Grundfos PHP A-1 4.0 User manual

PHP A-1 4.0, 5.6, 6.6 & 8.1

Instruction manual

UK version, original instructions

PHP A-1 Instruction Manual / Contents

Table of Contents

1. General

2. Mounting

2.1 Installing the device

2.2 Makeup PHP

2.3 Changing the positions of the hydraulic connections

2.4 Usage of devices without degassing

2.5 Usage of cooling vessels

2.6 Temperature sensor T2

2.7 Electric connection

3. Hydraulic diagrams

4. Wiring diagrams

5. Operation and display

5.1 Switching on

5.2 User and display elements

5.3 Display

5.4 Scroll and change values

5.5 Display level

5.6 User level 2

5.7 User level 3

5.8 Manual mode

5.9 Timer programs

6. Commissioning PHP A-1

6.1 Commissioning PHP

6.2 Commissioning the make-up water BREAKTANK

6.3 Commissioning the make up water PUMPS

7. Warnings and fault messages

8. Cleaning and maintenance

8.1 Cleaning

8.2 Maintenance

9. Technical data

9.1 PHP

9.2 Additional expansion vessels for

combination with PHP

10. Spare parts list

11. Hazard notes

12. Appendix

13. EC declaration of Conformity

NOTE

Figures in this document can vary due to model and

conﬁguration of the delivered PHP device.

INFORMATION

This document refers to PHP series devices with software

version V1.23. Design and operation can vary slightly due

to the existing software version.

DISCLAIMER

We improve out products permanently and so we

reserve the right to make modiﬁcations anytime and

without previous announcements. We do not assume

any guarantee for the correctness and completeness

of this document.

Any claims, particularly claims for damages and loss of

proﬁt or ﬁnancial losses must be excluded.

PHP A-1 Instruction Manual / General

1 General

1.1 Tender text

Modular PHP for lossless storage of the expansion volume

and for pressure maintenance in closed heating, climate

and cooling systems. Designed and manufactured acc. to

regulations of EN 12828 and SWKI 93-1.

The control unit is built very compact with two low-noise

pressure maintenance pump(s) which is executed ad

multistage centrifugal pump(s) with high quality ﬂoating-

ring type shaft seal. Also the PHP hydraulics includes one

continuously regulating, mechanically set overﬂow valve.

High-precision measuring of the plant pressure. Hydraulic

connections and necessary shut-off devices for on-site

piping are factory-provided on the right side of the control

unit (possibility for rebuilding to the left side of the control

unit). Temperature monitoring of the media streaming into

the vessel. Prepared connection point for mounting a make-

up module for accurate measuring Combinable with water

softening for standardised make-up water (if required).

All operations are controlled by the microprocessor

electronics. The operator panel is situated ergonomically and

contains an illuminated 4-line text display. The measure- and

control unit is executed in a closed electrical cabinet. Four

potential-free signalling contacts (fault, warning, makeup in

operation, device operation enabled).

For more signals two additional modules can be installed

easily in prepared mounting positions. Remote monitoring

can be done also via SMS-module, bus module or web module.

PHP series devices are equipped by default with integrated

economic low-pressure degassing, based on the principle

of pressure drop. External temperature monitoring via an

optional temperature sensor at the connection point is

prepared too.

PHP unit includes a CAT Break Tank with 2 x Pumps.

Modular PHP:

The PHP device is a nicely shaped,

self-contained unit with a pleasing design. It is designed for

a modular combination with external expansion vessels

(max. 0.5 bar). The connections for suction pipe and

overﬂow pipe are situated at the back of the device.

Max. operation temperature of the plant: 110 °C

(with cooling vessel)

Max. temperature at the connection point: 70 °C

Max. operating pressure (PN): 10 bar

PHP A-1 Instruction Manual / Mounting

2 Mounting

2.1 Installing the device

The PHP device must be installed and ﬁxed through the

applicable holes in the feet of the frame to a horizontal

and solid ﬂoor. Suitable lifting devices should be used with

heavy equipment. Please refer to weights and dimensions in

section 9 of this manual.

The connection into the system return must be executed

acc. to the hydraulic diagrams in Chapter 3 “Hydraulic

diagrams”.

Modular PHP devices can be used in plants with max.

temperature of 70 °C at the connection point. If the max.

temperature at the connection point exceeds 70 °C,

cooling vessels must be installed. See Chapter 2.6

“Usage of cooling vessels”.

The connection into the system return must be done at a

position where no external pressures can occur. External

pressures could affect the trouble-free operation of the

pressure maintenance device.

The dimension of the expansion pipe is determined acc. to

the standard ÖNORM H5151-1. See Appendix A.

2.2 Makeup PHP

Ex works modular PHP series devices are delivered without

makeup module EMCF-1 V ﬁtted. The mounting of the

module is done acc. to the assembly instruction which is

delivered with the makeup module for connection to the

break tank.

2.3 Changing the positions of the

hydraulic connections

Ex works the connections from/to system return at modular

PHP are situated at the right side of the device. If necessary,

they can be built to the left side easily. Unused connections

must be closed by using the delivered caps.

The connections from/to expansion vessel for the PHP

are situated on the back of the control unit.

INFORMATION

We recommend to install the PHP device with an

expansion pipe size of at least DN 25.

PHP A-1 Instruction Manual / Mounting

Figure 1: Changing the positions of the hydraulic connections

PHP A-1 Instruction Manual / Mounting

Figure 2a: Gland plate

The electric connections (pre-cut cable bushings in gland

plate) are also situated at the right side of the device. If

necessary they can also be built to the left side (Figure 2a).

The opening on the other side must be closed by using the

blank ﬂange, which is at the left side of the electronic unit

(Figure 2b).

Figure 2b: Blank ﬂange

PHP A-1 Instruction Manual / Mounting

2.5 Usage of cooling vessels

PHP modular series devices can be used in plants with a

max. temperature of 70 °C at the point of implementation.

If the temperature at this point can exceed 70 °C, a cooling

vessel must be used.

Depending on the arrangement of the piping from system

return to the cooling vessel, a vent valve must be set at the

upper connection. This valve must be vented in course

of commissioning.

NOTE

Cooling vessels must not be insulated. The entire

expansion overﬂow pipe from system return to the device

must not be insulated, too.

Figure 7: Usage of a cooling vessel

NOTE

The automatic degassing feature will be disabled if a

bypass set is used.

The degassing function must be disabled using the

“device set-up”-feature.

If not, unnecessary run-time of the pump but no fault.

Figure 6: Connection via bypass set and connection to the

system return

2.4 Usage of devices without degassing

PHP modular series devices can be operated without

degassing. For this purpose the unused connections have

to be connected acc. to Figure 6. This connection can be

built via the optional accessory “bypass set” EMCB-ZB.

The connection can also be executed on site (DN 25).

To connect the PHP device to the system return you must

use only one connection (“EXPANSION OVERFLOW PIPE”).

See Chapter 3 “Hydraulic diagrams”.

2.6 Temperature sensor T2 (Optional)

PHP modular series devices with an attached temperature

sensor T2 (optional accessory) provide a monitoring of the

temperature of the system return respective the expansion

overﬂow pipe.

Due to this monitoring the degassing feature will be disabled

in case of a too high temperature. Thus the membrane and

the components can‘t be damaged by too hot plant media

during the degassing. We recommend to use the temperature

sensor T2 in systems with a max. operational temperature of

95 °C (set at the system safety temperature limiter).

The installation of the temperature sensor T2 into the system

return must be executed on-site, the sensor must be mounted

immediately in front of the connection to the pressure

maintenance device (Figure 8a). If a cooling vessel is used, the

sensor must be mounted into the expansion overﬂow pipe on

top of the cooling vessel (Figure 8b).

Figure 8: Installation of the temperature sensor T2 without

(a) and with (b) cooling vessel

PHP A-1 Instruction Manual / Mounting

2.7 Electric connection

The supply line has to have a protective earth wire. The electric

connection should be done through an isolator that can either

be unplugged or, in case of a 3 phase supply, can be switched

off (4 pole) and lockable with a readily accessible spur.

WARNING

All relevant electric standards must be adhered to.

INFORMATION

The connected load can be read at the type plate of the

PHP device.

PHP modular with degassing

(standard diagram):

Options:

2 pcs. main vessels with level measurement, 2 pcs.

additional vessels, expansion modules, makeup module

EMCF-1 V, sensor T2

1. Makeup water

2. Expansion overflow pipe from system return min. DN25

3. Expansion pressure pipe to system return min. DN25

4. Discharge hopper for vessel safety valve

5. Suction pipe from expansion vessel

6. Overflow pipe to expansion vessel

7. Gas-side vessel connection DN20

8. Expansion pipe

9. Degassing pipe

PHP A-1 Instruction Manual / Hydraulic diagrams

3 Hydraulic diagrams

PHP A-1 Instruction Manual / Hydraulic diagrams

PHP modular without degassing:

Options:

Bypass set, 2 pcs. main vessels with level measurement,

2 pcs. additional vessels, expansion modules, makeup

module EMCF-1 V, sensor T2

1. Makeup water

2. Expansion overﬂow pipe from system return min. DN25

3. Expansion pressure pipe to system return min. DN25

4. Discharge hopper for vessel safety valve

5. Suction pipe from expansion vessel

6. Overﬂow pipe to expansion vessel

7. Gas-side vessel connection DN20

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