WALL PANELS INSTALLATION MANUAL

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PHP, Precision Hydronics Products
Home About Us Rep Directory Products Install Manuals Specs Contact PHP Application Drawings LEED - Building Green List Price Schedule WALL PANELS INSTALLATION MANUAL
WALL PANEL OPTIONS
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Easily Customize Your System With PHP Primary/Secondary Panels and Modules
PHP M-1 Series and Pro-Modular primary panels are pre-piped panels that provide all of the near-boiler piping and
components for new heating system installations or system replacements. These panels may be used as "stand alone"
components or can be configured to provide a complete primary/secondary zoned heating system. The Pro-ModularT secondary
zone assemblies may be used with either the M-1 or Pro-ModularT primary panels.
This manual will guide you through the selection and installation of the various components. Primary panels are available with or
without domestic water heater pumps, and include heat exchanger models when isolation of system components is required.
Secondary modules include zone pumps, zone valves, injection mixing modules, and manual mixing modules.
Contents:
1 - Primary Panels
M-1 Series
Pro-Modular Series
2 - Secondary Modules
Zone Pump Assembly
Zone Valve Assembly
3-Way Manual Mix Assembly
3-Way Taco i-Valve Assembly
2-Way Taco i-Valve Assembly
3 - Installing the Primary Panel
M-1 Series
Pro-ModularT Series
4 - Installing the Secondary Modules
http://www.phpinc.us/...D6%C6%D4%CE%B8%E5%DB%D5%C9%DB%DB%D8%DC%CA%D7%DD%CE%C4%C9%CF%DD%D0%DB%A5%D0%D5%D5%DB&did=1202502517[02/10/2012 11:25:32 AM]
Zone Pump Assemblies
Zone Valve Assemblies
5 - Purging
6 - Warnings
Appendix
I - Slip-Fit Connections
II - Differential Pressure By-pass Valve (DPBV)
III - Mixing Valves
IV - PHP Electric Control Modules
V - Application Drawings
M-1 Series
M-1 primary panels are mounted in a white metal cabinet with a removeable cover. M-1 panels include the "HI" (with system and
indirect water heater pumps), the "HO" (with system pump only), the "HX" (with pumps on both sides of the heat exchanger), and
the "MZ" (for use with the Monitor MZ boiler or any boiler with its own pump and air elimination).
Pro-Modular Series
Pro-ModularT primary panels are mounted on 1-5/8" strut and come ready for installation. Pro-ModularT panels include the "TKI"
(with system and indirect water heater pumps), and the "TK" (with system pump only). The M-1 "HX" and M-1 "MZ" also may be
special ordered as Pro-Modular versions mounted on strut.
The M-1 and Pro-ModularT primary panels include all of the near-boiler piping components that are normally found in the
primary loop of a mechanical system.
SW - Single Wall
DW - Double Wall
DPBV - Differential Pressure Bypass Valve
T/G - Taco or Grundfos Pump(s)
Since Jan 1, 2007 all M-1 and Pro-ModularT panels have freeze protection drain plugs just above the check valves on the
return lines from the heating system and DHW system. Due to the check valves, these areas do not drain well. If you
pressure test with water and anticipate freezing temperatures, remove the drain plugs and open all ball valves to prevent
freeze damage to the panel.
Figure 2 : Primary Panel Components and Connections
2 - Secondary Modules
PHP offers secondary modules in a variety of configurations. Note that any secondary modules may be used with either the
M-1 or Pro-ModularT primary panels. Components for the secondary modules may be mixed with other secondary modules.
Also, all secondary modules are available with either Slip-FitT or sweat connections (See Appendix I for details on Slip-FitT
connections).
Secondary Modules
The secondary modules are pre-assembled multiple zone configurations up to 5 zones. Additional modules may be added
to increase the number of zones. The secondary options include: zone valves, zone pumps, 3-way manual mixing, 3-way
injection mixing, and 2-way injection mixing. Depending on the secondary zoning, a primary/secondary transition adapter
may be required. When using zone valves on the secondary, a differential pressure bypass valve is required to be installed
in the primary panel.
Mixing module with Taco
2-way i-Valve
Mixing module with Cash Acme 3way Manual Valve
Mixing module with Taco
3-way i-Valve
Figure 3: Pro-ModularT Secondary Modules
3 - Installing the Primary Panel
Installing M1 Panels
Step 1
Verify If You Have The Correct M-1 panel. Make sure you have the right module for your job and that the BTU output of your panel
is matched to your system requirements. Check the configuration of your panel with Table 1 on Page 5.
Step 2
Inspect and familiarize yourself with the M-1 panel. Remove the M-1 panel
from its shipping box. It ships with the cover on. Remove the cover by
unscrewing the 6 cover retaining screws. Check for any shipping damage.
Do not install a damaged product.
Step 3
Familiarize yourself with the M-1 panel. Labels for each port are on the
underside of the bottom of the cabinet. Study Figure 2 on Page 6.
Step 4
Survey the installation space and the mechanical layout. The 1-inch and 11/4" M-1 panels are 2' high x 3' wide x 8" deep; the 2" piping panels are 32"
high x 28 3/4" wide. (the HX-75 is 2' x 2' x 8")
When using M-1 panels with secondary modules, anticipate how you will use the space and plan accordingly. Secondary module
assemblies come pre-mounted on strut. To assure that primary and secondary panels align correctly, it is recommended that the
mounting area be covered with plywood.
Review Figure 4 for dimensions when using secondary assemblies. Dimensions for secondary modules are:
Injection Mix Module
6" wide x 43.25" high
Pump Module
3-Way Manual Mix Module
Zone Valve Module
6" wide x 34" high
6" wide x 34" high
4" wide x 34" high
Figure 4: M-1 Installation Dimensions
Step 5
Mount the M-1 panel to the wall. Using lag bolts, securely mount the panel
to framing or a piece of plywood mounted to the wall.
If you are bolting to framing, locate the framing and drill 4 holes in the
enclosure that correspond to the framing. Note that there are sound
isolation gaskets that go behind the module on the bolts.
If you have mounted plywood to the wall, use lag bolts to secure the module to the plywood but remember you will need to place
plywood of the same thickness under the struts for the secondary modules or they will not align correctly on the wall.
Since the modules are heavy, it is recommended to build a temporary, but stable, stand underneath it, and with assistance lift the
module onto the stand where it may then be bolted in place. It is not recommended to remove the piping from the enclosure to
mount the module, but it is possible.
DO NOT mount the panel sideways or upside down as it will not vent properly. Carefully remove the piping assembly and lay it on a
cushioned surface.
Drill holes in the cabinet and mount it to the wall. Carefully reinstall the piping assembly.
Installing Pro-ModularT Panels
Step 1
Verify if you have the correct Pro-ModularT panel. Make sure you have the right module for your job and that the BTU output of your
panel is matched to your system requirements. Check the configuration of your panel with Table 1 on Page 5.
Step 2
Inspect and familiarize yourself with the Pro-ModularT panel. Remove the Pro-ModularT panel from its shipping box. It ships premounted to strut. Check for any shipping damage. Do not install a damaged product. Note that the TKI and TK panels are identical
except for the deletion of the indirect water heater pump on the TK panel. Study Figure 2
Step 3
Mount the Pro-ModularT panel to the wall. Survey the installation space and the mechanical layout. The Pro-ModularT panels are 2'
high x 3' wide x 8" deep. Individual pumping modules are 6" wide; zone valve modules are each 4" wide. Plan enough space to
accommodate the number of secondary zones.
If you will be mounting secondary modules, it is recommended that 3/4" plywood be firmly attached to framing members then mount
the panel and secondary module(s) to the plywood using 1" x 5/16" lag bolts and washers.
Note: Screw a level piece of blocking to the plywood to support the weight of the panel while you secure it to the wall. Remove the
blocking once the panel is securely bolted to the wall. Mount the module so the top pipe between the air separator and the system
pump is level.
DO NOT mount the panel sideways or upside down as it will not vent properly.
Step 4
To install an optional DPBV on the Pro-ModularT panel, remove the caps and screw the half-unions to the ports on the panel.
Check that the unions are tight and do not leak. Follow the instructions included with the DPBV kit to set the system flow rate.
Check that the flow rate set at least meets the system boiler's minimum required flow rate.
Figure 5: Secondary Module Installation Dimensions
4- Installing the Secondary Modules
The secondary components utilize factory-build multiple zone assemblies. These assemblies include zone valves, zone pumps, 3way manual mixing valves, 3-way injection mixing valves, or 2-way injection mixing valves and may be combined to provide for
various system requirements. Typical assemblies are available up to 5-zones, with additional zone add-ons available. Assemblies
utilizing zone pumping are connected to the primary panels using a primary/secondary transition adapter. Assemblies utilizing zone
valves require the addition of a DPBV installed in the primary panel (see Installing Zone Valve Assemblies on Page 14).
Secondary assemblies may be installed in a vertical or horizontal orientation by adding a "J-bend" kit. This kit changes the pump
assemblies from a horizontal orientation to a vertical one. The "J-bend" kit changes the zone valve assemblies from a vertical
orientaion to a horizontal one. Additionally, using optional bend kits of the same length will allow for installation in a corner. This may
be beneficial if space in the mechanical room is tight.
Installing Zone Pump Assemblies
Step 1
After mounting the primary panel to the wall, screw the
transition adapter fittings onto the the supply and return line
to the heating system and attach the transition adapter.
Note that secondary assemblies are available with
either Slip-FitT or sweat connections. Secure the Slip-FitT
connection with the horseshoe clamp and stainless steel
zip-tie.
Step 2
Attach the zone pump assembly to the transition adapter by
sliding it in place. Bolt the assembly strut to the wall using
lag bolts and washers and secure with the horseshoe
clamps and zip-ties.
Step 2 (alternate)
To install the pump assembly in a vertical orientation, add a "J-bend" kit to
the transition adapter. Then slide the zone assembly in place and bolt to the
wall using lag bolts and washers. Secure the connections with the horsehoe
clamps and zip-ties.
Step 3
Install the end caps with drains.
Secure with the horseshoe clamps and zip-ties.
Installing Zone Valve Assemblies
Step 1
Zone valve assemblies do not use a transition adapter. Instead,
a differential pressure by-pass valve (DPBV) is used to provide a
primary/secondary piping configuration. The DPBV is installed in the primary
panel as described on Page 10.
Step 2
After mounting the primary panel to the wall, screw the
transition adapter fittings onto the supply and return line
to the heating system.
Step 3
Attach the zone valve assembly to the transition adapter fittings. Bolt the
zone valve assembly to the wall using lag bolts and washers. Secure the
fittings with horseshoe clamps and zip-ties.
Step 3 (alternate)
To install the zone valve assembly in a horizontal orientation, add a "J-bend" kit to the transition adapter fittings then install the zone
valve assembly. Bolt the assembly to the wall using lag bolts and washers. Secure the connections with the horseshoe clamps and
zip-ties.
Step 4
Install the end caps with drains. Secure with the horseshoe clamps and zip-ties.
5- Purging
Fill and Purging
The M-Series and Pro-ModularT series systems are easy to purge of air since they have numerous purge valves, isolation ball
valves, and hose bib connections on the primary panels and secondary modules.
Primary Panel Purging
Isolate the primary panel by shutting off the isolation valves as necessary to isolate various system components and connect a
purge hose to the hose bib of the return line (as shown below left). Fill the panel using the fill water port connection and the fast-fill
setting on the Taco fill valve.
Close Isolation Valves as nessesary to isolate system components for purging.
Secondary Zone Purging
For zone pump systems, close the isolation ball valve on the return side of the transition adapter and attach a purge hose on the
return manifold hose bib. Fill the system using the fill water port connection and the fast-fill setting on the Taco fill valve. Then
isolate and purge each pump zone in sequence.
2-way and 3-way mixing modules should be purged through purge valves installed at distribution manifolds.
For zone valve systems, place the purge hose either on the panel return hose bib or the zone manifold return hose bib (primary
panel location preferred) as shown above right. Close the isolation ball valve on the panel return line and purge each zone in
sequence.
6- Warnings
Warnings
The PHP primary panels are designed as "near boiler piping modules" and as such are very flexible in that they may be used with
most boilers and with field installed secondary components or with PHP secondary assemblies. All primary and secondary
components are available in either sweat or easy to use "Slip-Fit"T versions.
Read and understand the following warnings before you make any connections.
Disconnect all electrical power to module and connected parts before servicing. Failure to
disconnect all electrical power may result in electrical shock, serious injury, or death.
For indoor hot water hydronic heating use only. Do not operate above 200°F. Do not use
with steam heating equipment.
Module should only be installed and serviced according to the latest PHP instructions, all
applicable codes by qualified hydronic heating professionals familiar with good hydronic
practice, code requirements, heat transfer and flow requirements of hydronic heating
systems.
Failure to follow warnings may result in an unsatisfactory or unsafe installation and could
result in serious injury or death.
Service only with heat source off and isolated from this module. Release water pressure
at a drain valve before disassembling or servicing. Never operate heat source with
expansion tank isolated or with fill water off. Failure to do so may result in malfunction,
explosive release of hot water or steam, injury or possible death.
Failure to follow latest PHP installation instructions will render warranty null and void.
Disconnect all electrical power to module and connected parts before servicing. Failure to
dissconnect all electrical power may result in electrical shock, serious injury or death.
See and follow all other warnings on the inside cover and inside this module.
Follow instructions and all warnings about isolating module and expansion tank. Never
operate heat source with module or expansion tank isolated or with fill water off. Failure
to do so may result in malfunction, explosive release of hot water, injury or possible death.
THIS HEATING SYSTEM MAY CONTAIN HOT WATER UNDER PRESSURE.
Shut off heat source. Such as boiler and allow fluids to cool before servicing. Make sure
heat source remains off during servicing.
Do not isolate the module using the isolation valves or sevice the module until the above
steps have been taken. Turn off fill water connection to module, then use isolation valves
to isolate module. Once isolated, release water pressure in module using drain valve with
hose attached and securely routed to an appropriate location such as a drain.
Failure to follow warning may result in burns, hot water leaks, injury or death.
After sevicing reverse procedure.
Never operate heat source with module or expansion tank isolated or with fill water off.
Failure to do so may result in malfunction, explosive release of hot water or steam, injury
or possible death.
1). Make sure you make connections to the correct ports shown in this manual. Do not
connect the module differently than shown as it could cause an unsatisfactory or
dangerous condition.
2). It is the installer's responsibility to verify that the pump sizing of all pumps in the
system is correct for your system. Many boilers require a specific flow for proper
operation and can differ significantly in resistance to flow. This may or may not require a
pump substitution. Failure to use the correct pump could result in a dangerous condition
or unsatisfactory performance. Similarly pumps on secondary components must be
correctly sized to the conditions in the field or unsatisfactory performance of the system
may result.
3). Purge air from system before operating pumps. Flush water through the system before
operating the system to prevent possible clogging of the air separator by flux from
soldering. Make sure the cap (if present) on the air eliminator is open during operation.
4). In start up phase make sure pumps are primed and air separator functioning. Most
pumps are water lubricated and running them dry for prolonged periods will result in pump
failure.
5). Using the heating pump on the TK or TKI as a system pump with zone valves requires
the installation and correct adjustment of a differential pressure valve kit. If needed, make
sure it is installed and correctly adjusted. See installing a DPBV kit on page 10.
6). Pressure test all systems to code before start up.
7). Verify that the boiler or heat source has a properly operating 30 PSI pressure relief
valve connected to the system. Never isolate it. Failure to do so may result in an
explosive condition, possible injury, or death.
8). It is the installer's responsibility to verify that the supplied backflow preventor is code
compliant where it is being installed. The PHP primary panels ship with a double check
back flow preventor. It is sufficient for most residential applications in most parts of the
country. Some areas require a double-check pressure-reducing principle back flow
preventor even on residential systems; many jurisditions require them for commercial
systems. You will need to check with your code officials. If a double check pressure
reducing principle backflow preventor is required you will have to add it upstream of the
fill water in port on the PHP primary panel. They usually require funnels and a specific
proximity to drains. Plumb from the backflow preventor port on the primary panel as
required by code, either to a floor drain or outside as allowed.
9). A correctly sized expansion tank must be attached to the PHP primary panels at the
correct port on the panel. See and follow warnings on previous page. When the system is
in operation make sure the valve to expansion tank is open. Remove the handle to prevent
tampering.
Appendix I - Slip-FitT Connections
Pro-Modular Slip-Fit Connections
The PHP Pro-Modular Slip-Fit connections consist of male/female connections, O-rings, horseshoe flange clamps, and stainless
steel zip ties. The male connection has a piston with two O-rings.
Lubricate the O-ring (male) side of the fitting with the silicone lubricant, then slide it fully into female receptor. Once fully seated, use
two half circle retaining clamps as shown to hold the fitting together. Then use a stainless steel zip tie in the retaining groove as
shown. Be sure the zip tie is snugged tight. A pair of needle nosed pliers works best.
Appendix II - Differential Pressure Bypass Valve (DPBV)
If a boiler with a flow requirement, such as a copper-tube or condensing
boiler, is installed, and primary/secondary piping is not used, the differential
pressure bypass valve should be installed and adjusted properly. Adjust the
DPBV according to the boiler manufacturer's instructions for proper flow. To
prevent the system pump from "dead heading", adjust the DPBV so that
when all zone valves are closed, some flow is diverted back to the boiler.
By installing a differential pressure relief valve, disturbing flow noises are
prevented in central heating systems when operating during low demand
periods. A minimum volume of circulating water is maintained in installations
with gas fired continuous-flow water heaters at times of "no demand", i.e.
when zone valves are closed. The differential pressure relief valve is
installed in a bypass pipe between supply and return pipe. The bypass is
opened with the pump head exceeding the set value of the differential
pressure relief valve.
Control Range: 50-500 mbar (0.725 and 7.250 psi), factory preset at 200
mbar (2.9psi).
Basic rule for selecting the valve size:
Choice of the bypass pipe and the DPBV * depends on the maximum
volume of the excess flow:
Recommendation:
Excess flow up to 0.55 l/s (8.7 GPM) use the 3/4" DPBV
Excess flow greater than 0.55 l/s (8.7 GPM) use the 1-1/4" DPBV
Examples of application:
A given central heating system under design, fitted with zone valves has a design flow of 0.28 I/s (4.4 GPM) at 25 kPa (3.6 PSI)
pressure loss (differential), see the intersection point of the pump curve with these two given values on the chart on the next page.
To find :
1. The size of the valve.
2. The value of preset for the differential pressure relief valve to commence opening at the design point of ?p 25 kPa (3.6 PSI)
(zone valves at the point of closing).
Solution:
1. Select 3/4" DPBV since the volume of the excess
flow is less than 0.55 I/s (8.7 GPM).
2. Set the preset indicator to 25 kPa (3.6 PSI).
The required nominal pressure of 25 kPa (3.6 PSI),
according to the chart, will be obtained after six (6)
turns of the handwheel. The intersection point for the
pump curve and the valve characteristic flow line
indicates the bypass flow 0.17 I/s (2.7 GPM) at a
pressure loss (differential pressure) of 31 kPa (4.5
PSI).
Therfore the possible maximum band of proportional
deviation Xp* is 6 kPa (0.87 PSI).
Valve adjustment:
Loosen the screw of the handwheel. By turning the
handwheel, set the required nominal pressure on the
indicator scale.
By tightening the screw of the handwheel, the setting
may be locked.
Other applications:
(For instance to maintain a minimum volume of
circulating water)
The intersection point for the flow rate and the pressure
loss is determined. Then from the oblique line which
runs through this point, the value of valve preset or the
number of turns of the handwheel can be read off on
the left side.
* Proportional deviation Xp is the rise in pressure
required for the valve to open from closed position to
the flow which corresponds to the intersection point
between the pump curve and the valve characteristic
line.
Appendix III - Mixing Data
Secondary modules and assemblies are available with either manual 3-way mixing valves or Taco i-Valves which include outdoor
reset and boiler return temperature protection. Set-point options are available.
The manual 3-way valve and Taco 3-way i-Valve both have 3/4" piping throughout. The table below shows flow rates and
corresponding pressure drop/head loss through the valve only. Losses through other components will need to be added to compute
the total system head losses. Capacity through the 3/4" valves can be 30,000 - 38,000 Btuh. Installer must verify calculations for
each installation.
The Taco 2-way i-Valve uses a 3/4" valve with 1" outboard piping. It is best suited for large Btuh mixing aplications. The table below
shows flow rates and corresponding pressure drop/head loss through the valve only. Losses through other components will need to
be added to compute the total system head losses. Capacity through the 1/2" valve can be 60,000 - 80,000 Btuh. Installer must
verify calculations for each installation.
Appendix IV - Electric Control Modules
If You are using the PHP Modular Electric Control first read, then follow the instructions and warnings in the "PHP Modular
Electric Control Panels and Pumps Installation, Operation and Maintenance Manual". If you are using controls
other than PHP controls, be sure to use listed quality components installed and inspected to all applicable codes by a qualified
installer.
The PHP Modular Electric Controls and Pumps are designed to provide you
with an ETL listed Control with receptacles and ETL listed prewired pumps
to plug into them. Together they will operate the pumps and control
functions of the specific PHP hydronic module it is designed to control.
The PHP Modular Electric Control uses of one or more Taco control boxes,
and PHP prewires all the high voltage connections. Each pump will ship with
a tag denoting which receptacle to plug it into. Modification of factory wiring
will void the ETL listing and PHP warranty.
The PHP Modular Electric Control will ship with a 20 Amp power cord that
must be plugged into a 20 Amp dedicated circuit. Please note that while the
unit is rated for 20 Amps, it should not be loaded with more than 16 Amps
(80% of the rated 20 Amps).
Low voltage connections to thermostats, aquastats or zone valves are to be field-wired. They must be installed and inspected to
applicable electrical codes.
Each ETL listed PHP Modular Electric Control is assembled with specific controls and each pump has a listing for use with it.
Contact PHP at 503-445-4188 for replacement parts. Failure to use factory-provided replacement parts will void the ETL listing and
PHP warranty.
Once your system controls and pumps are correctly wired and inspected,
and the system has been filled with fluid and purged of air, operate the
system through all sequences of operation.
Check for leaks and any control malfunctions.
Appendix V - Application Drawings
Drawings are illustrative only. Some components omitted for clarity.
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WALL PANELS INSTALLATION MANUAL

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