Instruction manual EN Version 2.0 /Release 06/2012
Table of content 1 Key background information...3 1.1 Limitation of liability...3 1.2 Responsibilities of the operator...3 1.3 Documentation...3 1.3.1 Contents and structure...3 1.3.2 Labelling system used in the documentation...4 1.4 Target group...4 1.5 Replacing wear parts...4 2 Safety...5 2.1 Important safety notices...5 2.2 Instructions for correct use...5 2.2.1 Area of use...5 2.2.2 Environmental conditions relevant to safety...5 2.3 Observance of the operating instructions...6 2.4 Residual risks and safety measures...6 3 Setup...7 4 Assembly and commissioning...8 4.1 Safety...8 4.2 Assembly...9 4.3 Initial operation...10 5 Maintenance...11 5.1 Safety...11 5.2 Recommended maintenance intervals...11 5.3 Maintenance works...12 5.3.1 Dismantle the circulation pump...12 5.3.2 Install the circulation pump...13 5.3.3 Dismantle the 3-way mixer...14 5.3.4 Install the 3-way mixer...15 5.3.5 Servomotor 3-way mixer...15 5.3.6 Change the supply and return flow...16 6 Technical data...17 7 Decommissioning, recommissioning...19 7.1 Decommissioning...19 7.2 Recommissioning...19 8 Dismantling...19 9 Disposal...19 9.1 Safety...19 9.2 Disposal...19 Page 2 Version 2.0 06/2012
1 Key background information 1.1 Limitation of liability The contents of these operating instructions have been created with due consideration of applicable legislation and standards. The device has been developed in accordance with the technological state of the art 1. The manufacturer accepts no liability for damage resulting from: X X X X X X Disregard for or non-compliance with the operating instructions Deliberate misuse Incorrect use The use of untrained professionals (for maintenance and repair work, etc.) Technical modifications to the device that have not been discussed with the manufacturer. Use of spare parts that have not been approved by the manufacturer 1.2 Responsibilities of the operator The safety, accident prevention and environmental protection regulations applicable to the area in which the device is used must be complied with. The following is of particular relevance: X X X The operator must ensure that these operating instructions are available for the entire life cycle of the. The operator must ensure that the maintenance intervals described in these operating instructions are complied with. The operator must ensure that all safety devices are being checked for proper function and completeness. notice When assembling and operating the, be aware of country-specific standards and guidelines. 1.3 Documentation 1.3.1 Contents and structure These operating instructions are an integral part of the device. They contain instructions and information regarding the safe use of the device and must be made available to all users for the device's entire life cycle. These operating instructions are intended for use by trained professionals. 1 Technical modifications reserved! 06/2012 Version 2.0 Page 3
1.3.2 Labelling system used in the documentation The following types of alert are used: Alert type Representation Meaning Acute danger of death danger Dangerous situation that will inevitably cause death or severe injury if it is not avoided Risk of death and severe injury warning Dangerous situation that may cause severe injury or death if it is not avoided Risk of mild to moderate injury caution Dangerous situation that may cause mild to moderate injury if it is not avoided Information, tips to make operation easier notice Indicates information that does not relate to personal hazards, e.g. warnings regarding material damage $ $ Indicates a general safety notice Indicates an instruction @ Indicates the consequences of an action 1.4 Target group These operating instructions are intended for use by trained professionals. The operator of this device must ensure that suitable and safe conditions are in place as described in these operating instructions. Professional Trained expert who understands the risks of the and who is familiar with the technology used in the device. Professionals are trained and capable of assembling, maintaining and repairing the device. 1.5 Replacing wear parts Be aware that the contains parts which, depending on how frequently and how much they are used, will be subject to technology-related wear and tear, even if they are cared for and maintained properly. Mechanical parts and components that come into contact with hot water and steam are particularly affected by this, such as hoses, gaskets, valves, etc. Wear-related defects of course do not represent faulty workmanship and are therefore not covered by the warranty or guarantee; regardless of this, faults and malfunctions must always only be rectified by trained professionals. For more information, contact your dealer. Page 4 Version 2.0 06/2012
2 Safety 2.1 Important safety notices $ $ Read these operating instructions carefully before use. $ $ Only connect the to a power supply that complies with the mains voltage specifications stated on the 's rating plate. $ $ Before carrying out any maintenance, cleaning or repair work, the power supply to the must be disconnected. $ $ Maintenance, cleaning and repair work must only be carried out by trained professionals. $ $ In the event of damage to the or if its function is impaired, the must not be used. Contact your dealer immediately. $ $ Note the maintenance instructions and intervals. $ $ Protect the from the influences of weather. $ $ Never use the outdoors. $ $ For your own safety and to ensure the long service life of the, you should only use original spare parts. $ $ The device must only be used in accordance with the instructions for correct use. 2.2 Instructions for correct use 2.2.1 Area of use The has been built in accordance with the technological state of the art and in compliance with safety technology regulations. No liability will be accepted for any damaged caused by inappropriate use, misuse, incorrect connections or incorrect maintenance / repair by untrained personnel. Such cases will also invalidate all warranty clauses. The is used to deliver heating water in heating systems. The is fully pre-assembled and designed for installation on a wall. The is not intended to be used by persons (including children) with limited physical, sensory or mental capacities or a lack of knowledge and experience. 2.2.2 Environmental conditions relevant to safety The must not be assembled or operated outdoors. The components are not UV resistant. The installation location for the must be selected so that maintenance and repair work can be carried out when required. 06/2012 Version 2.0 Page 5
2.3 Observance of the operating instructions notice Read these operating instructions carefully before use. To ensure the device is operated safely, the instructions in this operating manual as well as regional regulations (e.g. health and safety regulations) that must be made available to the operator of the device must be complied with. 2.4 Residual risks and safety measures Electrical energy! danger Risk of death from electric shock. h Do not touch live cables or components with wet hands. h Be aware of health and safety regulations when handling electric current. Hot water! warning Risk of severe scalding. h When draining the, do not touch the hot water. h Allow the to cool down before carrying out any maintenance, cleaning or repair work. Hot surfaces! warning Risk of severe burning. h During operation, do not touch any pipes or components. h Allow the to cool down before carrying out any maintenance, cleaning or repair work. h Wear heat-resistant safety gloves when having to work on any hot components. caution Working on the device by inadequately trained personnel! Risk of injury and material damage. h Maintenance, cleaning and repair work must only be carried out by trained professionals. Page 6 Version 2.0 06/2012
3 Setup HK 8130/8180 with HK 8130/8180 without 3-Way-Mixer A B 3-Way-Mixer 1 2 3 4 5 D C Fig. 1: Type overview 1 Ball valve with thermometer (return line) 4 3-Way-Mixer 2 Ball valve with thermometer (supply line) 5 Actuator 3 Circulation pump A Return input B Supply outlet C Supply input D Return outlet HK 8130 HK 8180 130 40 130 12 130 40 130 320 308 370 358 12 Fig. 2: Dimensions [mm] 125 300 125 300 06/2012 Version 2.0 Page 7
4 Assembly and commissioning 4.1 Safety Electrical Energy! hazard Mortal danger through electrical shock. h Do not touch the live cables or components with moist hands. h Follow the accident prevention regulations when dealing with electrical current. caution Hazard through material damages! The pump assembly is not protected against spraying and dripping water. h Install the pump assembly only in a dry location. caution Material damages through pressure shocks! Occurrence of pressure shocks caused by rapid opening of the gate valves. h Open the gate valves always slowly and in a controlled manner. note The assembly and commissioning of the pump assembly may be performed only by qualified professional technicians. Please follow the country-specific standards and directives when installing and commissioning the pump assembly! Do not make any changes to the components (e.g. pumps, valves etc.), supply and discharge lines, and/or safety equipments which may impair the operational safety of the pump assembly. Please ensure that the power supply to the pump assembly is always freely accessible. note Wear personal safety equipment during maintenance, cleaning and repair work. Seite 8 Version 2.0 06/2012
4.2 Assembly note Install the pump assembly in such a way that it is placed at eye level. Dismantle the front encasing of the pump assembly. Fig. 3: Dismantle encasing (represented in type 8130) Mark the drilling points for installing pump assembly. 130 40 130 12 Fig. 4: Drilling dimensions [mm] Drill the holes corresponding to the screw and anchor size. Place the anchor. Insert the pump assembly. Screw the screws into the anchor. Connect the front and return lines (system connections, See Fig. 1 on page 7). Check all the screw connections for firm position. 06/2012 Version 2.0 Page 9
4.3 Initial operation Requirement is completely installed. Connect power supply. Connect the power supply of the pump assembly. note The electrical installation of the pump assembly may be performed only by trained technicians. @ The pump assembly switches on automatically after connecting the power supply. Vent the heating equipment. note Switch off the circulation pump during the venting process. Thermometer handle settings A B C Fig. 5: Thermometer handle settings A B C Operational setting: check valve operational; ball valve open Empty: check valve open; ball valve ½ open (only in the supply run) Service setting: ball valve closed Seite 10 Version 2.0 06/2012
5 Maintenance 5.1 Safety Electrical Energy! hazard Mortal danger through electrical shock. h Do not touch the live cables or components with moist hands. h Follow the accident prevention regulations when dealing with electrical current. h Stop the power supply of the pump assembly before undertaking any maintenance, cleaning and repair works and secure it against being switched again. Hot water! warning Severe burns possible. h Let the pump assembly cool down before undertaking any maintenance, cleaning and repair works. h Do not touch the hot water when rinsing, filling and emptying the pump assembly. Hot surfaces! warning Severe burns possible. h Do not touch the pipes and components when doing maintenance, cleaning and repairs works. h Let the pump assembly cool down before undertaking any maintenance, cleaning and repair works. h Wear heat-resistant safety gloves when you need to work with hot components. 5.2 Recommended maintenance intervals Job Check gate and ball valves for smooth movement Watch out for any noise development in the pump Check the pump assembly for leakages (visual inspection) Check the 3-way mixer for proper operation Check the actuator for proper operation Annual Annual Annual Annual Annual Interval 06/2012 Version 2.0 Page 11
5.3 Maintenance works 5.3.1 Dismantle the circulation pump Stop the power supply of the pump assembly and secure it against being switched on again. Electrical Energy! hazard Mortal danger through electrical shock. h Do not touch the live cables or components with moist hands. h Follow the accident prevention regulations when dealing with electrical current. h Stop the power supply of the pump assembly before undertaking any maintenance, cleaning and repair works and secure it against being switched on again. Dismantle the front encasing of the pump assembly (see Fig. 3 on page 9). Close the ball valves (multifunction armature, Pos. A) by rotating the thermometer handle (see Thermometer handle settings on page 10). One after another dismantle the lower insulation (Pos. B), the thermometer handles forward and return travel (Pos. A) as well as the upper insulation (Pos. C). A A C B Fig. 6: Dismantle insulations (represented in type 8130) Loosen the wiring of the circulation pump. Page 12 Version 2.0 06/2012
Loosen the nuts (Pos. A) and dismantle the circulation pump (Pos. B). Hot water! warning Severe burns possible. h Let the pump assembly cool down before undertaking any maintenance, cleaning and repair works. h Do not touch the hot water when emptying the pump assembly. B A Fig. 7: dismantle the circulation pump (represented in type 8130) 5.3.2 Install the circulation pump Replace damaged or defective sealings if required. Insert the circulation pump and tighten the nuts (tightening torques see Technical data on page 17). Connect the wiring of the circulation pump. Slowly open the ball valves (multifunction armature, Pos. A, Fig. 6 on page 12) by rotating the thermometer handle (see Thermometer handle settings on page 10). Apply pressure gently to the circulation pump and vent the equipment if required. note Switch off the circulation pump during the venting process. 06/2012 Version 2.0 Page 13
Check the pump assembly for tightness. Reconnect the power supply of the pump assembly. Dismantle the thermometer handle. Install the inner insulations, the thermometer handle and the front encasing. 5.3.3 Dismantle the 3-way mixer Stop the power supply of the pump assembly and secure it against being switched on again. Electrical Energy! hazard Mortal danger through electrical shock. h Do not touch the live cables or components with moist hands. h Follow the accident prevention regulations when dealing with electrical current. h Stop the power supply of the pump assembly before undertaking any maintenance, cleaning and repair works and secure it against being switched on again. Dismantle the front encasing of the pump assembly (see Fig. 3 on page 9). Close the ball valves (multifunction armature, Pos. A) by rotating the thermometer handle (see Thermometer handle settings on page 10). Dismantle the lower insulation. Bring the boiler into the middle position with the help of manual adjustment of the mixer motor. Dismantle the mixer motor (Pos. B, the assembly/dismantling of the mixer motor should be taken from the respective manufacturer s manual). Dismantle the mixer (Pos. A) by loosening the swivel nuts. A B Fig. 8: 3-way mixer Page 14 Version 2.0 06/2012
5.3.4 Install the 3-way mixer Replace the sealings at the screw connections. Insert the 3-way mixer and tighten the nuts (tightening torques see Technical data on page 17). Install the mixer motor (Pos. B, Fig. 8 on page 14). $ $ The assembly/dismantling of the mixer motor should be taken from the respective manufacturer s manual. note Watch out for the correct insertion position when inserting the 3-way mixer. Slowly open the gate valves of the supply and return lines. Apply pressure to the heating equipment and vent it if required. note Switch off the recirculation pump during the venting process. Check the pump assembly for tightness. Reconnect the power supply of the pump assembly. Install the insulations and the front encasing. 5.3.5 Acutator 3-way mixer note The correct positioning of the bearing shaft must be checked when retrofitting the acutator. A Fig. 9: Settings boiler A Boiler 1 Boiler in position 1: mixer closed 2 Boiler in position 2: mixer open 06/2012 Version 2.0 Page 15
B Fig. 10: settings bypass lever B Bypass lever 3 Setting of the bypass lever (B): bypass closed 4 Setting of the bypass lever (B): bypass open (factory settings) 5.3.6 Change the supply and return flow Fig. 11: change supply and return flow Page 16 Version 2.0 06/2012
6 Technical data Dimensions (W x H x D) Type 8130 Type 8180 Weight Type 8130 Type 8180 Energy supply Maximum operating pressure Maximum permissible operating temperature General 300 x 320 x 235 mm 300 x 370 x 240 mm 5-10,5 kg 5,5-12 kg see pump-/controller manual 10 bar 90 C (observe specification of pump) Circulation pump For technical data of circulation pumps, see respective pump manuals. Fittings Pipes Plastics Flat gaskets O-rings Materials Hot-pressed brass Ms58 (CW614N) Stainless steel pipe Impact resistant and temperature resistant AFM34 and EPDM elastomer EPDM elastomer Tightening torque for screw connections with Reinz AFM 34 gasket 3 / 4 " 35 Nm 1" 55 Nm 1 1 / 4 " 90 Nm 1 1 / 2 " 130 Nm 2" 190 Nm 06/2012 Version 2.0 Page 17
Characteristics HK DN 20/25 Overall Gesamtdruckverlust pressure drop HK 8130/8180 HK DN 32 1.000 Pressure Druckabfall decline (mbar) 100 10 1 10 100 1.000 10.000 100.000 Flow Durchflluss rate (L/h) Overall Gesamtdruckverlust pressure drop HKM 8130/8180 HKM DN 32 with mit Mischer mixer Kvs=18,0 HKM DN 25 with mit Mischer mixer Kvs=10,0 HKM DN 25 with mit Mischer mixer Kvs=8,0 HKM DN 25 with mit Mischer mixer Kvs=6,3 HKM DN 25 with mit Mischer mixer Kvs=4,0 HKM DN 25 with mit Mischer mixer Kvs=2,5 1.000 Pressure Druckabfall decline (mbar) 100 10 1 10 100 1.000 10.000 100.000 Flow Durchflluss rate (L/h) Page 18 Version 2.0 06/2012
7 Decommissioning, recommissioning 7.1 Decommissioning Disconnect the energy supply to the pump assembly and ensure it cannot be switched back on. Electrical energy! danger Risk of death from electric shock. h Do not touch live cables or components with wet hands. h Be aware of health and safety regulations when handling electric current. h Disconnect the energy supply to the pump assembly and ensure it cannot be switched back on before carrying out any maintenance, cleaning or repair work. Remove the front cover on the pump assembly (see Fig. 3 on page 9). Close all shut-off cocks for the water connections. In the event of prolonged periods of non-use: Depressurise the pump assembly (for example by opening the venting screws). notice During the depressurisation process of the pump assembly, water can leak out. 7.2 Recommissioning Slowly open all of the shut-off cocks for the water connections (see Fig. 5 on page 11). Prime the pump assembly slowly with pressure and vent it if necessary. Restore the power supply to the pump assembly. Re-assemble the front cover on the pump assembly. 8 Dismantling Dismantling can be performed for two reasons: In order to reassemble the device elsewhere. In order to dispose of the device. 9 Disposal 9.1 Safety notice If the pump assembly is to be reassembled elsewhere, the dismantling process must be prepared properly. All installation and fastening parts must be carefully dismantled, labelled and, if necessary, packaged for transportation. This will ensure that, upon reassembly, all the parts can be correctly assigned and fitted back in the appropriate place. warning Incorrect disposal pollutes the environment and the groundwater! h When disposing of system parts and operating materials, the regulations and guidelines set down by the legislator of the respective country must be observed. 9.2 Disposal Separate the components of the pump assembly into recyclable materials, hazardous materials and operating materials. Dispose of the pump assembly components or recycle them. 06/2012 Version 2.0 Page 19
Art.-Nr.: 10025988