Allcan TM Installation Manual

Transcription

1 Allcan TM Installation Manual

2 NOTICE: READ THESE INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW INSTRUCTIONS VOIDS WARRANTY. Introduction: The PHP Allcan (USA patent pending) is a complete primary/secondary zoning package including air elimination and additional zone mixing capability. The Allcan reduces the space required for installation by utilizing an innovative pipe-in-pipe design and hydraulic separation that allows for a compact assembly. This process reduces the required time and materials typically used in a field-assembly of a zoned radiant heating system. Additionally, with the reduction of copper pipe and fittings, solder and flux, and space requirements, the Allcan contributes to green practices by reducing the amount of waste and the amount of transportation costs inherent in the supply of standard copper piping materials. The Allcan improves installation efficiency since the majority of system piping requirements are included within the compact design. Components are positioned properly for optimal performance. The expansion tank is located at the Point of No Pressure Change. The primary piping includes the primary circulator and taps for an indirect water tank while the secondary side can include up to 6 zone pumps. The Allcan can be fitted with either a 3-way manual mixing valve or a 3-way Taco ivalve to achieve multiple temperature delivery. Built into the assembly is a unique air eliminator which, combined with a pressure-reducing fill valve, completes the predominant system components. The use of end-suction flanges on zone pumps allows the output of the pump to be directed to facilitate piping connections. The end-suction flanges also contribute to the compact nature of the Allcan by limiting the width to 16 inches. The Allcan is also available with in-line pumps as an alternative pump option. The in-line pumps increase the width to 32 inches. The installing contractor saves installation time and space requirements in the mechanical room while being assured of proper system performance. The Allcan eliminates piping errors that may occur in field-assembled installations, especially when those installations include primary/ secondary, indirect water tank, zone pumping and mixing requirements. The Allcan is factory pressure-tested and PHP provides a 3-year leak-free warranty. Hydraulic Separation: The internal hydraulic separation chamber hydraulically uncouples the primary and secondary loops to prevent ghost flows similarly to closely-spaced Tees. Mixing patterns are dependent on flow rates in the primary and seconday loops as shown. A: Primary loop flow is GREATER than secondary loop flow - the secondary zones will always be the temperature of the primary loop. Secondary loop B: Primary loop flow EQUALS secondary loop flow - there is no mixing in the chamber. The secondary loops are the temperature of the primary loops and the boiler return is the temperature of the secondary return. C:Primary loop flow is LESS than secondary loop flow - secondary loops will be lower temperature than primary loop. Secondary loop Primary loop A B C Primary loop

3 Allcan TM Details Removable top assembly with two O-rings attaches with four screws (allows for Swirl Chamber instection and clean-out) Spriotop and internal Swirl Chamber eliminate air Top mounting bracket Zone pumps with end-suction flanges and check valve (pump outlet may be rotated up or down to accommodate system piping) Secondary-loop returns Temperature/pressure gauge Lower mounting bracket Sediment clean-out port Internal hydraulic separator Removable bottom assembly with two O-rings attaches with four screws (must be aligned with return line forward) Fast-fill pressurereducing valve Primary boiler pump with check valve (direction of flow is down when installing pump) Indirect DHW supply Boiler supply Indirect DHW return Boiler return Expansion tank with mounting bracket

4 Component Details: End-suction pumps: The default configuration for the secondary-loop pumps is the Grundfos I speed pump mounted to a proprietary PHP end-suction flange. The end-suction flange allows fluid to be drawn into the center of the pump impeller. The fluid is then directed 90 o from to inlet to the outlet. The pump must be mounted horizontally to properly lubricate the bearings. However, the outlet may be rotated up or down to facilitate system piping. Mixing options: To provide multiple secondary temperatures, the end-suction pumps may be fitted with a manual 3-way mixing valve kit or a Taco 3-way ivalve. When a mixing valve kit is used, the pump points sideways. The pump inlet must remain horizontal, however, the outlet may still be rotated. Pump outlet may be rotated 90 o. Outlet may be up, down, back, or forward. Pump inlet must be horizontal For the pumps and air elimination to work properly, the Allcan MUST be mounted vertically with the Spriotop at the top. Check valves: All zone pumps include a spring check assembly. The larger piece with the spring check goes onto the pump outlet, followed by the sweat adaptor. Use the supplied gasket to connect the spring check assembly to the pump outlet. The Allcan primpary pump may be used as a variable-speed injection pump allowing the Allcan to function as a variable-temperature injection module. The Allcan primary pump will be operated by a variable-speed injection controller. A separate primary-loop pump will be needed to maintain system flow and/or return water temperature to the boiler. Air elimination: At the top of the Allcan body is the Swirl Chamber. When a zone pump is operating, water is directed against the chamber wall causing it to swirl. This change of direction and volume causes a pressure change in the water to effectively eliminate air. The water swirls up the chamber wall and is drawn between the chamber wall and outer Allcan wall into the supply chamber where the pumps circulate to the various zones.

5 Allcan TM Operation 4) Compact, space-saving end-suction pumps circulate water to heating zones from the supply chamber of the Allcan. 3) Spirotop releases air from swirl chamber. 2) When a secondary-loop pump turns on, water travels up the internal supply pipe to the swirl chamber where aire is released. The water then flows between the Allcan wall and swirl chamber into the supply chamber where it is pumped to the corresponding zones. 5) Secondary-loop return water enters the internal return header which directs the flow back to the hydraulic separation chamber. The hydraulic separation chamber is the space between the circular plate with the secondary-loop supply/return connections and the bottom assembly with the primary-loop supply/return pipes. 1) Primary loop water circulates from the boiler to the hydraulic separation chamber. If there is no flow from the Allcan secondary-loop pumps, the primary-loop pump will circulate water from the boiler supply, through the hydraulic separation chamber, and back to the boiler. No heated water will be supplied to the zone pumps. Primary-loop return Primary-loop supply

6 Installing the Allcan: READ THESE INSTRUCTIONS CARE- FULLY. FAILURE TO FOLLOW INSTRUC- TIONS VOIDS WARRANTY. Installing the Allcan requires that you are a qualified installer with knowledge of local, national and other applicable building and mechanical codes, as well as an understanding of good hydronic practice, heat transfer, building heat requirements, friction losses, flow and control. If you do not have these skills you should not install the Allcan. It is the installers sole responsibility to verify the suitability of the Allcan for the project in which it is to be installed. 1) Unpack the Allcan and make sure you have received all the parts in good condition. Verify you have received the correct model for your job. The Allcan is available in the models shown elsewhere in this manual. The primary loop return pump and boiler return piece are normally shipped unattached. The return pump will be the conventional inline pump. The end suction pumps will be packed in boxes with the check valve assemblies on the outlet flange. The spirotop air vent may be removed in larger models so it will fit in a smaller box. The expansion tank, fill valve and expansion tank bracket are a separate assembly that will be installed once the Allcan is securely mounted to the wall. 2) Evaluate your mechanical room space and decide where you will place the Allcan with consideration where other components will be placed, and the components that will be connected to the Allcan. Also check as to required clearances to electrical panels and other components in a mechanical area. 3) It is recommended that 3/4 plywood be attached to the wall behind the Allcan installation location with the 3/4 plywood securely attached to framing. 4) Mount the Allcan vertically to the plywood, using four (4) 1 lag screws on both the upper and lower support bracket struts. Use washers to prevent the lag screws from working through the strut. 5) If the Spirotop has been removed for shipping, reinstall it using teflon sealing tape on the 1/2 threads. Do not over tighten. 6) Install the primary loop return pump and boiler return pipe assembly to the bottom of the Allcan. Use a gasket and 2 pump bolts on either side of the pump to securely attached the pump to the flanges. Make sure the direction of flow arrow of the primary loop return pump is DOWN. 7) Remove the end suction pumps from the boxes and attach them to the secondary loop outlet union flanges on the left and right of the Allcan. Use one of the provided gaskets on each. The check valve assembly is on the outlet of the pump. To this is attached a flanged sweat union. To prevent damage to the check valve, remove this flanged sweat union and sweat a starter piece of copper pipe to it then reattach the union to the check valve assembly. Make sure both the check valve assembly and the sweat union have a provided gasket installed and tighten. 8) Install fill/expansion tank assembly by aligning fill pipe union, and attaching expansion tank bracket to the plywood with two (2) 1 lag screws. 9) Pipe secondary-loop supply and return zones to the Allcan. Use a starter piece of copper as described in step 7 above to begin the secondary-loop supply piping from the end suction pumps. It is advisable to install a purge valve on the secondary loop return lines at a high point just before the connection to the Allcan secondaryloop return port ball valve. This will facilitate purging air out of the system with the secondary return port valve closed. 10) Pipe between the Allcan primary-loop supply in port to the boiler supply out port. Pipe between the Allcan primary loop return out port to the boiler return port.

7 11) If an indirect water tank is being used with the Allcan, pipe to and from the Allcan indirect supply and return ports. Be sure to use an appropriately sized pump with a spring check valve and good piping practice to prevent inducing undesired flow through the indirect tank. A DHW kit with the pump may be ordered from PHP. If indirect DHW tank is not being used make sure DHW taps are capped. 12) Pressure test the system as required by good practice and code. Wire pumps and controls. Fill with fluids. If necessary, protect system from freezing with propylene glycol or other methods. 13) Purge primary- and secondary-loops prior to operation of boiler or other heated water producing appliance. Purge secondary-loop zones one at a time sequentially with the secondary-loop return port ball valve closed and purge valve recommended in step 9 open and connected to a hose terminated out of doors or in a drain. Then once all zones have been purged close purge valves, open secondary-loop return port ball valves and run secondary-loop pumps sequentially to further purge system. Then operate primary-loop and DHW pumps to purge primary-loop. Only after system is well purged should boiler or other heated water prodcucing appliance be operated. Installing the Allcan with Taco in-line pumps: The support bracket for the Allcan is much wider to accomodate the in-line Taco pumps which point out sideways from the left and right of the Allcan. Mount the pumps to the flange with direction of flow pointing outward. Use only pumps with an internal spring check valve. Use one cushion clamp per pump to clamp the outboard side of the pump flange assembly to the vertical outrigger strut. When installed with in-line pumps, the unit is approximately 32 wide as opposed to the 16 wide Grundfos end-suction flange version, The two models are NOT interchangeable. Mixing modules are not an option when using in-line pumps. WARNINGS! Never operate boiler with expansion tank disconnected or isolated from the system. Failure to do so can result in explosive condition, injury or death. Purge air from system before operating pumps. Water lubricated pumps will fail if air-locked or run dry for extensive periods of time. Many boilers require a specific flow for correct operation and can differ significantly in resistance to flow. This may or may not require a pump substitution. It is the installers responsibility to verify the correct pump. Failure may cause premature failure of boiler or a dangerous condition. Make sure boiler or heat source has properly operating 30 PSI pressure relief valve connected to the system and and in good working condition. Never isolate it. Failure to do so may result in explosive condition, injury or death. It is the installers responsibility to install a code compliant backflow preventor on the fill line. The expansion tank supplied with the Allcan may not be the correct or adequately sized tank under certain conditions. It is the installers responsibility to verify that it is adequate, and if not replace it with a larger tank or add another so that the acceptance capacity is adequate for the system. Read and follow all instructions of components supplied as part of the Allcan. Always disconnect power from any component of the allcan or any connected to the Allcan before servicing the unit. Failure to do so could result in burns, electrocution, injury or death. For indoor hydronic use only. Do not use with steam or in steam heating applications.

8 Sample Mechanical Room Dimensions Front View Side View

9 Notes

10 Submittal Data Information Allcan tm Job: Engineer: Contractor: Rep: ITEM NUMBER MODEL NUMBER Application: The Allcan is a hydraulic separator with a high quality air separator built in. It is the space saving complete solution for any boiler. When configured with end-suction flanges, the top two pumps may be swiveled up and the bottom two down to aid in easy piping to the secondary-loop heating zones. This product comes with wall mounting brackets, fill valve, expansion tank, internal air separator, air vent, secondary loop Grundfos end-suction zone pumps (standard) or Taco 00R-MS in-line pumps (optional), primary loop pump/indirect water tank pump as specified, primary loop T s for an indirect water tank kit, and wall mounting hardware that includes an expansion tank retention mount. Optional secondary-loop mixing kits for multi-temperature systems are available using manual 3-way mixing valves or Taco 3-way ivalves. Models: All Products U.S. Patent Pending Part Number Description Primary & Optional Indirect Pump Secondary Pump PHP-ALLCAN-2G PHP-ALLCAN-2T PHP-ALLCAN-4G PHP-ALLCAN-4T PHP-ALLCAN-6G PHP-ALLCAN-6T 2-zone with Grundfos pumps 2-zone with Taco pumps 4-zone with Grundfos pumps 4-zone with Taco pumps 6-zone with Grundfos pumps 6-zone with Taco pumps UPS FC 0011-F UPS FC 0011-F UPS FC 0011-F UPS FC 00R-MS UPS FC 00R-MS UPS FC 00R-MS Note: The available head and flow in any manifolded pumping application is surprisingly dynamic. When more pumps come on, flow goes up, but not in a linear way since it is also influenced by the pressure drop and total flow rate of the manifold. Thus available flow at the same head loss will be reduced per pump when multiple pumps are on. Due to the dynamic difficulties of predicting all possible permutations of pressure and flow with multiple pumps and with multiple speeds it has become customary in the industry to use the single pump curves to design for each individual zone. Head (ft) Grundfos 1 UPS FC (hi spd) 2 UPS FC (med spd) 3 UPS FC (low spd) 4 UPS FC (hi spd) 5 UPS FC (med spd) 6 UPS FC (low spd) Flow (gpm) Head (ft) Taco F 2 00R-MS (hi spd) 3 00R-MS (med spd) 4 00R-MS (low spd) Flow (gpm) Precision Hydronic Products - Division of JL industries, inc NE 79th Court - Portland, OR Phone: ; Fax:

11 Submittal Data Information Allcan tm Job: Engineer: Contractor: Rep: ITEM NUMBER MODEL NUMBER Precision Hydronic Products - Division of JL industries, inc NE 79th Court - Portland, OR Phone: ; Fax:

12 Precision Hydronic Products Airport Business Center 6730 NE 79th Court - Portland, OR Phone: ; Fax: