0 Q [l/s] 0 100Q [m³/h] 0 max. '/12m 3 6'/10m 1 /1 39 1 '/8m 32 26 / 4 3 11/ 1 19 1/ 8 '/4m 3 1 2 1 69/ 16'/2m min. 100 200 300 Max Temperature 14°F to 230°F (-10°C to 110 °C) 10 20 400 Q [USg.p.m.] 300 15 40 20 60 25 80 Q [l/s] 100Q [m³/h] max. m 10 6'/ 13 / 1 32 3 2 m 1/ 4'/8 '/6m m 11/ 16 26 4 19 131/ 8 '/ 3,0 2,5 2,0 1,5 1 0,5 0 0 400Q [USg.p.m.] Module 2 P1 min. 0 100 200 300 Wilo-Stratos 3x3-40 400 Q [USg.p.m.] 0,5 0 Applications Module È Heating Systems È Cooling Circuits BACnet / Dual Pump È Air Conditioning È Industrial Circulation LONworks / Dual Pump È Solar Systems È Geothermal Systems 104°F (40°C) Min. Suction Pressure (122°F) 10 PSI Min. Suction Pressure (203°F) 21.3 PSI Min. Suction Pressure (230°F) 32.7 PSI SBM Run Signal / Ext. Off / Dual Pump SBM Run Signal / 0-10v / Dual Pump Ext. Min / 0-10v / Dual Pump .BUFSJBMTPG$POTUSVDUJPO Pump Volute P1[kW] 1,0 1,0 Module 1 200 4 2,0 Wilo-Stratos 3x3-40 5 *3.PEVMF4FMFDUJPO Technical Data Liquid Temp Range 3,0 1,5 P1 100 P1[hp] P1[kW] 2,5 m 6'/6 3/ 8 0 400 Q [USg.p.m.] 25 80 2 i n. 0 0 100 4 0 0 H[m] Ext. Off / 0-10v / Dual Pump Cast Iron (EN-GJL-250) Cataphoresis Coated Impeller Composite (PPS-40% GF) Shaft Stainless Steel (X46Cr13) Bearing Metal Impregnated Carbon Approval Stamp WIL-SDS-STRD001-01-11 81 H[ft] 25 0 60 5 30 80 0 2x4 100 1/4” C 1/4” D Drawing 3 E E 1/4” 82 C C 1/4” Q[US gpm] 5 2x3 1phase - 60Hz Wilo-TOP-S Top S Single Phase Circulator (115v or 230v) 40 x3 E x6 2x50 1.5 2x25 1.5x 20 1.5 x 0 1.5x4 5x 20 5 x1 25 1. 1.5x50 1.2 0 0 10 20 30 40 50 5 1.2 D Drawing 5 D Drawing 1 Two Speed Wet Rotor Circulator 30 E E 1/4” C 1/4” C D D 35 120 2x25 2x 2x 50 3x 50 160 0 3x7 200 5 3x2 Q[US gpm] 3phase - 60Hz Wilo-TOP-S C 1/4” 1/4” D Drawing 6 Top S Three Phase Circulator (208/230v, 460v, 575v) 1.25x35 40 80 0 x2 1.5 1.5 2x x4 40 1.5x 30 Drawing 4 0 0 10 Two Speed 20 Wet Rotor Circulator Drawing 2 2x60 1.5x70 50 1.5x5 0 40 60 H[ft] BUDERUS AM-10 QUICK REFERENCE SHEET Wiring: There are three sets of terminals along the bottom of the control. THE BOTTOM OF THE CONTROL WILL END UP UPSIDE DOWN WHEN LOOKING at it from the front looking into the boiler. It mounts only this way. Pair 1: The pair all the way to the left accepts the little white plug that is lying in the rear of the boilers wiring harnesses to plug into. This is how it gets powered up and how it communicates to the GB-142’s circuit board. Pair 2: The middle pair: accept a thermostat connection from a regular thermostat or an end switch in a pump relay box or a zone control relay box. Pair 3: The right hand pair: accept the outdoor sensor wire. This is typically a pair of 18-2 thermostat wires running outside the building to a sensor mounted on the north side of the building. Mode button: when depressed, moves the cursor from icon to icon Icons and their meanings: From left to right are the… House, Radiator, Target adjustment, Basepoint adjustment, and the Sun/Snowflake The House icon is non-adjustable: Tells you the current outdoor temperature according to the outdoor sensor. This is true when the cursor is located above the icon in the LED display. The Mode button is what moves the cursor to the icon position. The Radiator icon is non-adjustable and is referred to in the instruction manual as the FLOW TEMPERATURE SETPOINT and is the temperature that the boiler will target based on the outdoor temperature and the Setpoint adjustment temperature and the Basepoint settings. The Target adjustment is adjustable and is the temperature you want the boiler supply temperature to be when the outdoor temperature is at 14 degrees Fahrenheit. For Baseboard, the typical temperature setpoint is 165 degrees Fahrenheit. Of course, the BC-10 or “Boiler Control” itself must be set for at least 180 degrees as the boiler sees what is set on the dial of the BC-10 as its high limit. The logic is that the burner will ride off of that point and modulate whenever the “Radiator” target nears that temperature. 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 Buderus AM10 Quick Set UP Page 1 Michael Fox 02/21/2007 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 83 BUDERUS AM10 QUICK SET UP (CONT”D) The Basepoint adjustment is adjustable and is simply the minimum supply temperature that you want the boiler to shoot for whenever the boiler has a call for heat and is below Warm Weather Shut Down. Example of a need for a Basepoint: Baseboard heating elements work on convection and will not move air over their elements at a very fast pace if the difference in temperature between the element and the room is not large enough. What is large enough? Typically, if you have at least 100-110 degrees F, you CAN get heat out of baseboard. Another example might be for an air handler with a Hydronic Coil which will feel like it has cold air blowing from it when the supply water temperature going to it is below 115 degrees Fahrenheit. Sun/Snowflake: is simply your outdoor temperature shut down or Warm Weather Shut Down, otherwise referred to as your WWSD and will keep the boiler from turning on if the outdoor temperature is above this setting and there is a call for heat at the thermostat contacts on the center pair of the terminals on the AM-10 control module. This temperature is typically set at 68 degrees Fahrenheit. Remember, Outdoor + Target adjustment + Basepoint = Radiator target temperature Wrench icon: when seen in the LED display simply means that the boiler is locked out in fault mode. Depending on the code you see (you must look up the code in the Boiler installation Instruction Booklet under Troubleshooting), the boiler may or may not run. For instance, if the control doesn’t see an outdoor sensor, it will have three flat lines across the LED display like this - - - and will only let the boiler run until the supply temperature is 122 degrees F. The “Heat Call” Icon is what will appear in the LED display whenever there is a call for heat. The “Flame” Icon color. is what you will see when the burner is running. It is black in For more information, refer to the manual. For issues beyond that call Buderus Technical Support at 603-5521100 or Capco Energy Supply Inc. @ 781-721-0303. 781-721-0303 ENERGY SUPPLY, INC. FAX 781-721-9119 WWW.CAPCOSUPPLY.COM 10 INDUSTRIAL PARKWAY WOBURN MA 01801 Buderus AM10 Quick Set Up Page 2 Michael D. Fox 02/21/2007 THIS IS ONLY A CONCEPT DRAWING. ALL CONDITIONS AND NECESSARY COMPONENTS MUST BE FIELD VERIFIED AND ARE THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR 84 Technical Service Bulletin: FW 200 Control Quick Start Guide Models: Bosch Greenstar Combi 151/100, Bosch Greenstar 151/131/100/57 This is a quick reference to highlight the BASIC programming of this control. For a more in depth understanding or complete programming of the control, please refer to the FW 200 Installation and Operating manuals. Figure 1 9 15 6 At any time, pressing the Menu button (Fig.1, pos.3) will bring you back to the standard display. 18 3 24 h 3 Instructions for programming   4 Set Date and Time upon initial start-up 2 — Turn dial (Fig.1, pos.1) to adjust time and date. Press the dial to finalize your selection. 1 — You will be asked about System configuration, which is only necessary if you have added additional controls. If you see this prompt, press and hold the menu button (Fig.1, pos.3) until it disappears.  Turn dial counter-clockwise until General Settings is highlighted. — Push dial once and release. Time and Date will be highlighted. — Push dial again and Time will be highlighted. Set time by pushing dial and rotating. Once complete, push again to lock in time setting. — Set for constant heating (no night set back) This can be done two ways: Push the menu button once and release. On the display Vacation will be highlighted. — 6 * Controller with front flap open Set Date and Time after intitial programming — 5 1) Turn selector (Fig.1, pos.2) to the Comfort Symbol ( 2) Or change programming. To change programming: Turn dial until Date is highlighted. Set date by pushing dial and turning to select. Push dial once to lock in date setting. 85 — Press and release menu button. Vacation will be highlighted. — Turn dial one click counter-clockwise to highlight Heating and push dial to select. — Program will be highlighted. Push dial to select. — Activate will be highlighted. Turn the dial one click to highlight Edit and push dial to select. — Program A will be highlighted. Push dial to select. ). Technical Service Bulletin 2 | FW 200 Control Quick Start Guide — — — — Replace with preset program will be highlighted. Turn the dial counter-clockwise to display All days and push dial to select. P1 will be highlighted. Press the dial again and the display will flash. Turn dial one click clockwise to 12:00PM. Press the dial and rotate it until Comf. appears. The area around the display should fill in. — Press dial again to lock in your program. — Press the menu button to return to main display. Refer to manual for more custom settings. Table 1 Design Temp (°F) 90°F basepoint Desired Supply Temp (°F) 10 0 -10 180 176 158 150 160 156 144 138 140 134 128 122 Table 2  Set type of heating system Design Temp (°F) 80°F basepoint There are three seperate default presets: Baseboard, Radiators, Radiant Floor. They have an approximate basepoint of 75°F. With this basepoint, the heating system will take some time to raise the room temperature in warmer weather. Please see the FW200 ISM, Sec. 8.3.2 for more details on those presets. For a custom preset, see below. Desired Supply Temp (°F) 10 0 -10 140 134 124 110 120 118 110 106 100 98 95 92 — Rotate the dial counter-clockwise to display Maximum heating supply temperature. Press the dial and adjust as desired. Push dial once to lock in the setting. — Press the menu button to return the main screen. — Press and hold the menu button for about 5 seconds. — System Configuration will be highlighted. — Turn dial one click counter-clockwise to highlight Heating Parameters. Push dial to select. — Press and hold the menu button for about 5 seconds. System Configuration will be highlighted. — Heating Circuit 1 will be highlighted Press dial again and Heating circuit type will be highlighted. — Turn dial one click counter-clockwise to highlight Heating Parameters and push dial to select. — Press dial and Radiators will be highlighted. Press dial again and Radiators will flash. — Heating Circuit 1 will be highlighted. — Turn the dial to choose Baseline/Design temp and push dial to select. — — Heating circuit type will again be highlighted. Rotate the dial counter-clockwise. Turn the dial counter-clockwise until Heating OFF at outdoor temperature is displayed. The default is 68°F and is adjustable from 37°F to 77°F. Turning above 77°F will move it to 210°F, which disables WWSD. Push dial once to lock in the setting. — Base Line will be displayed. Press the dial and 78°F will flash. This is your minimum supply temperature at 14°F outdoor temperature. Set accordingly and press dial once to lock in the setting.  Adjust warm weather shut down (WWSD) To restore to factory defaults, hold the Delete button (Fig.1, pos.5) and the Menu button simultaneously for about 10 seconds. A count down display will appear. This will restore factory defaults. The only program that will be held is the date and time. For hydroair systems, the minimum supply temperature must be raised to the turn on temperature for that coil. — Rotate dial and Design Temp will be highlighted. Press the dial and 168°F will flash. — Use tables 1 & 2 to choose which temperature to enter. Set accordingly and press dial once to lock in the setting. Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel: 1-800-283-3787 Fax: (603) 965-7568 www.bosch-climate.us Data subject to change without notice | Printed in the USA | BTC 465002101 A | 01.2012 86 Bosch Thermotechnology Corp. to 185 F to 185 F 120 F w/ ecm 3 87 3 130 F to 150 F Aquastat Use only as a guide. Please follow manufacturers installation and service manuals 88 89 VITOTRONIC 200 ® Quick Start Programming Guide for use with the Operating, Installation and Service Instructions Vitodens 200, Programming unit with Vitotronic 200, H01 on-board control. 11 Vitodens 200, Vitotronic 200, H01 Control Lay-out A Time program for central heating B Time program for DHW heating C Holiday program D Information E Standby mode H F DHW only G Central Heating and DHW H Normal room temperature adjust I Energy saving mode ON/OFF J Party mode ON/OFF E D A B C K Factory default factory setting L Confirmation button M Adjustment buttons Q P N F N DHW temperature L O Emissions test function (heating contractors only) K M J P Reduced room temperature O Q Time/Date NOTE: The control will display the boiler temperature when not in the programming or fault mode. 12 G I Display Symbols These symbols are not displayed continuously, but appear according to system type and operating status. Risk of frost Central heating with normal room temperature Central heating with reduced room temperature Frost protection heating circuit pump ON Normal heating circuit pump ON Reduced heating circuit pump ON Mixing valve open Mixing valve closed Manual override operation Automatic operation 1 NOTE: To adjust the display contrast, press and hold 5728 014 v1.0 09/2010 DHW heating enabled DHW pump ON, DHW heating enabled DHW heating via solar heating system Burner ON Time adjustment display Emissions test ON Fault indicator Heating circuit number Scanning hours run, scanning number of burner starts and consumption and use the 90 buttons for the desired setting. Product may not appear exactly as shown. 13 Fault Messages on Initial Start-up .. On initial start-up the word Storung (fault) may appear on the display. If no fault appears, go to ‘Setting the Time and Date’, otherwise follow the steps below: 1 Press the information button . 2 Read and record the fault code and number. 3 Press . Quittieren? Ja (acknowledge? yes) is displayed. 4 To acknowledge the fault, press . 2 1 3 4 NOTE: Faults can be corrected after all the programming and coding is completed. 14 Setting the Time and Date On initial start-up the word Uhrzeit (time) will come up flashing. To set the time and date follow the steps below: 1 Press the buttons to set to the current time (24:00 format). 2 To confirm the time, press date will come up flashing. 24:00 . The 1 3 Press the buttons to set to the current date (DD/MM/YY format). 4 To confirm the date, press 2 . 4 NOTE: If the system is equipped with remote 3 control units (Vitocontrol 300), the time and date may be set at each remote location. To change the time and date at any time and at any location, press the button and follow the same procedure as shown above. 15 Changing Language The control language defaults to German, to set the control language to English follow the steps below: 1 Press the information button . .. 2 Heizkreis Wahlen (select heating circuit) may be displayed, if requested select the again. heating circuit and press 3 Press buttons and scroll through the menu until English is displayed on the screen. 4 Press the button to accept. 3 1 4 2 NOTE: If the system is equipped with remote control units (Vitocontrol 300), the language must be set at each remote location. Following the same procedure as shown and change to the desired language. 91 5728 014 v1.0 Changing the Temperature Display from oC to oF 16 To change the temperature display from oC to oF call up coding level 2. 1 Press and buttons simultaneously . and hold for 2 seconds and confirm with 2 The display will show 00: 0 (00: is flashing). 3 Press the 4 Press buttons to set 00: to 88: , (only the 0 will be flashing). 5 Press the 6 Press 3 buttons to set 0 to 1. 1 2 , (Accepted will be displayed). 7 4 6 7 To exit coding level 2, press and buttons simultaneously for 1 second. 5 NOTE: Displays are changed at remote locations. 17 Setting Room, Reduced Room and DHW Temperatures If the system is equipped with remote control units, temperature settings for room, reduced room and DHW must be set at each control location. 1 For normal room temperature (default 68oF) press the button, then rotate dial to select the desired temperature. 2 For reduced room temperature (default 37oF) press the button, then press the buttons to select the desired temperature. 3 Press , to set the temperature. 4 For DHW temperature (default 122oF) press the button, then press the buttons to select the desired temperature. 5 Press , to set the temperature. 18 1 1 2 3 2 4 5 4 Relay Test, Temperature Sensor Check and Operating Conditions Scan Relay test 1 Press and simultaneously for approximately 2 seconds. 2 Select the relay outputs with the buttons. 3 To exit the test mode, press . Temp. sensor check and operating conditions scan 4 Press the button. 1 2 4 5 Select the heating circuit if requested and 1 5 button again. press the 7 6 Scan required information with the 3 6 buttons. 7 To exit, press . NOTE: For additional information and value lists for relay tests, temperature sensor checks and operating conditions, refer to the Operating, Installation and Service Instructions supplied with the system. 5728 014 v1.0 92 19 Coding Level 1 and 2 Calling up coding level 1 (Basic programming) 1 Press and simultaneously for approximately 2 seconds. 2 Select the required coding address with the buttons, the address will flash, confirm with , the value will flash. 3 To change the value, press the buttons, once complete confirm with . 4 Call up additional coding addresses with the buttons. 5 To exit coding level 1, press and simultaneously for approximately 1 second. Calling up coding level 2 (Detailed programming) 1 Press and simultaneously for approximately 2 seconds and confirm with . 2 Select the required coding address with the buttons, the address will flash, confirm with , the value will flash. 3 To change the value, press the buttons, once complete confirm with . 4 Call up additional coding addresses with the buttons. 5 To exit coding level 2, press and simultaneously for approximately 1 second. Resetting the codes to the factory setting 1 Press and simultaneously for approximately 2 seconds . 2 Press factory default button and confirm ‘Base setting? Yes’ with . NOTE: Coding level 2 contains all of coding level 1 programming information. 1 10 NOTE: For coding level 1 and coding level 2 listings, refer to the Installation and Service Instructions supplied with the system. Troubleshooting Calling up acknowledged fault messages Retrieving fault codes from the fault history 1 Press for approximately 2 seconds. 2 Select the acknowledged fault code message with the buttons. 3 Correct each fault as per the troubleshooting section of the Installation and Service Instructions. 4 After each fault is removed, press the reset to acknowledge. 1 Press and simultaneously for approximately 2 seconds. 2 Select the saved fault code message with the buttons. 3 All fault codes can be deleted by pressing . for yes or no. Delete? Yes, will appear, press 4 To finish the fault scan, press . NOTE: For additional information on troubleshooting and operating status, refer to the Operating, Installation and Service Instructions supplied with the system. 11 1 Additional Functions Heating Time Program Domestic Hot Water Time Program DHW Recirculation Pump Time Program Holiday Program Heating Curve Slope (located in Coding 2) Heating Curve Shift (located in Coding 2) Standby Mode Domestic Hot Water Only Party Mode Energy Saving Mode Technical information subject to change without notice. ! ! ! ! ! ! ! Participant Check (only on LON devices) Boiler Sequence (on Cascade Control) Cascade Control Starting/Stopping DHW Heating Only Starting/Shutting Down Heating System Only Starting/Stopping DHW and Heating System Remote Controls NOTE: For information to access the additional functions, refer to the Operating, Installation and Service Instructions supplied with the system. 93 5728 014 v1.0 Stratos “Quick Start” Manual Stratos guide d’installation rapide Stratos Manual rápido de Comienzo This manual is intended as a quick reference guide to install and start up a Stratos pump. Please refer to the full Installation and Operation manual (or contact your WILO representative) if additional or more detailed information is required. Ce manuel est un guide rapide et simplifié de l’installation de la pompe Stratos. Pour plus de détails, veuillez vous référer à la notice de montage et de mise en service ou appeler votre représentant WILO. Este manual es como una guía de referencia rápida para instalar y para encender una bomba de Stratos. Favor de refierir a la instalación completa y manual de operación (o contactese con su representante de WILO) si se requiere información adicional o más detallada . 1. Install Installation Instalar - Mounting Positions- SHAFT MUST BE HORIZONTAL. See Table for additional recommendations - If motor requires turning remove 4 Allen Screws and rotate. Mounting Positions Positions de Montage Montar las Posiciones - Positions d’installation- L’AXE DU MOTEUR DOIT ETRE EN POSITION HORIZONTALE. Voir le tableau ci-contre pour plus de recommandations. - Si vous souhaitez changer la position du module d’affichage, enlevez les 4 vis et tournez le bloc moteur. - Posiciones de Montaje- El TUNEL DEBE ESTAR HORIZONTAL. Vea la tabla para recomendaciones adicionales. - Si el motor requiere dar vuelta quita 4 tornillos de Allen y girar. 2. Wiring Câblage Alambrado - Refer to local electrical codes - Minimum 14 AWG cable size rated for 167°F (75°C) - Total voltage 1~230V ±10% - If voltage exceeds limits see troubleshooting guide on reverse - Additional wiring (Interface Modules, Fault Contact etc. refer to full manual) - Respectez les réglementations électriques locales en vigueur. - Câble de 14 AWG pour 167°F (75°C) minimum. - Voltage total 1~230V ±10% - Si le voltage est en dehors des limites prévues, voir le guide de dépannage au dos. - Câblages additionnels (Modules d’Interface, Report Défaut etc. voir la notice de montage et de mise en service complète) 3. Startup Démarrage Wiring ! Achtung Attention 1 - 230V 230V~ FC Achtung Option Netzspannung IF-Modul Attention Mains Voltage - Refiérase a códigos eléctricos locales - Mínimo 14 AWG tamaño del cable clasificado para 167°F (75°C) - Voltaje total 1~230V ±10% - Si el voltaje se excede los límites Vea la guía de soluciones la revés - Alambrado adicional (Contacto de Falta, etc. refiera al entero manual) Installation éléctrique Alambrado Marchar - Open suction and discharge valves - Purge and fill system (pump is automatically vented) - Turn on power- pump LED performs diagnostics - LED reads either factory default or settings prior to shut down (see table) Example Reads: - Pump is set at 16.4 feet of differential head - Pump is set for differential pressure - Automatic night setback is turned on but not active - To increase head setpoint rotate red button CW and push in (and release) - To decrease head setpoint rotate red button CCW and push in - For additional setting changes please refer to full manual - If a problem occurs during start-up see reverse or contact WILO - Ouvrir les vannes d’isolement - Purger et remplir le système (la pompe est purgée automatiquement) - A la mise sous tension, tous les symboles s’affichent pendant 2 secondes. Ensuite s’affichent les paramètres d’usine ou ceux précédemment enregistrés (voir tableau ci-contre) Exemple d’affichage - La pression H est réglée à 16.4 pi (ft) - Le contrôle utilisé est différentiel de pression variable - Mode ralenti nuit activé mais pas en fonction - Pour augmenter la pression, tourner le bouton rouge vers la droite et appuyer 1 fois et relâcher pour valider. - Pour diminuer la pression, tourner le bouton rouge vers la gauche et appuyer 1 fois et relâcher pour valider. - Pour des réglages additionnels, se référer à la notice de montage et de mise en service. - En cas de problème durant la mise en service, voir le guide de dépannage au dos ou contacter WILO. - Abra succión y descargar las vavulas - Purgar y llenar sistema (la bomba se ventila automáticamente) - Encender la energia - El LED de la bomba LED realiza diagnósticos - El LED lee defecto o ajustes de la fábrica antes de apagar (véa la tabla) El ejemplo Lee: - La bomba se fija en 16.4 pies de la cabeza diferenciada - La bomba se fija para la presión diferenciada - Se prende el revés automático de la noche pero no esta activo - Para aumentar el setpoint principal gira el botón rojo CW y empuje hacia adentro (y soltar) - Para disminuir el setpoint principal gira el botón rojo CCW y empuje hacia adentro - Cambios adicionales del ajuste, favor de referir al manual completo l del contacto - Si un problema ocurre durante la marcha vea revérsa o contactar a WILO WILO USA LLC 1290 North 25th Avenue Melrose Park, Illinois 60160 Phone: 866 945 6872 Fax: 708 338 9455 www.WILO-NA.com 94 LED Display Affichage DEL Despliegue LED WILO Canada Inc Bay 7 - 2915 - 10th Ave N. E. Calgary, Alberta, T2A 5L4 Phone: 866 945 6236 Fax: 403 277 9456 Stratos “Quick Start” Manual Stratos guide d’installation rapide Stratos Manual rápido de Comienzo Troubleshooting Problem Cause Pump does not run with power on Remedies Electric fuse faulty Noisy pump operation Check fuse Pump has no power Rectify interruption to power Cavitation due to insufficient Increase system admission pressure admission pressure within permissible range Check pump lift setting, set lower lift if necessary 10.1 Error messages: Code Number E04 Symbol Flashing Supply Error LED "permanent light" Problem Cause Mains undervoltage Remedies Mains overloaded Check electrical Installation terminal E05 Supply Mains overvoltage Check electrical Installation terminal E10 Motor Pump blocked e.g. sedimentation De-blocking routine starts automatically Should this not remove the blockage, the pump switches off after 10 sec Call customer service E20 Motor Winding overheated Motor overloaded Let motor cool down, check the settings. Ambient temperature too high Reduce water temperature E21 Motor Motor overload Sediment in the pump Call customer service E23 Motor Short circuit / contact Motor defect Call customer service Reinstall module fault E25 Motor Contact error Module not correctly installed E30 Module Excess temperature module Air intake to module heat sink is blocked E31 Module Excess temperature Ambient temperature too high Improve ventilation in room Electronic components Faulty Call customer service / swap module power component E36 Module Module faulty 10.2 Warning messages: Code Number E03 E04 E05 E07 E09 E11 E38 E51 E52 MA Symbol Flashing Motor Error LED "off" Problem Cause Remedies Water temperature >110°C Mains undervoltage Mains overvoltage Generator operation Generator operation Heating control incorrectly set Mains overloaded Pump idling Temp. sensor medium faulty Non-Permissible Combination Master/Slave communication error. Pump switched from standard mode to fixed characteristic (depending on chosen set value) Master/Slave not set Air in the pump Motor faulty (auto night setback) Different pumps Stratos IF module not correctly positioned, cable faulty. Driven by admission pressure pump Driven by reverse flow through "off" pump Set to lower temperature Check electrical installation Check electrical installation Balance pump capacity regulation Check circulation Direction. Fit a check valve at the pressure side. Vent pump and unit Call customer services After 5 mins, the modules switch to check cables. Specify master and slave If the fault cannot be remedied, please contact your local heating specialist or WILO customer services. WILO USA LLC 1290 North 25th Avenue Melrose Park, Illinois 60160 Phone: 866 945 6872 Fax: 708 338 9455 www.WILO-NA.com 95 WILO Canada Inc Bay 7 - 2915 - 10th Ave N. E. Calgary, Alberta, T2A 5L4 Phone: 866 945 6236 Fax: 403 277 9456 Residential Models and Packages EXTROL® • Factory pre-charged to 12 psig • Maximum working pressure: 100 psig • Maximum operating temperature: 240°F EXTROL Specifications Model Number Tank Max. Accept. Volume Volume (Gallons) (Gallons) 15 30 60 90 1 2.0 4.4 7.6 14.0 EXTROL Combination Packages A Height (Inches) 0.9 2.5 2.5 11.3 B Diameter (Inches) 12 5⁄8 15 1⁄2 23 21 8 11 11 15 3⁄8 System Conn.1 (Inches) Shipping Weight (lbs.) ⁄ 1⁄2 1⁄2 1⁄2 5 9 14 23 12 Model Number 1500/1 or 1 1⁄4 3000/1 or 1 1⁄4 6000/1 1⁄4 6000/1 1⁄2 Extrol Model Purger Model Vent Model Ship. Wt. (lbs.) 15 30 60 60 443 or 444 443 or 444 444 445 700-C 700-C 700-C 700-C 9 14 19 19 EXTROL Package System Connection is NPTM Sizing the EXTROL Sizing Based on BTU’s BOILER Net Output in 1000'S of BTU/Hr. Sizing Based on Maximum System Temperature Finned Tube Baseboard or Radiant Panel TYPE OF RADIATION Convectors or Unit Radiators Heaters Cast Iron MBH Use Model Use Model Use Model Use Model 25 50 75 100 125 150 175 200 250 300 350 400 15 15 30 30 30 30 60 60 60 90 SX-30V SX-30V 15 15 30 30 60 60 60 60 90 SX-30V SX-30V SX-40V 15 30 30 60 60 90 SX-30V SX-30V SX-30V SX-30V SX-40V SX-40V 15 30 60 60 90 90 SX-30V SX-30V SX-40V SX-40V SX-60V SX-60V Baseboard Cast Iron Sizing based on: • Fill Pressure 12 psig • Relief Pressure 30 psig • Average System Temp. 200°F • System filled with water • Consult factory for compatibility and sizing for other fluids. Max. System Temp. °F Model 15 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 125 93 72 58 48 40 34 30 26 23 20 18 17 15 14 System Water Content in Gallons Model 30 Model 60 275 205 158 128 105 89 76 65 57 51 45 40 37 33 30 417 311 239 194 160 134 115 99 87 77 68 61 55 50 46 Model 90 876 653 502 407 336 282 241 208 182 161 143 129 116 106 96 Sizing by system temp. based on: • Max. Operating Temperature 240°F • Fill Pressure 12 psig • Relief Pressure 30 psig • Water Fill Temperature 40°F For Radiant Systems, Use RADIANT EXTROLTM • • • • • • Specifically designed for high-efficiency radiant systems Plastic liner compatible with barrier and non-barrier systems Suitable for use in glycol applications Non-ferrous system connection for corrosion resistance Maximum working pressure: 100 psig Maximum operating temperature: 200°F RADIANT EXTROL Tanks for Radiant Systems Model Tank Max. Accept. A B Number Volume Volume Height Diameter (Gallons) (Gallons) (Inches) (Inches) RX-15 RX-30 RX-60 1 2.0 4.4 10.3 0.9 3.2 10.3 System Connection is NPTM 12 5⁄8 15 1⁄2 19 1⁄4 8 11 15 3⁄8 System Conn.1 (Inches) Shipping Weight (lbs.) ⁄ ⁄ 1 5 9 23 34 34 RADIANT EXTROL Radiant Extrol Quick Sizing Chart Feet of Tubing 3/8" 1000 5000 7500 10000 14000 18000 22000 30000 RX-15 RX-15 RX-15 RX-15 RX-15 RX-30 RX-30 RX-30 Nominal Pex Tubing Size 1/2" 5/8" RX-15 RX-15 RX-15 RX-30 RX-30 RX-60 RX-60 RX-60 RX-15 RX-15 RX-30 RX-30 RX-60 RX-60 RX-60 Based on 120°F operating temp. with 12psi fill and 30psi relief valve. For glycol applications, consult AMTROL Technical Support. 96 3/4" 1" RX-15 RX-30 RX-30 RX-60 RX-60 RX-60 RX-15 RX-30 RX-60 RX-60 See Precise Sizing on back page. Bell & Gossett Commercial ASME Expansion Tank Quick Sizing Guide - Factory pre-charged to 12 psig - Pre-charge should be adjusted to equal minimum operating pressure @ tank location - Maximum working pressure: 125 psig - Maximum operating temperature: 240F Boiler Type of Radiation & Piping System Finned Tube Convectors or Radiators (One Radiators Net Output BB or Radiant Unit Heaters Pipe) (Series Loop) Panels in MBH Use Model Use Model Use Model Use Model 200 D-40V D-40V D-40V D-40V 250 D-40V D-40V D-40V D-40V 300 D-40V D-40V D-40V D-40V 350 D-40V D-40V D-40V D-60V 400 D-40V D-40V D-60V D-60V 450 D-40V D-60V D-60V D-120V 500 D-40V D-60V D-60V D-120V 550 D-40V D-60V D-60V D-120V 600 D-40V D-60V D-120V D-120V 650 D-60V D-60V D-120V D-120V 700 D-60V D-60V D-120V D-120V 750 D-60V D-60V D-120V D-120V 800 D-60V D-120V D-120V D-120V 850 D-60V D-120V D-120V D-120V 900 D-60V D-120V D-120V D-120V 950 D-120V D-120V D-120V D-120V 1000 D-120V D-120V D-120V D-120V 1100 D-120V D-120V D-120V D-240V 1200 D-120V D-120V D-120V D-240V 1300 D-120V D-120V D-240V D-240V 1400 D-120V D-120V D-240V D-240V 1500 D-120V D-120V D-240V (2) D-120V These recommendations are calculated on average boiler water volumes and the average water volumes of currently poplular types of radiation and piping systems. The industry operating standards of 12 psig fill pressure and 30 psig relief pressure are used. PART NUMBER MODEL NUMBER TANK VOLUME 116493 D-40V 21.7 116525 D-60V 33.6 116528 D-120V 116532 D-240V ACCEPTANCE A DIAMETER VOLUME (INCHES) B HEIGHT (INCHES) APPROX. WEIGHT (LBS.) 29 1/2 90 45 1/8 110 11.3 16 1/4 68 34 24 43 7/8 224 132 46 30 53 1/2 427 7 Sixth Road - Woburn, MA - 01801 - Phone: (800) 423-7187 - Fax: (781) 933-3965 FIA - Fluid Industrial Associates Inc. - New England’s premier plumbing, HVAC, radiant heating, and snow melting manufacturers representative 97 Precise Sizing Precise Sizing of EXTROL® & RADIENT EXTROLTM Table 1. Net Expansion of Water Things you must know: Max.Sys. Temp. °F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F 150°F 160°F 170°F 180°F 190°F 200°F 210°F 220°F 230°F 240°F .0005 .00149 .00260 .00405 .00575 .00771 .0100 .0124 .0150 .0179 .0209 .0242 .0276 .0313 .0351 .0391 .0434 .0476 .0522 .0049 .00143 .00254 .00399 .00569 .00765 .0099 .0123 .0149 .0178 .0208 .0241 .0275 .0312 .0350 .0390 .0433 .0475 .0521 1. Total System Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . .(1)_____ gallons 2. Minimum System Temperature . . . . . . . . . . . . . . . . . . . .(2)_____°F 3. Maximum System Temperature . . . . . . . . . . . . . . . . . . .(3)_____ °F 4. Minimum Operating Pressure at Expansion Tank . . . . . .(4)_____ psig 5. Maximum Operating Pressure at Expansion Tank . . . . .(5)_____ psig Selection of Expansion Tank: 6. Find and enter "Net Expansion Factor" . . . . . . . . . . . . . . . .(6)_____ (see table 1) 7. Amount of Expanded Water = line (1) x line (6) . . . . . . . . . .(7)_____ gallon 8. Find and enter "Acceptance Factor” . . . . . . . . . . . . . . . . . .(8)_____ (see table 2) 9. Minimum Total Tank Volume = line (7) ÷ line (8) . . . . . . . . . .(9)_____ gallons 10. Using Specifications on pages 6 and 7, select an Expansion Tank that is at least equal to line (9) for "Total Volume" and line (7) for Max. Expanded Water Acceptance Gallons. Mulitiple tanks may be required. Minimum System Temperature °F 60°F 70°F 80°F 90°F — .00094 .00204 .00350 .00520 .00716 .0095 .0118 .0145 .0173 .0204 .0236 .0271 .0307 .0346 .0386 .0428 .0471 .0517 — — .00111 .00256 .00426 .00622 .0086 .0109 .0135 .0164 .0194 .0227 .0261 .0298 .0336 .0376 .0419 .0461 .0507 — — — .00145 .00315 .00511 .0074 .0098 .0124 .0153 .0181 .0216 .0250 .0287 .0325 .0365 .0408 .0450 .0496 — — — — .00170 .00366 .0060 .0083 .0110 .0133 .0165 .0201 .0236 .0272 .0311 .0351 .0393 .0436 .0482 100°F — — — — — .00196 .0043 .0066 .0093 .0121 .0148 .0184 .0219 .0255 .0294 .0334 .0376 .0419 .0465 Note: For ethylene glycol and for propylene glycol contact AMTROL technical services. Table 2. Acceptance Factors* Max.Oper. Pressure at Tank (psig) 5 10 12 15 20 Minimum Operating Pressure at Tank (psig) 30 40 50 60 70 80 27 30 35 40 45 50 55 60 65 70 75 80 90 100 110 0.527 0.560 0.604 0.640 0.670 0.696 0.717 0.736 0.753 0.767 0.780 0.792 0.812 0.828 0.842 0.408 0.447 0.503 0.548 0.586 0.618 0.646 0.669 0.690 0.708 0.725 0.739 0.764 0.785 0.802 0.360 0.403 0.463 0.512 0.553 0.587 0.617 0.643 0.665 0.685 0.702 0.718 0.745 0.767 0.786 0.288 0.336 0.403 0.457 0.503 0.541 0.574 0.602 0.627 0.649 0.669 0.686 0.716 0.741 0.762 0.168 0.224 0.302 0.366 0.419 0.464 0.502 0.536 0.565 0.590 0.613 0.634 0.669 0.698 0.723 — — 0.101 0.183 0.251 0.309 0.359 0.402 0.439 0.472 0.502 0.528 0.573 0.610 0.642 — — — — 0.084 0.155 0.215 0.268 0.314 0.354 0.390 0.422 0.478 0.523 0.561 — — — — — — 0.072 0.134 0.188 0.236 0.279 0.317 0.382 0.436 0.481 — — — — — — — — 0.062 0.118 0.167 0.211 0.287 0.347 0.401 — — — — — — — — — — 0.056 0.106 0.191 0.261 0.321 — — — — — — — — — — — 0.096 0.174 0.241 * Acceptance factors based on expansion tank being charged to minimum operating pressure while empty of liquid. Corporate Headquarters 1400 Division Road, West Warwick, RI USA 02893 Telephone: 401-884-6300 • Fax: 401-884-5276 AMTROL Canada, Ltd. 275 Shoemaker Street, Kitchener, Ontario N2E 3B3 Telephone: 519-478-1138 • Fax: 519-748-4231 w w w . a m t r o l . c o m The AMTROL® logo EXTROL® Therm-X-Trol® and Fill-Trol® are registered trademarks of AMTROL Inc. In the interest of continuous development, AMTROL Inc. and it’s subsidiaries reserve the right to alter designs and specifications without prior notice. Part # 9003-031 Rev. B MC# 2680 (9/05) ©2005 AMTROL Inc. Printed in USA 98 Pipe Volumes In Gallons Per Foot Use for Anti-freeze Calculations Type Copper Copper Copper Copper Copper Copper Copper Copper Copper Copper Copper Copper Copper Nominal Pipe Diameter ID " Area sq. in. 1/4" 0.305 0.07 3/8" 0.402 0.13 1/2" 0.527 0.22 5/8" 0.652 0.33 3/4" 0.745 0.44 1" 0.995 0.78 1 1/4" 1.245 1.22 1 1/2" 1.481 1.72 2" 1.959 3.02 2 1/2" 2.435 4.66 3" 2.907 6.64 3 1/2" 3.385 9.00 4" 3.857 11.69 Volume cu in / ft 0.88 1.52 2.62 4.01 5.23 9.33 14.62 20.68 36.19 55.91 79.68 108.04 140.27 Gallons/ft Multiplier 0.0038 0.0066 0.0113 0.0174 0.0227 0.0404 0.0633 0.0895 0.1566 0.2420 0.3449 0.4677 0.6072 PEX PEX PEX PEX PEX PEX PEX PEX 5/16" 3/8" 1/2" 5/8" 3/4" 1" 1 1/4" 1 1/2" 0.292 0.35 0.475 0.574 0.671 0.862 1.053 1.243 0.07 0.10 0.18 0.26 0.35 0.58 0.87 1.21 0.80 1.16 2.13 3.11 4.25 7.01 10.45 14.57 0.0035 0.0050 0.0092 0.0134 0.0184 0.0303 0.0453 0.0631 Steel Steel Steel Steel Steel Steel Steel Steel Steel Steel Steel Steel 3/8" 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 0.493 0.622 0.824 1.049 1.38 1.61 2.067 2.469 3.068 4.026 5.047 6.065 0.19 0.30 0.86 1.50 1.50 2.04 3.36 4.79 7.40 12.74 20.01 28.90 2.29 3.65 10.38 17.96 17.96 24.44 40.29 57.48 88.75 152.83 240.18 346.84 0.0099 0.0158 0.0449 0.0777 0.0777 0.1058 0.1744 0.2488 0.3842 0.6616 1.0397 1.5015 Multiply total length of piping in ft. by gallons per foot multiplier. This will give you total volume of liquid content in piping. Multiply by % of glycol desired to determine gallons of anti-freeze needed. 99 CONVERSIONS CONVERSION FACTORS 1 U.S. Gallon 1 Imperial Gallon Equals 231 Cubic Inches 0.1337Cubic Feet 3.785 Liters 0.833 Imperial Gallons 1 Cubic Foot 1 Liter Equals 1.2 U.S. Gallons Equals Equals 7.48 U.S. Gallons 0.0283 Cubic Meters 0.264 U.S. Gallons 1 Cubic Meter Equals 35.314 Cubic Feet 264.2 U.S. Gallons 999.97 Liters CONVERSIONS To Convert This… P(kW) Kilowatts BAR Of Pressure BAR Of Pressure To This.. Multiply by This… HP Horsepower kW x 1.34= kW ÷ .746= PSI Absolute (PSIA) BAR x 14.5 + 14.7= Pound per square inch of pressure(includes atmospheric pressure at sea level) PSI Gauged (PSIG) Pounds per square inch of pressure as it would be read BAR x 14.5 = on a pressure gauge (does not include atmospheric pressure) PSIG Gauge Pressure Head, Feet PSI x 2.31 ÷ SP.GR= Head, Feet PSIG Gauge Pressure Muliply by .4328 Millimeters Inches (mm) x .0394= Meter Feet (Meters) x 3.28= Centimeters Inches Centimeters ÷ 2.54= °C °F Degree's Celsius Degree's Fahrenheit °F °C Degree's Fahrenheit Degree's Celsius (F-32) ÷ 1.8 Watts Horsepower Watts x .001341= Watts Btu/hr ° C (9/5) + 32= British Thermal Units Per Hour Watts x 3.4127= kW Btu/hr 3412 BTU's=1 kW Boiler Horsepower Btu/hr Boiler Hp x 33479= GPM Liters per second (l / s) 0.06309 GPM Liters per minute (l / min) 3.7854 100