for Fonterra radiant heating and cooling, regulation of the supplytemperature (constant)

Model Year built:1254.2 from 01/2012

en_INT

Manifold control station ‒ preset value

Instructions for Use

Manifold control station ‒ preset value 2 from 18

Table of contents

1 About these instructions for use 41.1 Target groups 4

1.2 Labelling of notes 4

1.3 About this translated version 5

2 Product information 62.1 Standards and regulations 6

2.2 Intended use 6

2.2.1 Areas of use 6

2.3 Product description 7

2.3.1 Overview 7

2.3.2 Technical data 8

2.3.3 Operating mode 9

2.4 Information for use 9

2.4.1 Installation variation 9

3 Handling 103.1 Assembly information 10

3.1.1 Installation dimensions 10

3.1.2 Preconditions for installation 10

3.2 Commissioning 11

3.2.1 Making the electrical connection 11

3.2.2 Filling the system 11

3.2.3 Flushing the heating circuits 12

3.3 Control 12

3.3.1 Setting the underfloor supply temperature 12

3.3.2 Limiting the underfloor supply temperature 13

3.3.3 Pump control 14

3.4 Faults 16

3.4.1 Troubleshooting 16

3.5 Disposal 18

Table of contents

Manifold control station ‒ preset value 3 from 18

1 About these instructions for useTrade mark rights exist for this document; for further information, go toviega.com/legal.

1.1 Target groupsThe information in this instruction manual is directed at the followinggroups of people:

n Heating and sanitary professionals and trained personneln Qualified electriciansn Operators

Individuals without the abovementioned training or qualification are notpermitted to mount, install and, if required, maintain this product. Thisrestriction does not extend to possible operating instructions.

The installation of Viega products must take place in accordance withthe general rules of engineering and the Viega instructions for use.

1.2 Labelling of notesWarning and advisory texts are set aside from the remainder of the textand are labelled with the relevant pictographs.

DANGER! This symbol warns of possible life-threatening injury.

WARNING! This symbol warns of possible serious injury.

CAUTION! This symbol warns of possible injury.

NOTICE! This symbol warns of possible damage to property.

This symbol gives additional information and hints.

About these instructions for use

Manifold control station ‒ preset value 4 from 18

https://www.viega.com/legal

1.3 About this translated versionThis instruction for use contains important information about the choiceof product or system, assembly and commissioning as well as intendeduse and, if required, maintenance measures. The information about theproducts, their properties and application technology are based on thecurrent standards in Europe (e. g. EN) and/or in Germany(e. g. DIN/DVGW).

Some passages in the text may refer to technical codes in Europe/Germany. These should serve as recommendations in the absence ofcorresponding national regulations. The relevant national laws, stand-ards, regulations, directives and other technical provisions take priorityover the German/European directives specified in this manual: Theinformation herein is not binding for other countries and regions; as saidabove, they should be understood as a recommendation.

About these instructions for use

Manifold control station ‒ preset value 5 from 18

2 Product information2.1 Standards and regulations

The following standards and regulations apply to Germany / Europe.National regulations can be found on the relevant web site of yourcountry at viega.com/standards.

Regulations from section: Fields of application

Scope / Notice Regulations applicable in Ger-many

Heating water VDI 2035

Regulations from section: Filling the system

Scope / Notice Regulations applicable in Ger-many

Water quality of hot water heatingsystems

VDI 2035

Regulations from section: Limiting the underfloor supply temperature

Scope / Notice Regulations applicable in Ger-many

Maximum supply temperature ofthe heating water

DIN EN 1264-4

Maximum supply temperature ofthe heating water

DIN 18560

2.2 Intended use2.2.1 Areas of use

The manifold control station is used to keep the supply temperature inlow-temperature surface heating constant. The supply temperature canbe set continuously between 20 and 70 °C using the thermostat head. Alimitation of the setting range according to minimum and maximum tem-perature is to be recommended. Permitted transport media are waterand glycol mixtures, as well as heating water (also refer to Ä „Regula-tions from section: Fields of application“ on page 6). When using glycolmixtures, the transportation data of the pump should be adaptedaccordingly.

The manifold control station is used in heating systems where on theone hand their heat output takes place with a high supply temperature(e. g. radiators, heating ventilators or similar) and on the other handthrough low-temperature heat surfaces (e. g. underfloor or wall heating).Supply of both heating circuits takes place via a common supply line.

Product information

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https://www.viega.com/standards

NOTICE! This manual as well as the documents supplied about thecirculation pump, controller and further components arepart of the product and must be observed and kept.

2.3 Product description2.3.1 Overview

0 80

20 60

40

°C

0 80

20 60

40

°C

0 80

20 60

40

°C

1 32 4 5

68912 10 711

Fig. 1: Component overview

1 - thermostat head2 - safety contact thermostat (factory setting 60 °C)3 - eccentric thread with supply sensor4 - heating circuit supply5 - manifold6 - filling valve (flow direction)7 - drainage valve (drainage direction)8 - protective cap9 - heating circuit return10 - boiler return11 - backflow preventer12 - boiler supply

Product information

Manifold control station ‒ preset value 7 from 18

2.3.2 Technical dataThe manifold control station - preset value can be combined with Fon-terra manifolds DN 25.

n High-efficiency pump Wilo Yonos PARA RS 15/6 RKA(model 1252.9)

n Safety contact thermostat (model 1219.6)n Thermostat head (model 1254.1)n Thermometern Ball valve setn Double nipple set

Materials

Flat seals AFM 34 or EPDM

Fittings Brass Ms 58

Pipe sections Brass Ms 63

O-rings EPDM

Plastics Impact and temperature resistant

Technical data

Maximum permitted operatingtemperature

80 °C

Maximum permitted operatingpressure

0.6 MPa (6 bar)

Temperature control range 20–70 °C

Nominal heating capacity approx. 14 kW 1)

Pump capacity 3–45 W 2)

Operating voltage 230 V, 50/60 Hz

1) Pressure difference primary side to control station minimum 200 hPa(200 mbar)

2) See pump specification plate

Components

Product information

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2.3.3 Operating modeThe injection valve of the control station is designed as a proportionalaction controller. It is controlled via a thermostat head with capillarytube and sensor element at the heating circuit supply. Any deviationfrom the target value immediately causes a change to the valve lift,resulting in a change of the amount of hot water injected from the boilercircuit. Mixing with the return water from the heating circuit, the injectedwater keeps the supply temperature constant within a narrow range.The system temperature can be read directly at the thermometer. Abackflow preventer is installed at the connection of the boiler returnwhich prevents the intake of heating water from the boiler circuit return.

2.4 Information for use2.4.1 Installation variation

The manifold control station comes factory preset for left-side mountingto the manifold. To mount the station to the right side of the manifold,turn the eccentric thread at the supply and switch the thermometerover.

Product information

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3 Handling3.1 Assembly information3.1.1 Installation dimensions

Fig. 2: Installation dimensions

Installation and connection dimensions

Height approx. 328 mm 1)

Width approx. 192 mm

Axis distance approx. 210 mm

Connections G1 flat sealing

1)without ball valves

3.1.2 Preconditions for installationThe station is designed for direct mounting to the right or left side ofmanifolds with G1 connection. To achieve the nominal heating capacity,the pressure difference between the boiler circuit and the control stationmust be minimum 200 hPa (200 mbar).

Handling

Manifold control station ‒ preset value 10 from 18

3.2 Commissioning3.2.1 Making the electrical connection

DANGER! Danger due to electrical currentAn electric shock can lead to burns and serious injury andeven death.

– Work on the electrics may only be carried out by trainedelectricians.

– Always de-energise the connection line before work iscommenced.

The circulation pump and the contact thermostat are factory wired.

Connect the manifold control station to the 230 V mains system asshown in the figure.

To ensure that the pump only runs when heat is required,we recommend to connect the pump to a pump relay (e. g.a basic unit with pump module which also controls theactuators). As an alternative, the pump may be operated viatimer.

3.2.2 Filling the systemRequirements:

n The control station and the manifold are properly connected.n The heating water meets the requirements of the applicable regula-

tions; also refer to Ä „Regulations from section: Filling the system“on page 6.

De-energise the control station.

Close the ball valves to lock the control station on the boiler side.

Close all heating circuits at the manifold.

It is sufficient to close the valves at the return flow beam of themanifold by means of the protective caps.

NOTICE! To remove the air from the pump housing, the control sta-tion must be filled for the first time against the flushing anddraining direction. Do not carry out this step before com-missioning the control station.

UWP

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PE

N

PEC 2 1

Handling

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Connect the filling water hose at the filling/drainage valve at thesupply flow beam of the manifold.

Use the quadratic integrated in the cap to open the flush valve atthe supply flow beam.

Also open the valve at the return flow beam. Collect any escapingwater in a suitable container or let it drain.

Then, close the filling and the drainage valve.

3.2.3 Flushing the heating circuits

NOTICE! Only rinse the heating circuits in flow direction to preventdamage to the system.

The backflow preventer above the pump prevents the formation of abypass which would preclude proper flushing and/or filling of theheating circuits. During flushing and after closing of the flushingdevices, the system pressure must not exceed 0.25 MPA to preventopening of the safety valve and escape of heating water.

Connect the filling and drainage line to the filling and drainagevalves integrated in the manifold.

Open heating circuit one and flush it in flushing direction until all airand contamination are fully removed from the circuit.

After flushing, close the heating circuit once more.

Repeat flushing for every heating circuit.

After you have flushed the entire system, open and adjust all heatingcircuits.

3.3 Control3.3.1 Setting the underfloor supply temperature

If maximum power (nominal power) is required, set the boiler supplytemperature at least 15 °C higher than the desired supply temperaturein the underfloor circuit.

The setting handwheel of the thermostat head has a scale of 1 to 7 andallows for continuous setting of a supply temperature between 20 and70 °C. Refer to the table below for the respective target temperature:

Scale value 1 2 3 4 5 6 7

Target temperaturein °C

20 28 37 45 53 62 70

Handling

Manifold control station ‒ preset value 12 from 18

3.3.2 Limiting the underfloor supply temperatureUsually, surface heating does not use supply temperatures of more than50 °C. The temperature in the boiler or radiator circuit is often muchhigher (e. g. 70/50 °C or 60/40 °C). To prevent damage to the floorstructure due to overtemperature of the heating medium, Viega recom-mends to limit the target value of the supply temperature at the thermo-stat head in accordance with the respective installation situation.

Requirements:

n The desired target value is set at the thermostat head(e. g. level 3 = 37 °C).

n The set temperature roughly corresponds to the indication at thethermometer.

Place the locks (1) before and after the marker arrow (2).

ð The temperature value is fixed and protected from accidentalre-adjustment.

Maximum supply temperature of the heating water

wall heating Temperature *

Gypsum or lime plaster 50 °C

Loam rendering 50 °C

Lime-cement plaster 70 °C

Side 12 (plaster boards) 50 °C

* Maximum supply temperature according to current regulation, seeÄ „Regulations from section: Limiting the underfloor supply tempera-ture“ on page 6

How to limit the supply temper-ature:

Handling

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Underfloor heating Temperature *

Calcium sulphate screed and cementscreed

55 °C

Reno 50 °C

* Maximum supply temperature according to current regulation, seeÄ „Regulations from section: Limiting the underfloor supply tempera-ture“ on page 6

In case of malfunction, the safety contact thermostat switches the circu-lation pump off to prevent overtemperature of the underfloor heating. Toavoid arbitrary actuation, set the temperature at the safety contact ther-mostat at least 10 K higher than the desired supply temperature (factorysetting: 60 °C).

NOTICE! Make sure that the permissible maximum floor temperatureis not exceeded in the vicinity of the heating pipe.

When all heating circuits are equipped with actuators and no pumprelay is used, the contact thermostat should be mounted at the supplyline of the manifold.

3.3.3 Pump controlThe pump has a wet rotor motor with permanent magnet rotor and anelectronic regular with integrated frequency converter. The self-regu-lating pump RKA has an LED indicated the operating status of thepump.

At delivery, the pump is factory preset for the operation in underfloorheating systems (pressure difference constant Δp-c max.).

Safety contact thermostat

Factory setting

Handling

Manifold control station ‒ preset value 14 from 18

Over the permissible delivery rate range, the pressure difference targetvalue H is kept constantly at the set pressure different target value up tothe maximum characteristic curve. We recommend this type of regula-tion for underfloor heating systems.

Set the operating button to central position.

ð 3 seconds after you have set the operating button to centralposition, the pump starts ventilation.

The pump runs for 10 minutes at alternately high and lowspeed and guides the air drawn from the pump directly to thebleeder valve of the heating system. This may be noisy.

After 10 minutes, the pump stop and automatically goes toregulation mode Δp-c max Ä „Factory setting“ on page 14

To abort the ventilation process, turn the operating buttonat any time.

Ventilation function

Handling

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3.4 Faults3.4.1 Troubleshooting

Malfunction Cause Remedy

Floor heating cir-cuits do not getwarm.

The setting of the safety contact thermo-stat is too low and switches the controlstation pump off.

Set the safety contact thermostat at least10 K higher than the supply temperatureof the underfloor heating.

Pay attention to the permissible maximumtemperature of the underfloor heating.

Note: The switching difference of thesafety contact thermostat is approx. 5 K.To ensure that the control station is avail-able again as fast as possible, remove thesafety contact thermostat for a short timeuntil it has cooled down to switch-on tem-perature.

The safety contact thermostat switchesthe control station pump off.

The pump remains switched on eventhough the heating circuits of the under-floor heating are closed. The water in thecontrol station heats up due to the wasteheat of the pump. The safety contact ther-mostat switches the pump off as soon asthe system reaches its maximum temper-ature.

Remove the safety contact thermostatfrom the control station, allow it to cooland check it for proper function. Use thebasic station with pump module. Thepump logic ensures that the pump willonly run if at least one heating circuit ofthe underfloor heating is open.

The pump is connected to a room ther-mostat or electrical manifold. If all actua-tors close, the pump switches off. In caseof prolonged standstill, the supply of theunderfloor heating switches off. The con-troller causes the injection mixing valve toopen. Hot water is injected from the pri-mary circuit. This heats the control stationup. The safety contact thermostatswitches the pump off as soon as thesystem reaches its maximum tempera-ture.

Remove the safety contact thermostatfrom the control station and mount it tothe supply manifold.

The difference between the boiler supplytemperature and the desired supply tem-perature of the underfloor heating is toosmall for the existing heating load.

Set the supply temperature at the boiler toa higher value. With maximum powerrequirement of the underfloor heating, thesupply temperature of the heat generatormust be at least 15 C higher than thedesired supply temperature of the under-floor heating.

The pressure difference of the boiler/radi-ator circuit to the low-temperature circuitis insufficient.

Hydraulically adjust the system in such away that a pressure difference of 200 hPa(200 mbar) is applied upstream of thecontrol station.

Handling

Manifold control station ‒ preset value 16 from 18

Malfunction Cause Remedy

The supply temper-ature cannot be setto the desired valueor fluctuatesheavily.

The connections for supply and returnflow of the control station have beenreversed.

Check all connections of the control sta-tion for proper connection, switch con-nections if applicable.

The delivery head / pump level of thepump has been set too low.

Increase the delivery head / pump level ofthe pump.

The heating load is too high for the controlstation, i.e. the heat consumption exceedsthe nominal capacity of the control sta-tion. This condition may occur temporarilyfor example when heating up a "cold"floor.

Define the maximum heat requirementand compare to the nominal capacity.Possibly, some of the heating circuitsneed to be assigned to a second controlstation by means of an appropriate mani-fold. If the fault occurs during initial heat-up of an underfloor heating, it is possiblethat the system will achieve regular func-tion after the heat-up phase (i.e. after 2 to3 days). This applies particularly when thesystem operates close to the upper limitof the nominal capacity.

The thermostat head is defective. Mount a new thermostat head.

Improper characteristic curve is set. Set Δp-c characteristic curve.

LED Meaning Operating status Cause Action required

Emits green light Pump is running Pump is running asset.

Normal operation

Flashes green rap-idly

Pump housing ven-tilation

Pump runs in venti-lation mode for 10minutes. After-wards, set thedesired power.

Normal operation

Flashes red/green Pump is operativebut does not run.

Pump will re-startautomatically oncethe fault is no longerpending.

UndervoltageU < 195 V

OvervoltageU > 253 V

Check powersupply

195 V < U < 253 V

Module overtem-perature; motortemperature toohigh

Check temperatureof operating fluidsand environment

Flashes red Pump not operative. Pump is stalling. Pump does not re-start automatically.

Replace the pump.

LED off No power supply No voltage at elec-tronic system.

Pump is not con-nected to the powersupply.

Check the cableconnection.

LED display of the pumps

Handling

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LED Meaning Operating status Cause Action required

LED is defective. Check whether thepump is running.

Electronic system isdefective.

Replace the pump.

If you cannot remedy the fault, call a qualified technician or the technicalsupport of Viega Service Center.

3.5 DisposalSeparate the product and packaging materials (e. g. paper, metal,plastic or non-ferrous metals) and dispose of in accordance with validnational legal requirements.

Handling

Manifold control station ‒ preset value 18 from 18

Table of contents1About these instructions for use1.1Target groups1.2Labelling of notes1.3About this translated version

2Product information2.1Standards and regulations2.2Intended use2.2.1Areas of use

2.3Product description2.3.1Overview2.3.2Technical data2.3.3Operating mode

2.4Information for use2.4.1Installation variation

3Handling3.1Assembly information3.1.1Installation dimensions3.1.2Preconditions for installation

3.2Commissioning3.2.1Making the electrical connection3.2.2Filling the system3.2.3Flushing the heating circuits

3.3Control3.3.1Setting the underfloor supply temperature3.3.2Limiting the underfloor supply temperature3.3.3Pump control

3.4Faults3.4.1Troubleshooting

3.5Disposal