Swegon TBXZ-3-42 User manual

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 1

Installation Instructions for the

TBXZ-3-42 Pipework Package, GOLD SD/GOLD CX 100/120

1. General

The pipework package is used for circulating a mixture of

water and glycol between two interconnected heat recov-

ery coils in a closed system.

The supply includes the following: The pipework package

is supplied complete with insulated sheet-metal casing,

pump, control valve with actuator, expansion vessel,

safety valve, manometer and shut-off cocks, thermom-

eters, ﬁlling valve and air purging valve.

Basic circuit diagram

10 1 Air purging valve

2 Manometer

3 Safety valve

4 Filling valve

5 Expansion vessel

6 Shut-off valve

7 Pump

8 Thermometer

9 Control valve with actuator

10 Adjustment valve

11 Temperature sensor

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice.

2 www.swegon.com

2. Installation

2.1 Pipework Package.

1. Install the pipework package at a suitable location in

the fan room.

Wall mounting

Remove the wall mounting bracket from the pipework

package and secure it to a suitable place on a wall. In

order to reach and unfasten the wall mounting bracket,

you must ﬁrst dismantle the front panel of the sheet-metal

casing.

Floor mounting

A stand for ﬂoor mounting, TBXZ-2-43, is available as an

accessory, see illustration to the right. Secure the stand to

a suitable spot on the ﬂoor. In order to reach the pipework

package and secure it to the stand with screws, you must

ﬁrst dismantle the front panel of the sheet-metal casing.

2. Mount the pipework package onto the wall mounting

bracket/ﬂoor stand.

3. Fit the pump to the pipework package. Give careful

attention to the direction of ﬂow. See the label on the

front of the pipework package and the illustration to the

right. It may be necessary to dismantle the drive side of

the pump and turn it so that the electrical terminal box

will be positioned upward. This can be done after remov-

ing four socket head cap screws.

4. Mount the shut-off valve + pipes onto the pump.

5. Mount the pressure expansion vessel and accessories.

2.2 Control unit.

The control unit is designed for wall mounting should be

mounted at an appropriate location. Make sure that you

position the safety isolating switch on the control unit 0.6

– 1.9 metres above ﬂoor level.

2.3 Installing the pipework

The pipework between the heat exchanger coils and the

pipework package should be installed and insulated in a

professional manner by a ventilation and sanitation ﬁtter,

according to customary trade standards and regulations.

Connect the heat exchanger coils for counter-ﬂow cir-

culation according to the arrows on the coil connection

branches. Incorrect connection may cause a reduction in

efﬁciency. Make sure that the pipework package and the

connecting pipework do not block inspection of the other

functional sections.

Check that the deadweight of the pipework and/or the

expansion forces will not be applied to liquid connections.

Use an appropriate sealing/jointing compound for sealing

the threads on the heat exchanger connections.

Connect the safety valve, appropriately using a hose, to a

collecting vessel (not supplied by Swegon ).

Supply air

Extract air

The height from

ﬂoor level to the

thermometers on

the installed pipe-

work package is

1480 mm.

2.4 Temperature sensor

A type strap-on temperature sensor is supplied with the

pipework package. Secure the sensor onto the return

pipe, as shown in the basic circuit diagram on page 1, for

instance by means of a bundling strap. The sensor is used

as a limiting sensor to counteract freezing.

Wire the temperature sensor leads to terminals 107-108 in

the control unit of the pipework package.

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 3

3. Dimensions

Wall

Pipework Package

GOLD

Size

TBXZ-42

Size

Coil heat

exchanger

connections

Pipework

package con-

nections

12, 14, 20 20 DN 32 DN 32

25, 30 30 DN 40 DN 40

35, 40 40 DN 40 DN 50

50, 60 60 DN 40 DN 50

70, 80 80 DN 50 DN 50

100, 120 120 DN 65 DN 65 Flange

GOLD

Size

TBXZ-42

Size

B H

12, 14, 20 20 600 415

25, 30 30 770 530

35, 40 40 770 530

50, 60 60 770 530

70, 80 80 770 530

100, 120 120 840 640

GOLD

Size

TBXZ-42

Size

12, 14, 20 20 100

25, 30 30 120

35, 40 40 120

50, 60 60 120

70, 80 80 120

100, 120 120 165

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice.

4 www.swegon.com

105

106

107

108

101

104

107

102

106

108

103

105

101

104

107

102

106

108

103

105

COM POWER

IQlogic+

1234 5678 9101112

-+-+ -++--S-S

Com 1Heat/Cool Com 2

103

3. Electrical Connections

The electrical connections are to be wired by a qualiﬁed

electrician in accordance with local electrical safety regula-

tions.

Connect the cable between the GOLD unit and the control

unit for the pipework package from terminal to terminal,

i.e. from Terminal No. 1 in the GOLD unit to Terminal No.

1 in the control unit for the pipework package. See the

ﬁg. to the left.

The cable between units is not included in the supply.

Twisted-pair cables are recommended. Use one cable pair

for 24 V and the other cable pair for bus communication.

Terminals, Cable

adapter - Control

unit for the pipe-

work package

Terminal No. 1 = -24 V DC

Terminal No. 2 = +24 V DC

Terminal No. 3 = EIA-485 B BUS

Terminal No. 4 = EIA 485 A BUS

Max permissible cable length: 100 metres

Terminals – Cable adapter, GOLD air handling unit.

GOLD SD: Cable adapter in the supply air or

extract air handling unit.

GOLD CX 100/120: Cable adapter marked EIA-485

in the upper electrical equipment cubicle.

Pump, 3x400 V

Pump TP

(thermostatic contacts)

Control valve, actuator

Temp. sensor

Bus communication

Power supply: 3x400 V,

5-wire cable or 1x230

V*, 3-wire cable. Wire

to a safety isolating

switch. Rec. fuse: 10 A.

Brown

Black

Grey

Blue

Brown

Black

Grey

Blue

The function selector

switch must be set to

position 1.

Bus contacts

Wiring

terminals

Cable adapter

Control unit for the pipework package

L1 L2 L3

Pump,

3 x 400 V

Safety isolating switch

Pump, TP

24 V AC/GO

24 V AC/G

0-10 V DC/Y

0-10 V DC/U

TEMP/GND (Brown)

TEMP/DTA (White)

Violet

Orange

Yellow

L1 L2 L3

Pump,

1 x 230 V

* If 1x230 V is supplied, con-

nect the phase wire to L3 on the

safety isolating switch.

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 5

4. Commissioning

1. The height of lift for the control valve is automatically

calibrated the ﬁrst time it is commissioned.

2. Check the pre-pressure by measuring the level dif-

ference from the centre of the expansion vessel to the

highest point of the pipe connection system. Convert the

level difference to bar (1 metre = 0.1 bar). Add another

0.3 bar (for the coil) to this ﬁgure to obtain the pre-pres-

sure.

The safety valve must be sized to withstand at least 1 bar

above the pre-pressure. The safety valve supplied is sized

to withstand 2.5 bar.

Example:

Measured level difference of 2 metres = 0.2 bar

Pre-pressure = 0.2 bar + 0.3 bar (coil) = 0.5 bar

Min. permissible safety valve pressure = 0.5 bar + 1 bar =

1.5 bar

This ﬁgure is well below the max. limit of the safety valve

supplied, which is 2.5 bar.

Equipped with the safety valve supplied, the pipe connec-

tion system will manage a level difference of 12 metres (=

1.2 bar).

If the level difference is more than 12 metres, you will

either have to move the expansion vessel with accessories

to a higher position or replace the safety valve. Since the

expansion vessel manages max. 5 bar, a safety valve sized

for a max permissible pressure of 5 bar must be used.

The expansion vessel is factory-rated for a pre-pressure of

0.5 bar, which also is the minimum limit. If the pre-pres-

sure of the expansion vessel threatens to drop below 0.5

bar, ﬁll more air through the nipple on the underside of

the expansion vessel.

3. Preset the adjustable red pointer on the manometer, to

the corrected pre-pressure in the expansion vessel.

4. Open "the cap" on the automatic air purging valve.

5. Fill the system with water (usually water mixed with

glycol). Please note that if glycol is used, it must be meant

for cooling medium systems, not motor vehicles. Fill the

system slowly. Vent the liquid circuit at the air purging

points as you ﬁll it.

6. Adjust (ﬁll / drain) the system so that the pressure in the

system will conform to the corrected pre-pressure reading

(see the red pointer on the manometer).

7. The system is now ready to be commissioned. Under

normal operating conditions, the pressure in the system

must not drop below the corrected pre-pressure preset on

the manometer (see the red pointer on the manometer) or

exceed the red mark.

Sizing diagram

EVOPLUS B 150/250,40

For the GOLD SD, sizes 12-40

5. Circulation pumps, wet motor

Survey – Pump data

Temperature range, liquid: -10°C – +110°C

Max. perm. operating pressure: 16 bar

Size of pipe connections: DN40

Max. permissible static pressure: PN 16

Enclosure class: IP44

Weight: 16 kg

Electrical data

Frequency: 50 Hz

Rated voltage: 1 x 230 V

Output: 610 W

Nominal current: 2.9 A

Motor protection: Integrated

Head

Power input P1

Total eciency

62,6%

Tot. e.

8 m

4 m

8 m

4 m

[m]

0,1

0,2

0,3

0,4

0,5

0,6

[kW]

[%]

0 4 8 12 16 20 24 [m³/h]

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice.

6 www.swegon.com

Sizing diagram

EVOPLUS B 150/280.50

For the GOLD SD, sizes 50-60

Sizing diagram

EVOPLUS B 150/340.65

For the GOLD SD, sizes 70-120,

GOLD CX, sizes 100/120

Survey – Pump data

Temperature range, liquid: -10°C – +110°C

Max. perm. operating pressure: 16 bar

Size of pipe connections: DN50

Max. permissible static pressure: PN 16

Enclosure class: IP44

Weight: 18 kg

Electrical data

Frequency: 50 Hz

Rated voltage: 1 x 230 V

Output: 640 W

Nominal current: 3 A

Motor protection: Integrated

Head

Power input P1

Total eciency

64,5%

Tot. e.

12 m

8 m

4 m

12 m

8 m

4 m

[m]

0,1

0,2

0,3

0,4

0,5

0,6

[kW]

[%]

0 5 10 15 20 25 30 [m³/h]

Survey – Pump data

Temperature range, liquid: -10°C – +110°C

Max. perm. operating pressure: 16 bar

Size of pipe connections: DN65

Max. permissible static pressure: PN 16

Enclosure class: IP44

Weight: 20 kg

Electrical data

Frequency: 50 Hz

Rated voltage: 1 x 230 V

Output: 1210 W

Nominal current: 5.5 A

Motor protection: Integrated

Head

Power input P1

Total eciency

70,3%

Tot. e.

10 m

5 m

10 m

5 m

[m]

0,2

0,4

0,6

0,8

[%]

010 20 30 40 [m³/h]

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 7

6. Adjustment valve, 9505/9555P

General

Draining

The valves without drain nipple have a cover sleeve. This

cover sleeve can be exchanged for a set of drain ﬁttings

available as accessories.

Measurement tappings

The measurement tappings are self sealing. For measure-

ments, remove the cover. Then insert the measurement

needle through the self-sealing measurement tapping.

Technical Description

Range of Application

Heating and cooling systems. Tap water installations.

Function

Commissioning, pressure drop and ﬂow measurements,

shut off and drainage.

The valve can regulate the ﬂow when you turn the handle

to change the setting. There are 40 (9505) or 80 (9555P)

different positions on the handle.

The valve can stop the ﬂow and on a restart there is a

memory function that returns the valve back to the previ-

ous setting.

The valve can be used for measuring the ﬂow across the

valve by measuring the pressure in the two measurement

points.

Pressure class

9505:

PN 20. (PN 25 at max. permissible operating temperature,

100°C)

9555P:

PN 16.

Temperature

Max. permissible operating temperature: 130°C.

Min. permissible operating temperature: - 10°C.

Kv values

The values or chart on the next page can be used for cal-

culating the pipe system.

1 21,9

1,5 26,4

2 31,1

2,5 35,7

3 40,1

3,5 44,4

4 49,3

4,5 53,2

5 57,7

5,5 64,4

6 71,8

6,5 76,6

7 80,4

7,5 84,1

8 88,8

Commissioning valve 9505

Turns

Commissioning valve 9555P

0,5 0,09 0,37 0,4 1,4 1,4 2,7 3,9

1 0,19 0,55 0,7 2 3,3 3,5 7,8

1,5 0,33 0,75 0,9 2,6 4,1 4,5 10,6

2 0,5 0,94 1,2 3,5 5,1 6,1 14,8

2,5 0,66 1,18 1,5 4,8 7,6 10 19,9

3 0,81 1,75 2,2 5,5 10,4 14,1 23,9

3,5 0,92 2,44 3,4 6 11,2 17,6 27,2

4 0,97 2,67 4,1 6,4 12 19,5 29,8

10 15 20 25 32 40 50

Turns

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice.

8 www.swegon.com

Presetting

The valve can be preset by means of the appropriate ﬂow

diagram for the relevant valve size. The presetting of the

valve can be read in the "main" and "secondary" scale on

the handle. Double zeros indicate that the valve is closed.

- The primary valve setting (main) is shown in the lower

window, where the values move in a vertical direction.

Each number indicates one whole turn.

- The secondary valve setting (secondary) is shown in the

upper window, where the values move in a horizontal

direction. Each number indicates one tenth of a turn.

To set a valve to a certain pressure drop setting that e.g. is

equivalent to 2.3 turns in the diagram, proceed as follows:

1. Close the valve completely.

2. Open the valve 2.3 turns.

3. The memory stop can be set as follows:

- Remove the plastic cover on the handle using a small

tool:

- Insert the 3 mm Allen key supplied into the hole in the

center. Make sure that the topset® is in its required posi-

tion and tighten the inner screw clockwise until it stops.

Do not tighten it too hard.

- Replace the plastic cover. You can prevent unauthorized

persons from changing the setting by security sealing the

cover of the handle's upper section. This can be done by

using a special wire with a security seal that you insert

through the existing grooves.

The valve can now be closed, and thus inﬂuence the ﬂow

at anytime. When the valve is opened again the memory

stop will return to the previous setting.

4. The valve is now set.

To check the presetting, close the valve. The setting indi-

cated should then be 0.0. After that, open it to stop. The

presetting will then be indicated, in this case: 2.3.

Diagrams that indicate the pressure drop at various set-

tings and ﬂows for each size of valve are provided for

guidance in determining the correct valve size and preset-

ting (pressure drop).

A fully open valve corresponds to 4 turns (9505) or 8

turns (9555P). Opening the valve additional turns will not

increase its capacity.

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice. www.swegon.com 9

Important!

If the ﬂow is outside the chart, it can be read as follows:

Assume the example above that reads 10 kPa, Kv=5 and a

ﬂow of 1.6 m3/h. For 10 kPa and Kv=0.5 you read a ﬂow

of 0.16 m3/h and for Kv=50 you read 16 m3/h. Therefore,

for every given pressure drop you can read 0.1 or 10 times

the ﬂow and Kv.

Example

This chart shows the pressure drop across the valve. A

straight line that interconnects the scales for ﬂow – Kv

- pressure drop constitute the relationship between the

different readings.

7. Chart

The position for each valve size can be obtained by plot-

ting a horizontal line from the value intersected on the Kv

scale.

Sought

Presetting for DN 25 and required 1.6 m ﬂow 3/h and pres-

sure drop of 10 kPa.

Solution

Plot a line between 1.6 m3/h and 10 kPa. This intersects

the Kv scale at KV=5. Then plot a horizontal line from Kv 5

to the DN 25 scale where you read 2.75 turns.

7.1 DN 32 – 50 (GOLD SD 12-80)

GB.TBXZ342.130915

Registered design. The company reserves the right to make changes without prior notice.

10 www.swegon.com

Important!

If the ﬂow is outside the chart, it can be read as follows:

Assume the example above that reads 25 kPa, Kv=53 and

a ﬂow of 27 m3/h. For 25 kPa and Kv=5,3 you read a ﬂow

of 2,7 m3/h and for Kv=53 you read 270 m3/h. Therefore,

for every given pressure drop you can read 0.1 or 10 times

the ﬂow and Kv.

Example

This chart shows the pressure drop across the valve. A

straight line that interconnects the scales for ﬂow – Kv

- pressure drop constitute the relationship between the

different readings.

The position for each valve size can be obtained by plot-

ting a horizontal line from the value intersected on the Kv

scale.

Sought

Presetting for DN 65 and required 27 m ﬂow 3/h and pres-

sure drop of 25 kPa.

Solution

Plot a line between 27 m3/h and 25 kPa. This intersects the

Kv scale at KV=53. Then plot a horizontal line from Kv 53

to the DN 65 scale where you read 4,5 turns.

7.2 DN 65 (GOLD SD 100/120, GOLD CX 100/120)

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