Watts FlowBox HKF25 Series User manual

Series HKF25

Pump mixing valve group with

thermostatic fix point control for heating systems

Installation and Operating Manual

WattsWater.eu

EN ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

1 General information

1.1 Important information

The operator is responsible for ensuring

adherence to the local laws and regulations

(e.g. accident prevention regulations, etc.).

Incorrect operation or operating the pump

group contrary to the specifications shall

void all rights to any warranty claim.

This Installation and Operating Manual

• is a component of the pump group

• contains instructions and information on safe and correct

installation and commissioning of the pump group

• must be available to all users throughout the entire service

life of the pump group

• is intended for trained personnel who are familiar with the

applicable standards and provisions and, in particular, with

the relevant safety concepts and the operation and mainte-

nance of the pump group

• is protected by copyright and may not be changed without

the manufacturer’s permission

• may not be made accessible to non-authorized personnel;

neither in original form nor as a copy

1.2 Product conformity

A Declaration of Conformity according to the Machinery

Directive 2006/42/EC has been issued for this pump group

product.

1.3 Product features

• stable mounting bracket including mounting hardware

• patented 3-piece EPP insulating shell

• compact, space-saving design

Contents

1 General information ................................... 2

1.1 Important information.....................................................2

1.2 Product conformity.........................................................2

1.3 Product features.............................................................2

2 Safety ........................................................... 3

2.1 Presentation of the safety instructions............................3

2.2 Important safety instructions..........................................3

2.3 Intended use ..................................................................3

2.4 Foreseeable misuse .......................................................3

2.5 Responsibilities of the operator ......................................3

2.6 Groups of persons .........................................................3

3 Technical data............................................. 4

4 Pressure loss curve ................................... 5

5 Overall dimensions..................................... 5

6 Construction ............................................... 6

7 Installation and commissioning ............... 6

7.1 Installation diagram ........................................................7

7.2 Installation ......................................................................7

7.3 Initial Commissioning......................................................7

7.4 Thermometer handle position ........................................7

7.5 Exchanging the supply and return line ...........................8

8 Maintenance ............................................... 9

8.1 Annual maintenance intervals.........................................9

8.2 Replacement of wear parts............................................9

8.3 Disassembling the circulation pump............................. 10

8.4 Installation of the circulation pump............................... 10

8.5 Disassembling of the thermostatic mixing valve ........... 11

8.6 Installation of the thermostatic mixing valve ................. 11

9 Disposal..................................................... 12

9.1 Return shipment to the manufacturer........................... 12

9.2 Reporting to administrative bodies and manufacturer.. 12

10 Guarantee.................................................. 12

ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

2 Safety

2.1 Presentation of the safety instructions

DANGER indicates an imminent danger

that may cause serious physical injury or

death without the corresponding safety

precautions.

WARNING indicates a danger arising

through incorrect behavior that may cause

serious physical injury or death (e.g. misuse,

disregarding notices, etc.).

CAUTION indicates a potentially dangerous

situation that may cause minor or slight

injuries without the corresponding safety

precautions.

NOTICE indicates a situation that may cause

material damage without the corresponding

precautions.

2.2 Important safety instructions

• Carefully read through these operating instructions.

• Only connect the pump group to a power source that

corresponds to the mains voltage specified on the rating

plate of the pump group.

• The power supply to the pump group must be

disconnected prior to maintenance, cleaning and repair

work.

• Only trained specialist personnel are permitted to perform

maintenance, cleaning and repair work.

• The pump group must not be used if it is damaged or if the

pump group is no longer operating correctly. In this case,

contact your specialist dealer immediately.

• Adhere to the maintenance instructions and intervals.

• Protect the pump group from the influences of weather.

• Never use the pump assembly outdoors.

• The machine is only permitted to be used for the purpose

for which it was intended.

2.3 Intended use

The pump group is used to distribute heating water in heating

systems.

The pump group is completely pre-assembled and designed

for mounting on a wall.

The pump group is not intended to be operated by people

(including children) with physical, sensory or mental

disabilities, nor by people with insufficient experience or

previous knowledge.

2.4 Foreseeable misuse

The following is considered to be foreseeable misuse:

• operating the pump group contrary to the specifications

• improper use of the pump group

• modifications to the pump group that were not agreed with

the manufacturer

• use of replacement or wear parts that were not approved

by the manufacturer

• operating the pump group outdoors (parts and

components are not UV resistant)

2.5 Responsibilities of the operator

The operator must ensure that:

• the pump group is only used for its intended purpose

• the pump group is installed, operated and maintained

according to the specifications in the Installation and

Operating Manual

• the pump group is only operated according to local

regulations and occupational health and safety regulations

• all precautionary measures have been carried out to avoid

dangers originating from the pump group

• all precautionary measures for first aid treatment and

firefighting have been carried out

• only authorized and trained users have access to the pump

group and operate it

• users have access to this Installation and Operating

Manual at all times

2.6 Groups of persons

Only qualified persons may operate the pump group or

perform service and maintenance work.

User

A user is deemed to be qualified if they have read these

operating instructions and understood the potential risks

associated with incorrect behavior.

Fitter/commissioner

Due to their specialist training and knowledge, and taking into

consideration the applicable standards, provisions, regulations

and laws, a fitter/commissioner is capable of performing work

on the pump group and recognizing and avoiding potential

risks.

EN ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

3 Technical data

Hydraulic performance data

Max. operating pressure 6 bar

Ambient temperature -2°C to +40°C (observe pump specification!)

Operating temperature +2°C to +90°C (observe pump specification!)

Opening pressure of gravity brake 10 mbar

Kvs mixing valve 4,5

Temperature display area 0-120 °C

Temperature setting area 20-43°C / 20-55 °C / 30-70°C (depending on type of thermostatic mixing valve)

Media Water / water-glycol mixtures according to VDI 2035/ÖNORM H 5195

Electrical connection

Power supply See separate pump documentation!

Dimensions

Width x height x depth with EPP shell 300x370x 240 mm

Axis center distance 125 mm

Sealing surfaces distance 342,5 mm

Connections to pipe network

Heating circuit (top) 1½" AG male connection; flat sealing. Fitting 1½" Union nut x1" IG female connection

Boiler circuit (bottom) 1½" male connection; flat sealing

Tightening torques for screwed connections

¾" 35 Nm

1" 55 Nm

1¼" 90 Nm

1½" 130 Nm

Material

Fittings brass CW617N

Pipes galvanized steel Ø48 mm

Plastics impact resistant and temperature resistant

Flat seals AFM 34/2

Bypass pipe brass CW617N

Gravity brake POM. NBR. stainless steel

O-rings EPDM

Insulation EPP

Wall bracket Galvanized steel sheet

Circulation pump

The technical data on the circulating pumps can be found in the respective pump documentation.

ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

5 Overall dimensions

240,5

370

384

125

300

G11/2" G11/2"

Rp1" Rp1"

40130 130

4 Pressure loss curve

100

1.000

100 10.0001.000

Flow rate [l/h]

Pressure loss [mbar]

EN ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

6 Construction

1Ball valve with gravity brake 1) (supply)

2Ball valve (return)

3Circulation pump

4Thermostatic mixing valve

5Bypass connection pipe

6Wall bracket

7Distance pipe

ASupply outlet (heating circuit)

BReturn inlet (heating circuit)

CReturn outlet (boiler circuit)

DSupply inlet (boiler circuit)

1) see 7.4 on page 7

7 Installation and commissioning

Electricity!

Risk of death from electric shock.

• Work on parts carrying live voltage must only

be carried out by trained electricians.

• Disconnect the power supply of the system

and secure it against being switched back on

before carrying out any installation, mainte-

nance, cleaning or repair work.

The installation and commissioning of the

pump group must only be carried out by

trained personnel who have been authorized

by the manufacturer.

Take care to adhere to the specified

installation positions and flow directions of

the individual components to be replaced

during repair or replacement work!

Material damage!

A water hammer may occur if the stop valve

is opened quickly.

• Always open the stop valve slowly and in a

controlled way.

ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

7.1 Installation diagram

7.2 Installation

All screw fittings must be checked and tightened if

required prior to installation and commissioning!

Torque:

• ¾" fittings 35 Nm

• 1" fittings 55 Nm

• 1¼" fittings 90 Nm

• 1½" fittings 130 Nm

Requirement

• The valves are pre-installed at the factory but must be

checked for leaks during commissioning (pressure test).

1. Dismantle the front panel of the pump group.

2. Mark the drilling points for installing pump group.

3. Drill the holes corresponding to the screw and anchor size.

4. Place the anchor.

5. Screw the screws into the anchor.

6. Place the pump group to the wall in a vertical installation

position (see „7.1 Installation diagram“).

7. Screw the screws into the anchor.

8. Remove the thermometer handles and dismount the inter-

mediate insulation.

9. Connect the supply and return lines and check that all

screw connections are tight.

7.3 Initial Commissioning

Requirement

• The pump group is completely assembled.

Connection of the power supply

1. Connect the power supply (see separate pump

documentation).

9The pump group switches on automatically after being

connected to the power supply.

2. Vent the heating system.

The pump group must be switched off

during the ventilation process!

3. Mount intermediate insulation and attach thermometer grips.

4. Mount the front panel of the pump group.

Setting the supply temperature

1. While the pump group is operational, you can set the

desired supply temperature using the hand wheel on the

thermostatic mixing valve.

2. The target value is checked using the supply thermometer.

9For further information on thermostatic mixing valve,

please refer to the enclosed instructions.

7.4 Thermometer handle position

A B C

AOperation position: Gravity brake ready to work; ball

valve open

BEmpty: Gravity brake open; ball valve ½ open (only

included in the supply line)

CService position: Ball valve closed

EN ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

7.5 Exchanging the supply and return line

Initial situation: the supply is on the right side.

9Disconnect the power supply and secure it against

being switched on again.

1. Disassemble the upper fittings.

2. Loosen the nuts on the pump bottom connection and

remove the distance tube.

3. Turn the pump and the flow ball valve by 180 degrees.

4. Loosen the nut on the return ball valve and turn the ball

valve through 180 degrees.

5. Rotate the pump group by 180 degrees and tighten all

connections and fittings.

The supply line is now on the left side.

6. Tighten the loosened connections to the pump and ball

valve (observe tightening torques!).

9Check the pump group for leaks.

ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

8 Maintenance

Electricity!

Only perform maintenance work on the

pump group if the voltage supply has been

disconnected.

Hot water!

Severe scalds possible.

Do not reach into the hot water when

emptying the pump group.

Ensure that the pump group has cooled

down before carrying out maintenance,

cleaning and repair work.

Install a suitable scald protection device

at every tapping point (for example, safety

shut-off valve or thermostat mixer tap).

More detailed information on scald

protection can be found in DIN 1988, sheet

2, clause 4.2.

Hot surfaces!

Serious burns possible.

Do not touch the pipelines or the

components during operation.

Ensure that the pump group has cooled

down before carrying out maintenance,

cleaning and repair work.

Wear heat-resistant safety gloves if it

is necessary to carry out work on hot

components.

The maintenance of the pump group must

only be carried out by trained personnel who

have been authorized by the manufacturer.

8.1 Annual maintenance intervals

1. General visual inspections

• Check the station for leaks and retighten sealing connec-

tions or replace seals, as required.

2. Functional checks

• Check that settings and operating and performance

parameters are set correctly.

• Check flow noise during operation.

• Ask users if there are any noticeable problems.

3. Ball taps

• Check that stop valves and ball taps can move freely.

4. Pump

• Pay attention to the noise of the pump.

5. Thermostatic mixing valve

• Check the thermostatic mixing valve for function.

7. Actions following maintenance work

• Check that all screw fittings that were unscrewed have

been retightened and retighten if necessary.

• Remove all tools, materials and other equipment used from

the working area.

• Vent the system.

8.2 Replacement of wear parts

Please note that the pump group contains parts that, for

technical reasons, are subject to wear depending on the

intensity of use, even if the specified care and maintenance

have been observed.

This especially applies to mechanical parts and parts that

could come into contact with water and steam, for example,

hoses, seals, valves, etc.

By their nature, defects as the result of wear do not represent

a fault and therefore are not covered by the warranty or the

guarantee. Nevertheless, these defects and malfunctions

must only be remedied by trained specialist personnel.

Contact your specialist dealer for this.

EN ENGLISH

HKF25-IM-DE-W-UK-11-2020-Rev.0 | Part no. 10027337

8.3 Disassembling the circulation pump

1. Disconnect the power supply and secure it against being

switched on again.

2. Remove the front panel of the pump group.

3. Close all stop valves.

4. Disassemble thermometer handles and intermediate

insulation.

Risk of heavy scalding from hot water!

• Allow the pump group to cool before

servicing.

• Do not reach into the hot medium when

emptying.

8.4 Installation of the circulation pump

1. Replace damaged or defective seals if necessary.

2. Insert the circulation pump and tighten the nuts (X) (for

tightening torques see “Technical data” on page 4).

3. Connect the wiring of the circulation pump.

4. Slowly open the ball valves by turning the thermometer

handle.

5. Slowly pressurize the pump assembly and vent the system

if necessary.

6. Check the pump group for leaks.

7. Restore the power supply to the pump group.

8. Disassemble the thermometer handles.

9. Install the intermediate insulation, the thermometer

handles, and the front panel.

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