Heat Link SSP Series SS Manifold Pump Panel Manual NEUTRAL GROUND LIVE CAUTION 115 VOLTS ONLY SSPLR106T GROUND LIVE NEUTRAL CAUTION 115 VOLTS ONLY 120 40 60 60 80 100 C F 200 0 180 20 40 140 160 80 100 SSPSS106B MECHANICAL ROOM IN A BOX L6SSPxx000x-BMS
Table Of Contents Warnings...3 Tools Needed...3 Function...4 Unpacking...5 Panel Components...6-7 Specifications...8 Panel Component Specifications...8-14 Manifold Balancing...10 Recessed Housing Mounting...15-16 Surface Mount Housing Mounting...17 Piping Hookup...18 Fill and Purge...19 Panel Wiring...20 Panel Control Sequence & Wiring...21 Troubleshooting...22 Maintenance...22 Schematics...23-25 2
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 # 2 O-ring Lubricant (#79951 or #79952) 3
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 6-16). Note: This panel does not regulate or monitor the operating safety limit temperatures of the fluid leaving the heat source. 4
Unpacking Step 1 Examine carton for any damage that may have occurred during shipping. If damage is visible notify your courier and supplier immediately. Step 2 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; 2-3 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: (2) 1" rubber washers (2 spares) 5
Panel Components # Component Part Number SSPSx1xxx SSPLx1xxx SSPLx2xxx 1 Primary Pump PUMP1558 PUMP2699 PUMP2699 2 Stainless Steel Manifold 76100 series 76100 series 76200 series Flow Meter Valve Insert (supply) (0-1.5 US gpm lock nut) 76916 76916 n/a Balancing Valve Insert (supply) n/a n/a 76912 Zone Valve Insert (return) 76911 76911 76911 3 Thermometer 4 SS Manifold Port Caps 77100 77100 77100 5 Hose Bib 76930 76930 76930 6 Isolation Ball Valve 7 120Vac Terminal Block for Pump 8 Enclosure Recessed or Surface Mount Recessed or Surface Mount Recessed or Surface Mount Cover (not shown) 9 Key Lock (installed on cover) 71902 71902 71902 Accessory Pack 1" Washer NTRWSH1 NTRWSH1 NTRWSH1 Optional Installed Items 10 SSAPB - Installed Accessory Pressure Bypass for SS Manifolds 76936 76936 76936 11 SSASL - Installed StatLink Base Module 40226 40226 40226 12 SSASLEM - Installed StatLink 4 Zone Expansion Module 13 SSASLEMHD - Installed StatLink 2 Zone Heavy Duty Expansion Module 40234 40234 40234 40242 40242 40242 Sold Separately 1 2" 77105 77105 77105 14 PEX to Manifold Connectors 5 8" 77119 77119 77119 3 4" 77122 77122 77122 6
Heat Link 8 GROUND NEUTRAL LIVE CAUTION 115 VOLTS ONLY 7 10 6 6 5 1 4 11 120 40 60 60 20 40 80 100 C F R C 200 0 180 2 140 160 5 80 100 3 4 12 106030C SSPLR106T 13 GROUND NEUTRAL CAUTION 115 VOLTS ONLY LIVE 8 7 14 3 120 40 60 60 80 100 C F 200 0 180 20 40 140 160 80 100 2 5 15 4 1 5 6 6 4 SSPSS106B 7
Specifications SSPSx104x SSPSx106x SSPSx108x SSPSx110x SSPSx112x Nominal panel output 45,000 Btu/h 62,000 Btu/h 78,000 Btu/h 90,000 Btu/h Nominal fl ow 4.5 US gpm @ 20 F ΔT 6.2 US gpm @ 20 F ΔT 7.8 US gpm @ 20 F ΔT 9.0 US gpm @ 20 F ΔT Nominal pressure drop outside of based on 250' loops of 1 2" tubing panel Max ambient temperature 120 F Max water temperature 180 F Circulator Ferrous, Grundfos UPS15-58 Power supply: pre-wired on system controller 110 V(ac); max. current 3A Auxiliary terminal No Piping 1" piping Piping connections 1" FNPT Enclosure Galvanized steel, visible parts are satin coated steel. Recessed Surface Mount 4-6 loop 8-10 loop 12 loop 4-6 loop 8-10 loop 12 loop Enclosure Width 34-1 2" (876 mm) 42-1 2" (1080 mm) 46-1 2" (1180 mm) 34-1 2" (876 mm) 42-1 2" (1080 mm) 46-1 2" (1181 mm) Enclosure Height 28-1 2" (724 mm) 28-1 2" (724 mm) 28-1 2" (724 mm) 28-1 2" (724 mm) 28-1 2" (724 mm) 28-1 2" (724 mm) Enclosure Depth 5-7 8" (149 mm) 5-7 8" (149 mm) 5-7 8" (149 mm) 5-7 8" (149 mm) 5-7 8" (149 mm) 5-7 8" (149 mm) Door Width 36" (915 mm) 44" (1118 mm) 48" (1219 mm) 32-7 8" (835 mm) 40-7 8" (1038 mm) 44-7 8" (1140 mm) Door Height 30" (762 mm) 30" (762 mm) 30" (762 mm) 26.9" (683 mm) 26.9" (683 mm) 26.9" (683 mm) Weight 8
60 Heat Link Panel Component Specifications 80 40 100 120 140 40 60 20 80 0 100 C F 160 180 200 Thermometer The pipe mounted thermometer reads the supply fluid temperature. Specifications: Temperature range of 32-210 F (0-100 C). 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 curve applies. UPS26-99FC Pump Curve 35 30 25 Type UPS 26-99 FC 115 V 1 PH 60 Hz 20 uf 1/1(A) P1 (w) 1.30 150 1.50 179 1.80 197 99K4 U C L US LISTED MAX. FlUID TEMP. 230 F P/N: 52722512 P1 PC: 0939 US Class F IMPEDANCE PROTECTED FOR INDOOR USE ONLY LISTED U L 99K4 Head (feet) 20 15 10 5 0 0 5 10 15 20 25 30 35 Flow (gpm) 1st Speed 2nd Speed 3rd Speed 9
Stainless Steel Manifold Specifications: Material: Stainless Steel EN 1.4301 (X5CrNi18-10) which is equivalent to SAE 304 (V2A) Maximum Trunk Flow Rate: 18 US gpm (4.1 m3/h) Maximum Circuit Flow Rate: 76100 Series - 1.5 US gpm (0.34 m 3 /h) 76200 Series - 2.5 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: 0-1.5 US gpm or 0-5 L/min. Supply Manifold Secondary Balancing (Fine Tuning). Remove locking cap to adjust fl ow 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 1 CW = close CCW = open CW = close CCW = open ➀ CW = close 76100 Series 76200 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. 1 2 Balancing Method 1: Valve setting or flow characteristic known (pre-balancing) 1. Fully open supply valve (flow meter) [factory open]. 2. 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 2: Only flow rate known 1. Ensure all supply valves are open [factory open]. 2. 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. 10
76100 Series (Flow Meter) Friction Head Graph 30 (90) Stainless Steel Manifold # of turns from closed position 0.25 0.5 0.75 1 1.5 2 3.5 10 (30) 5 (15) Pressure Drop in ft H 2 O (kpa) 1 (3) 0.5 (1.5) 0.1 (0.3) 0.05 (0.15) 0.01 (0.03) 0.01 (0.04) 0.05 (0.19) 0.1 (0.38) 0.5 (1.89) Mass Flow Rate in US gpm (L/min) 1 (3.78) 3 (11.36) Working loop flow ranges from 0.1 to 1.25 US gpm (0.38 to 4.7 L/m) for floor heating and from 1.5 to 2.5 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. 11
76200 Series (High Flow) Friction Head Graph 30 (90) Stainless Steel Manifold # of turns from closed position 0.25 0.5 0.75 1 1.5 2 2.5 3 10 (30) 3.5 5 (15) Pressure Drop in ft H 2 O (kpa) 1 (3) 0.5 (1.5) 0.1 (0.3) 0.05 (0.15) 0.01 (0.03) 0.01 (0.04) 0.05 (0.19) 0.1 (0.38) 0.5 (1.89) Mass Flow Rate in US gpm (L/min) 1 (3.78) 5 (18.9) 12
SSAPB - Optional Installed Accessory Pressure Bypass (#76937) Adjustable pressure bypass valve kit for 76100 and 76200 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: 0.05-0.5 bar (1.67-16.73 ft H 2 O) 13
R C Heat Link StatLink 6 Zone Base Module (#40226) 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 1 or 2. 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 #40234 or #40242 module. Specifications: Actuator Contact: Triac Pump Contact: DPST NO relay (8 amps) Other Contact: DPST NO relay (8 amps) Timer Channels: 2 SSASLEM - Optional Installed StatLink4 Zone Expansion Module (#40234) 106030C 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. SSASLEMHD - Optional Installed StatLink2 Zone Heavy Duty Expansion Module (#40242) The StatLink 2 zone heavy duty expansion module (40242) connects to the StatLink 6 zone base module, allowing 2 more room thermostats to connect to up to 12 actuators each. 14
Recessed Enclosure Mounting Step 1 Use a screwdriver or similar thin tool through the hole to bend the mounting tabs out 90 degrees from the enclosure. Step 2 If electrical wiring will be coming from the top, remove the appropriate knockouts. 2" 12-3 16" 22-5 16" 32-7 16" 7 8" O.D. 3-3 4" 34-1 2" 2" 14-13 16" 27-5 8" 40-1 2" 7 8" O.D. 3-3 4" 42-1 2" Step 3 Build a 2 6 supporting frame where the panel is to be mounted. The panel should be mounted at least 12" above the floor. 15
Recessed Housing Mounting continued Step 4 Lift and place the panel onto the supporting frame. This panel is heavy; 2-3 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. 16
Heat Link 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 1 4-5 8" 7-1 8" Step 4 Lift and place the housing onto the mounting screws. 16" Bottom Feed 3-1 8" 4-7 8" 6-1 8" 3" 16" 16" GROUND LIVE CAUTION 115 VOLTS ONLY NEUTRAL Note: Skirting by others. 16" 120 100 140 160 80 Step 5 Screw the remaining mounting screws into the holes at the bottom of the housing and tighten the top screws. 4" 3-1 8" 40 60 80 100 C F 200 0 180 20 60 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 1 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. 17
Piping Hookup SSPLR106T shown Primary Return Primary Supply Step 1 Step 2 Before making any connections, identify the required connections to and from the panel. Connect mains piping using 1" MNPT fittings. Note: Use precautions when soldering or applying heat within 16" of the panel. Floor Return Floor Supply Step 3 Connect all tubing to manifold adapters. (77100 series connecters sold separately) 1. Lubricate the inside of the manifold port with silicone o-ring lubricant (#79952 sold separately). 2. 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 18
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. SSP 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 1 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 2 Fully close valves A, B, and C. Fully close all supply E and all return F manifold valves. Fully open valve D. SSP 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 5 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. 19
Panel Wiring 20
Panel Control Sequence 1. When power is provided to the 120V pump terminal block 1, the circulator 2 moves fluid through the panel. 1 2 21
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 fl uid 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) Make sure thermostat is not being infl uenced 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 qualifi ed electrician prior to alteration of wiring between heat source and panel. Compare output of heat source to the requirements of the heating system. Check that the circulator is receiving power. The circulator may be defective. High Temperature Within Room Check current setting of the thermostat. Adjust the temperature setting on thermostat to a lower setting. High supply mixed fl uid temperature. Adjust the Mixing Valve to the appropriate settings. Installed electronic actuators remain open after the thermostat is satisfi ed. 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. 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 5620x 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. 22
1-866-661-5332 For all SSP panels, primary piping with circulator must have no pressure differential between panel primary supply and return, i.e. close tees. Heat Source (e.g. Boiler or Heat Exchanger) T SSP Panel SSP Panel Control: Pump Control A. Hardwired 120Vac Power (Default) B. Hardwired switch supplied by others (Optional) C. Hardwired relay supplied by others (Optional) D.BMS System supplied by others (Optional) Zone Control for Stainless Steel Manifold A. Manual (Default) B. Automatic (Optional) i) HeatLink StatLink 6 Zone Base Module #40226 (SSASL) and HeatLink Actuators #56201 (SSAACT) 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: 2014-05-21 Generic SSP Series Radiant Heating Schematic #: Rough-in wiring see: Wiring detail see: SCH-SSP-M010 23
Cold Water Supply 1-866-661-5332 Outdoor Sensor Building Management System By Others Boiler M P1 P2 Circuit Balancing Valves by others T T T SSP Panel SSP Panel SSP Panel Snow/Ice Detector OR In-Slab Temp. Sensor By Others 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: Boiler SSP Series Snow Melting Schematic #: Rough-in wiring see: SCH-SSP-M014 2014-07-24 Wiring detail see: SCH-SSP-E014 24
1-866-661-5332 Building Management System By Others Snow/Ice Detector Pump Pump Pump Snow/Ice Detector by others LNG LNG LNG SSP Panel SSP Panel SSP Panel 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. Application: Multiple SSP Panels connected to a BMS. Schematic #: Date: 2014-07-24 Rough-in wiring see: SCH-SSP-E014 25
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Canada Manufactured & distributed by HeatLink Group Inc. Head Office: 4603E - 13 th Street N.E. Calgary, Alberta, T2E 6M3 Toll Free: 1-800-661-5332 International Phone: +1 (403) 250-3432 Fax: 1-866-450-1155 China Distributed by Cathay-Links International Phone: 852-25693213 Fax: 852-25359271 Ireland Distributed by Jamoni Ltd. Phone: 057-932 4062 Fax: 057-932 4063 Freephone: 1800-311338 México Distributed by Distribuidora Caisa S.A. de C.V. Phone: (52-55) 3300-4400 Fax: (52-55) 3300-4406 United States Distributed by HeatLink Group Inc. USA Distribution Center: 1000-100 th Street SW, Suite B Byron Center, MI, 49315 Toll Free: 1-800-661-5332 Fax: 1-800-869-6098 info@heatlink.com July 24, 2014 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.