Heat Link MECHANICAL ROOM IN A BOX. SSP Series SS Manifold Pump Panel Installation, Operation, and Maintenance Manual. L6SSPxx000x SSPLR106T SSPSS106B

Transcription

1 SSP Series SS Manifold Pump Panel Manual GROUND LIVE NEUTRAL CAUTION 5 VOLTS ONLY C F SSPLR06T GROUND LIVE NEUTRAL CAUTION 5 VOLTS ONLY C F SSPSS06B MECHANICAL ROOM IN A BOX L6SSPxx000x

2 Table Of Contents Warnings...3 Tools Needed...3 Function...4 Unpacking...5 Panel Components Specifications...8 Panel Component Specifications Manifold Balancing... Recessed Housing Mounting Surface Mount Housing Mounting...7 Piping Hookup...8 Fill and Purge...9 Panel Wiring...0 Panel Control Sequence & Wiring... Troubleshooting... Maintenance... Schematics Mechanical Electrical Detail...5 Electrical Rough-in...6

3 Warnings The zone control panel is for indoor use only and must be installed by a qualified installer/service technician. This product must be installed and operated in strict accordance with the terms set out in this manual and in accordance with the relevant requirements of the Local Authority Having Jurisdiction. Failure to comply will result in a void of warranty, and may also result in property damage, serious injury, or death. Servicing Prior to commencing installation of this panel it is necessary to read and understand all sections of this manual. The symbols below are used throughout this document to ensure proper operation of the panel, and your safety. Please pay attention to these symbols. Warning Possible Hazard Warning Live Power Warning Hot Pipes Warning Treated Water In order to avoid injury or death, switch off the power to the panel prior to inspecting or making connections to the terminal strip. Disclaimer HeatLink Group Inc. shall not be responsible for errors in its brochures or printed materials. HeatLink Group Inc. reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon HeatLink Group Inc. and the Purchaser. All trademarks in this material are property of the respective companies. HeatLink and the HeatLink logotype are trademarks of HeatLink Group Inc. All rights reserved. Tools For Installation Level Screwdriver or power drill Flat head bit Phillips head bit # O-ring Lubricant (#7995 or #7995) 3

4 Function This panel can provide distribution, and zoning for a wide variety of hydronic heating applications. The effectiveness of the system is dependant on the system being designed and installed correctly. Proper consideration of factors such as BTU loads, outdoor design temperature, indoor design temperature, room set-point temperature(s), differential fluid temperatures, head loss, flow rates, and transfer capacities of the heat emitters is critical. Once these factors have been considered and the system requirements determined, these can then be evaluated and compared to the zone control panel capabilities (refer to pages 6-4). Note: This panel does not regulate or monitor the operating safety limit temperatures of the fluid leaving the heat source. 4

5 Unpacking Step Examine carton for any damage that may have occurred during shipping. If damage is visible notify your courier and supplier immediately. Step Open the carton by removing the strapping. Step 3 Remove the cardboard spacers from the carton, then remove the panel from the carton. Lift the panel by the enclosure, not the cover. This panel is heavy; -3 person lift required. Step 4 Remove the cover from the panel by unlocking the coin/screwdriver locks. Lift the top of the cover upwards to disengage the tongues from the slots at the bottom of the panel and then pull the cover off. Step 5 Verify the following items: () " rubber washers ( spares) 5

6 Panel Components # Component Part Number SSPSxxxx SSPLxxxx SSPLxxxx Primary Pump PUMP558 PUMP699 PUMP699 Stainless Steel Manifold 7600 series 7600 series 7600 series Flow Meter Valve Insert (supply) (0-.5 US gpm lock nut) n/a Balancing Valve Insert (supply) n/a n/a 769 Zone Valve Insert (return) Thermometer 4 SS Manifold Port Caps Hose Bib Isolation Ball Valve 7 0V(ac) terminal strip 8 4V(ac) 40VA Transformer 9 StatLink Base Module Enclosure Recessed or Surface Mount Recessed or Surface Mount Recessed or Surface Mount Cover (not shown) Key Lock (installed on cover) Accessory Pack " Washer NTRWSH NTRWSH NTRWSH Optional Installed Items SSAPB - Installed Accessory Pressure Bypass for SS Manifolds 3 SSASLEM - Installed StatLink 4 Zone Expansion Module 4 SSASLEMHD - Installed StatLink Zone Heavy Duty Expansion Module Sold Separately " PEX to Manifold Connectors 5 8" "

7 0 GROUND NEUTRAL LIVE CAUTION 5 VOLTS ONLY C F 06030C SSPLR06T GROUND NEUTRAL CAUTION 5 VOLTS ONLY LIVE C F SSPSS06B 7

8 Specifications SSPSx04x SSPSx06x SSPSx08x SSPSx0x SSPSxx Nominal panel output 45,000 Btu/h 6,000 Btu/h 78,000 Btu/h 90,000 Btu/h Nominal flow 4.5 US 0 F T 6. US 0 F T 7.8 US 0 F T 9.0 US 0 F T Nominal pressure drop outside of based on 50' loops of " tubing panel Max ambient temperature 0 F Max water temperature 80 F Circulator Ferrous, Grundfos UPS5-58 Power supply: pre-wired on system controller 0 V(ac); max. current 3A Auxiliary terminal Yes Piping " piping Piping connections " FNPT Enclosure Galvanized steel, visible parts are satin coated steel. Recessed Surface Mount 4-6 loop 8-0 loop loop 4-6 loop 8-0 loop loop Enclosure Width 34- " (876 mm) 4- " (080 mm) 46- " (80 mm) 34- " (876 mm) 4- " (080 mm) 46- " (8 mm) Enclosure Height 8- " (74 mm) 8- " (74 mm) 8- " (74 mm) 8- " (74 mm) 8- " (74 mm) 8- " (74 mm) Enclosure Depth 5-7 8" (49 mm) 5-7 8" (49 mm) 5-7 8" (49 mm) 5-7 8" (49 mm) 5-7 8" (49 mm) 5-7 8" (49 mm) Door Width 36" (95 mm) 44" (8 mm) 48" (9 mm) 3-7 8" (835 mm) " (038 mm) " (40 mm) Door Height 30" (76 mm) 30" (76 mm) 30" (76 mm) 6.9" (683 mm) 6.9" (683 mm) 6.9" (683 mm) Weight 8

9 60 Panel Component Specifications StatLink 6 Zone Base Module (406) The StatLink base module connects room thermostats to their corresponding actuators. Each zone has an LED which indicates if it is calling for heat. A timer thermostat (46643 or 46673) can send a setback signal to other thermostats via terminal Clock or. As soon as there is a heat demand from one zone, a relay with two dry contacts is switched on (Pump, Boiler ). Add more zones by plugging in the #4034 or #404 module. Specifications: Actuator Contact: Triac Pump Contact: DPST NO relay (8 amps) Other Contact: DPST NO relay (8 amps) Timer Channels: R C C F Thermometer The pipe mounted thermometer reads the supply fluid temperature. Specifications: Temperature range of 3-0 F (0-00 C). 9

10 Circulator The circulators moves the heated fluid through the hydronic system when there is a call for heat from the thermostat. Factory set to 3 rd speed. Specifications: The following pump curves apply. UPS5-58CIL Pump Curve Type UPS 5-58 CIL 5 V ~ 60 Hz 8 μf /(A) P (W) IMPEDANCE PROTECTED FOR INDOOR USE ONLY P/N: PC: 3HLK FR IP4 TF 95 Max..0MPa Max. water temp. 03 F Head (feet) Flow (gpm) st Speed nd Speed 3rd Speed UPS6-99FC Pump Curve Type UPS 6-99 FC 5 V PH 60 Hz 0 uf P/N: 575 P PC: 0939 US /(A) P (w) Class F IMPEDANCE PROTECTED K4 U FOR INDOOR USE ONLY C L US LISTED U MAX. FlUID LISTED L 99K4 TEMP. 30 F Head (feet) Flow (gpm) st Speed nd Speed 3rd Speed 0

11 Stainless Steel Manifold Specifications: Material: Stainless Steel EN.430 (X5CrNi8-0) which is equivalent to SAE 304 (VA) Maximum Trunk Flow Rate: 8 US gpm (4. m3/h) Maximum Circuit Flow Rate: 7600 Series -.5 US gpm (0.34 m 3 /h) 7600 Series -.5 US gpm (0.57 m 3 /h) Return Manifold Primary Balancing. Black cap for manual shut-off only. Use drip cap ➀ for balancing. Flow meter balancing adjustment range: 0-.5 US gpm or 0-5 L/min. Supply Manifold Secondary Balancing (Fine Tuning). Remove locking cap to adjust flow meter. Please note: Do not use tools to adjust flow meters. (Damage to the flow meter will occur, and will not be covered under warranty). CCW = open CW = close CCW = open CW = close CCW = open ➀ CW = close 7600 Series 7600 Series Balancing Notes: Return : Use for primary balancing purposes and manual shut-off. Use drip cap to adjust the return manifold.➀➁ Caution: Opening the return valve too far will result in removing the valve stem. Supply : Use for secondary balancing / fine tuning the flow rate. Remove locking cap to adjust the flow meter by hand, do not use tools. Balancing Method : Valve setting or flow characteristic known (pre-balancing). Fully open supply valve (flow meter) [factory open].. Close return valve completely [factory open]. 3. Open return valve the number of turns as per heatloss calculation or friction head graph. 4. After all valves are set, field adjustments may be necessary. Balancing Method : Only flow rate known. Ensure all supply valves are open [factory open].. Ensure all return valves are open (remove black cap). 3. Use the return valve to adjust flow to desired setting (flow meter). 4. Valves adjusted first may need to be re-adjusted once all other loops have been set. Notes: Hose bib thread is an ASME thread.➁ After fill procedure: the drip cap ➀ should be placed back on to the hose bib ➁. Pipe to manifold connectors sold separately.

12 7600 Series (Flow Meter) Friction Head Graph 30 (90) Stainless Steel Manifold # of turns from closed position (30) 5 (5) Pressure Drop in ft H O (kpa) (3) 0.5 (.5) 0. (0.3) 0.05 (0.5) 0.0 (0.03) 0.0 (0.04) 0.05 (0.9) 0. (0.38) 0.5 (.89) Mass Flow Rate in US gpm (L/min) (3.78) 3 (.36) Working loop flow ranges from 0. to.5 US gpm (0.38 to 4.7 L/m) for floor heating and from.5 to.5 US gpm (5.7 to 9.5 L/m) for snowmelting. Pressure drop must be closely checked when water flow is beyond the upper working range.

13 7600 Series (High Flow) Friction Head Graph 30 (90) Stainless Steel Manifold # of turns from closed position (30) (5) Pressure Drop in ft H O (kpa) (3) 0.5 (.5) 0. (0.3) 0.05 (0.5) 0.0 (0.03) 0.0 (0.04) 0.05 (0.9) 0. (0.38) 0.5 (.89) Mass Flow Rate in US gpm (L/min) (3.78) 5 (8.9) 3

14 SSASLEM - Optional Installed StatLink4 Zone Expansion Module (4034) The StatLink 4 zone expansion module connects to the StatLink 6 zone base module, allowing 4 more room thermostats to connect to their corresponding actuators C SSASLEMHD - Optional Installed StatLink Zone Heavy Duty Expansion Module (4043) The StatLink zone heavy duty expansion module (404) connects to the StatLink 6 zone base module, allowing more room thermostats to connect to up to actuators each. SSAPB - Optional Installed Accessory Pressure Bypass (#76937) Adjustable pressure bypass valve kit for 7600 and 7600 series stainless steel manifolds. This valve prevents a steep rise of the pump head and maintains flow at a stable rate. Also ensures only required amount of circulating water is used for hydronic systems. Specifications: Adjustment Range: bar ( ft H O) 4

15 Recessed Enclosure Mounting Step Use a screwdriver or similar thin tool through the hole to bend the mounting tabs out 90 degrees from the enclosure. Step If electrical wiring will be coming from the top, remove the appropriate knockouts. " - 3 6" - 5 6" 3-7 6" 7 8" O.D " 34- " " 4-3 6" 7-5 8" 40- " 7 8" O.D " 4- " Step 3 Build a x6 supporting frame where the panel is to be mounted. The panel should be mounted at least " above the floor. 5

16 Recessed Housing Mounting continued Step 4 Lift and place the panel onto the supporting frame. This panel is heavy; -3 person lift required. Step 5 Complete the supporting frame by adding a top plate. Be sure to drill corresponding holes in the top plate if any knockouts were removed. Step 6 Secure the panel in place by putting screws into each of the mounting tabs. Note: Panel contents are not shown in the diagrams. 6

17 Surface Mount Housing Mounting Wall Stud Prior to mounting the panel, ensure the wall is capable of supporting the weight of the panel. Top Feed " 4 3-8" 4-5 8" 7-8" Step 4 Lift and place the housing onto the mounting screws. 3-8" 4-7 8" 6-8" 3" 6" 6" GROUND LIVE CAUTION 5 VOLTS ONLY NEUTRAL Note: Skirting by others. 6" Bottom Feed Step 5 Screw the remaining mounting screws into the holes at the bottom of the housing and tighten the top screws. 6" C F Step 3 Screw three of the supplied mounting screws into the wall studs (or backing plywood) leaving ¼" of screw out from the wall. 4' min from floor 40 Step Determine the locations and distance between the wall studs. With a level at a minimum height of 4' from the floor draw a straight line on the wall and mark the stud locations. If the housing cannot be secured directly to the studs, or suitable backing boards, plywood may need to be installed behind the housing to properly secure it in place. 7

18 CAUTION 5 VOLTS ONLY LIVE C F Piping Hookup SSPLR06T shown Primary Return Primary Supply Step Before making any connections, identify the required connections to and from the panel. NEUTRAL GROUND Step Connect mains piping using " MNPT fittings. Note: Use precautions when soldering or applying heat within 6" of the panel. Floor Return Floor Supply Step 3 Connect all tubing to manifold adapters. (7700 series connecters sold separately). Lubricate the inside of the manifold port with silicone o-ring lubricant (#7995 sold separately).. Cut the PEX tubing at a 90 angle. 3. Place the Nut and Split Ring Ferrule onto the PEX tubing. Note: For the 3 4" connecter, the Split RIng Ferrule must be placed inside the Nut before putting them onto the PEX tubing. Method A 5. Push the Brass Insert onto the PEX tubing as far as it will go. 6. Push the PEX tubing with Brass Insert as far as it will go into the manifold module. Ensure the o-ring is clean and take care not to pinch it. Method B 5. Push Brass Insert as far as it will go into the manifold. Ensure the o-ring is clean and take care not to pinch it. 6. Push PEX tubing onto the Brass Insert as far as it will go. 7. Use a wrench to tighten the nut. 90 Brass Insert with O-ring Split Ring Ferrule Nut 8

19 Fill And Purge The following steps are recommended in order to fill the panel with water and purge entrained air once piping is completed, and before activation of the panel. SSTL Series top feed The discharged system fluid from the fill and purge process is not for consumption or washing. D C F E A T B Note: Additional purging steps may be required for the rest of the hydronic system. Note: Step Isolation and drain valves are not included with the panel, but are necessary to properly fill and purge the panel, and to isolate the panel for service. Ensure the panel is not powered. SSP Panel Step Fully close valves A, B, and C. Fully close all supply E and all return F manifold valves. Fully open valve D. SSTL Series bottom feed Step 3 Attach a purge hose (not included) to D. Pressurize the main supply line. Open valve B. Step 4 Open the first return manifold valve F. Open the first supply manifold valve E. Watch the hose in the pail until you observe a steady stream of water (no air or spitting). Close the first return manifold valve F. T E F C D Step 5 Step 6 Repeat Step 4 for each loop until all loops are filled with water, and air is purged from pipes. Purging is complete when there is no more air and/or spitting. Close valve D then valve B. B A SSP Panel Step 7 Remove hose from drain valve D. Step 8 Check for leaks at connections. If any leaks are found use a back-up wrench and carefully tighten until leak stops. Do not overtighten. 9

20 Panel Wiring Note: Terminal headers are removable to make wiring connections easier. Thermostat Wiring 4V low voltage power may be supplied to the thermostat. Wiring of thermostat should be done by qualified electrician and should meet local codes and jurisdictions. Wiring to the terminal strip requires 8 gauge 4 wire. W R C Signal 4 V -Wire Thermostat (battery only or non-electric) W R C Signal 4 V 4 V 3-Wire Thermostat (HeatLink thermostats) W R C Signal Jumper to Dry Contact 4 V 4 V 4-Wire Thermostat (with dry contact signal) Other Terminals Auxiliary Contacts Actuator Contacts The auxiliary contact set is dry, meaning no supply of power is present at the terminal. The maximum allowable load is 8A. The auxiliary dry contact located on the terminal is to switch another device (ie. the heat source) when there is a call for heat from any zone. Connect up to 4 actuators per zone. Auxiliary Contacts 0

21 Panel Control Sequence. When power is provided to the 0V terminals connected to the power module, the transformer provides 4V power to the StatLink Base Module.. When the thermostat calls for heat, its internal 4V contacts close, the StatLink Base Module dry contacts close, and the pump 3 turns on. If actuator(s) 4 are connected to the thermostat's zone, the actuator(s) will open. 3. When the requirements of the thermostat are met, the internal contacts of the thermostat open, the StatLink Base Module dry contacts open, and the circulator stops. If actuator(s) 4 are connected to the thermostat's zone, the actuator(s) will close. 3 4

22 Troubleshooting Problem Check / Verify Possible Cause Low Temperature Within Room Misplacement of thermostat location within room. Low temperature setting of the thermostat. The system fails to turn on if the thermostat is set to high setting The electronic actuator fails to open during a call for heat Low supply mixed fluid temperature. Wiring from heat source to panel. Output of heat source is unable to meet demand of heating system. Circulator is not on during a call for heat. (Use a stethoscope or similar device to verify) A qualified electrician should verify 4V power is supplied to the thermostats and actuator. Make sure thermostat is not being influenced by an additional heat source, such as lighting or air duct. Adjust the temperature setting on thermostat. Thermostat may be out of calibration or defective. Replace thermostat. The electronic actuator may be improperly seated or may be defective. Replace if necessary. Adjust the Mixing Valve to the appropriate settings. Check that the wiring is done properly. Consult qualified electrician prior to alteration of wiring between heat source and panel. Compare output of heat source to the requirements of the heating system. The StatLink module or circulator may be defective. The 4V transformer may have failed. High Temperature Within Room Check current setting of the thermostat. Adjust the temperature setting on thermostat to a lower setting. High supply mixed fluid temperature. Installed electronic actuators remain open after the thermostat is satisfied. Adjust the Mixing Valve to the appropriate settings. An obstruction inside the zone valve is not allowing the actuator to fully close or the thermostat is still calling for heat. Maintenance Yearly maintenance should be done on the panel prior to each heating season to ensure the efficient and accurate operation of the panel. Complete the following check list: Raise all thermostats to cause a call for heat within the system. Verify that the circulator starts, via a stethoscope or similar device. Confirm that the Auxiliary Contacts close. If applicable, verify that each zone valve opens during the call for heat the actuator should be warm to the touch, the LED will light up (on 560x models) and the white indicator should rise from the top of the actuator. Return all thermostats to a desirable setting. You are now ready for another heating season with HeatLink.

23 For all SSP panels, primary piping with circulator must have no pressure differential between panel primary supply and return, i.e. close tees. Thermostat Heat Source (e.g. Boiler or Heat Exchanger) T SSP Panel SSP Panel Control: Pump Control A.HeatLink Thermostat #46544 B. BMS System Zone Control for Stainless Steel Manifold A. Manual (Default) B. HeatLink StatLink 6 Zone Base Module #406 (Included) and HeatLink Actuators #560 (Optional) Notes: Drawings are for HeatLink suggested system layout only! User must determine if system layout will work for their particular application. Air vents, expansion tanks, pressure relief valves, etc. for heat source as per local codes. Use isolation ball valves for all circuits and components. Local codes, regulations, and authorities have final jurisdiction. Heat Source: Panel(s): Heat Load(s): Date: Generic SSP Series Radiant Heating Schematic #: Rough-in wiring see: Wiring detail see: SCH-SSP-M00 3

24 Cold Water Supply Outdoor Sensor 3355 Compact Mixing Reset Control Menu Menu Item R Boiler M P P Notes: Drawings are for HeatLink suggested system layout only! User must determine if system layout will work for their particular application. Air vents, expansion tanks, pressure relief valves, etc. for heat source as per local codes. Use isolation ball valves for all circuits and components. Local codes, regulations, and authorities have final jurisdiction. Circuit Balancing Valves by Thermostat others Thermostat Thermostat T T T SSP Panel SSP Panel SSP Panel Heat Source: Panel(s): Heat Load(s): Boiler SSP Series Heating Schematic #: Rough-in wiring see: SCH-SSP-M0 Date: Wiring detail see: SCH-SSP-E0 Item 4

25 C W R NTC L N G SSP Panel AUX R C W R C Notes: Drawings are for HeatLink suggested electrical schematics only! User must determine if electrical schematic will work for their particular application. User must also confirm all HeatLink schematics with manufacturer schematics of each particular control chosen. In all cases manufacturer equipment schematics will take precedence over HeatLink electrical schematics. Local codes, regulations, and authorities have final jurisdiction HeatLink Mixing Reset Control Perm / Ext Dem Lock / Unlock Setback / Off Opn 3 Com Cls No Power Timer IN Com MIX Com OUT Pwr Pwr Sys Dem C R Pump Com 6 Heat Dem 7 8 Boiler Wiring as shown applies for mixing valve supply on the left. If mixing valve supply is on the right, reverse terminal & 3 leads. M N Mix Sensor Supply Outdoor Sensor Boiler Contacts C W R NTC L N G SSP Panel AUX R C W R C L N G SSP Panel AUX Application: Multiple SSP Panels Schematic #: Rough-in wiring see: Date: C W R NTC W R C R C SCH-SSP-E0 black brown blue L N 4 Vac Class II Transformer 0V or 0V P C 4 V R P Rough-in wiring see: SCH-MRIB-R00 R 4 Vac DPDT Relay Rough-in wiring see: SCH-MRIB-R00 Rough-in wiring see: SCH-MRIB-R SCH-MRIB-R00 5

26 Heat Source Room Thermostat Standard 4-wire to be run from thermostat to mechanical room. Floor Sensor (optional) Standard -wire to be run from thermostat to floor sensor Notes: Drawings are for HeatLink suggested electrical schematics only! User must determine if electrical schematic will work for their particular application. User must also confirm all HeatLink schematics with manufacturer schematics of each particular control chosen. In all cases manufacturer equipment schematics will take precedence over HeatLink electrical schematics. Local codes, regulations, and authorities have final jurisdiction. 4 Heating Load Application: Rough-in Wiring for One Zone Heating Schematic #: Date: SCH-MRIB-R00 6

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28 Canada Manufactured & distributed by HeatLink Group Inc. Head Office: 4603E - 3 th Street N.E. Calgary, Alberta, TE 6M3 Toll Free: International Phone: + (403) Fax: China Distributed by Cathay-Links International Phone: Fax: Ireland Distributed by Jamoni Ltd. Phone: Fax: Freephone: México Distributed by Distribuidora Caisa S.A. de C.V. Phone: (5-55) Fax: (5-55) United States Distributed by HeatLink Group Inc. USA Distribution Center: th Street SW, Suite B Byron Center, MI, 4935 Toll Free: Fax: info@heatlink.com April 9, 07 HeatLink, the HeatLink logo, and Mechanical Room in a Box logo are either registered trademarks or trademarks of HeatLink Group Inc. Printed in Canada HeatLink Group Inc.