1. home and garden
2. appliances

Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
ORMANDY MINIBREEZE
Wall Mounted Consumer Interface Unit
Please note that this a generic instruction and the
details provided herein are not site specific
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 1
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
CAUTION
During the operation of this appliance the internal components of the
appliance and service pipework leading into and out of the appliance
will exhibit elevated temperatures. Operators, Service Engineers or
other personnel should take adequate precautions to protect
themselves from hazards caused by hot surfaces and hot pipework.
CAUTION
This appliance is a heavy object and requires a
minimum of two people for unloading, unpacking
and manual handling. Please refer to the safety
instructions on page 4 for further details.
CAUTION
This appliance requires an electrical supply to operate. Only fully
qualified competent electrical engineers should attempt any
installation, servicing or maintenance of the electrical systems of this
appliance.
IMPORTANT WARRANTY INFORMATION
Following installation of this appliance, failure to flush and add inhibitor to the system will
invalidate the appliance warranty. Flushing should be carried out in accordance with BS7593
(Refer to sections 6.1 & 8.2).
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 2
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
IMPORTANT
INSTALLATION, SERVICING, COMMISIONING & REPAIR
Warning: Before installation check the information shown on the data plate of the
appliance, or stated within the technical specification given in this manual, is compatible
with local supply conditions.
This appliance must be installed in accordance with the manufacturer’s instructions and
should also be installed in accordance with the rules and regulations in force in the region in
which it is installed. The appliance is suitable only for installation in a vertical position on the
surface of a flat wall capable of supporting the weight of the appliance and any ancillary
equipment. The addition of anything that may interfere with the normal operation of the
appliance without express written permission from the manufacturer or his agent could
invalidate the appliance warranty. Read the instructions fully before installing or using the
appliance.
The installation of this appliance must be carried out by a competent person. It must be
carried out in accordance with the relevant requirements of the:
• Appropriate Building Regulations, either: The Building Regulations, The Building
Regulations (Scotland), Building Regulations (Northern Ireland).
• The Water Fittings Regulations or Water Byelaws in Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British
Standard Code of Practice, or the standard code of practice that applies in the region in
which the appliance is installed. The manufacturer’s notes must NOT be taken, in any way,
as overriding statutory obligations.
In GB the following Codes of Practice may apply:
Standard
Scope
BS 5546
Installation of hot water supplies for domestic purposes
BS 5449
Forced circulation hot water systems
BS 7074
Expansion vessels and ancillary equipment for sealed water systems
BS 7593
Treatment of water in domestic hot water central heating systems
BS EN 14336 Installation & Commissioning of Water Based Heating Systems
When replacing any part on this appliance, use only spare parts that you can be assured
conform to the safety and performance specification required by the specification of the
appliance. Do not use reconditioned or pattern parts that have not been clearly authorised
by Ormandy Rycroft.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 3
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
GENERAL SAFETY INSTRUCTIONS
Safe Handling
This appliance is a heavy object and may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during movement into its installation
location. Manoeuvring the boiler may include the use of sack truck or other suitable trolley
and involve lifting, pushing and pulling. Additional guidance on manual handling techniques
and assessment of manual handling task can be found in the appendix at the end of this
manual.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when performing these tasks
and the following precautions should be considered:
• Clear the working area before attempting to lift
• Ensure co-ordinated movements during the lift
• Be physically capable.
• Use PPE as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt should be made to ensure the
following unless unavoidable and/or the weight is light.
• Minimise the number of times needed to move the appliance - plan ahead.
• Keep back straight.
• Keep load as close to body as possible.
• Avoid twisting at the waist, move your feet.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds (refer to instructions and diagrams in this manual).
• Keep load as close to the body as possible.
• Always use assistance if required.
The circumstances of each installation are different. Always asses the risks associated with
handling and lifting according to the individual conditions.
If at any time when installing the appliance you feel that you may have injured yourself
STOP!!
DO NOT ‘work through’ the pain - you may cause further injury.
IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE APPLIANCE - OBTAIN ADVICE OR
ASSISTANCE BEFORE PROCEEDING!!
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 4
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Electrical Safety
This appliance requires connection to a suitable electrical supply. Refer to the detailed
appliance specification in this manual to ensure that the local supply conditions are
appropriate for this appliance before attempting installation. Where there are any doubts
DO NOT install the appliance and contact Ormandy Rycroft immediately to confirm the
suitability of the local supply for the appliance.
Connection of the appliance to the local supply must be carried out by a qualified Electrician,
and in GB the installation must comply with the current I.E.E. Wiring Regulations. For
electrical connection of the appliance in other regions the appliance must be connected in
accordance with the rules and regulations in force in the region in which it is installed.
It is the responsibility of the Electrician who is to carry out the connection of the appliance
to the local supply to ensure that the local supply is turned off/fully isolated before
connection is attempted. Appropriate checks should be made before installation is
attempted to ensure that isolation is complete.
DHW & LTHW Appliance: Elevated Temperatures & Hot Pipework
If the appliance has recently been in operation it is highly likely that internal pipework and
components will have a temperature that is much greater than the ambient temperature of
the location in which the appliance is installed. Care should be taken, and where it is
deemed necessary the appropriate PPE should be used, to ensure that there is no danger or
hazard to personnel working on the appliance whilst the internal pipework and components
are at an elevated temperature.
Alternatively the appliance can be isolated from the primary hot water supply and then left
for a sufficient amount of time to allow the internal pipework and components to cool to a
level that will allow them to the handled safely.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 5
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
CONTENTS
Section
Page
1|
Introduction .
.
.
.
.
.
.
.
7
2|
General Layout
.
.
.
.
.
.
.
11
3|
Appliance Operation .
.
.
.
.
.
.
20
4|
Technical Data & Specifications
.
.
.
.
.
22
5|
Dimensions & Fixings .
.
.
.
.
.
.
26
6|
System Details
.
.
.
.
.
.
35
7|
Installation Requirements
.
.
.
.
.
.
38
8|
Installation
.
.
.
.
.
.
40
9|
Commissioning the Appliance
.
.
.
.
.
46
10 |
Completing Installation
.
.
.
.
.
.
47
11 |
Servicing Information
.
.
.
.
.
.
51
12 |
Component Replacement
.
.
.
.
.
.
52
13 |
Schematic Diagrams .
.
.
.
.
.
.
59
14 |
Troubleshooting
.
.
.
.
.
.
.
71
15 |
Parts List
.
.
.
.
.
.
.
74
.
.
.
.
Appendices
i|
Installation & Commissioning Checklist
ii |
Appliance Service Interval Record
iii |
Manual Handling Guidance & Assessment Charts
iv |
Flow Regulator with Electric Controller 2488N / 5757-7
v|
Temperature Regulator 43-2N
vi |
Junction Board U22-2
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 6
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
1 | INTRODUCTION
1.1 | Description
The Ormandy Minibreeze Consumer Interface Unit is a compact and complete wall mounted
district heating interface unit that can serve the following in domestic applications:
a) both domestic hot water (DHW) and central heating (LTHW).
b) central heating (LTHW) with points to allow primary connection to domestic hot
water cylinder coil.
c) only central heating (LTHW).
d) only chilled water (CHW).
The Minibreeze appliance comprises separate plate heat exchangers for DHW, LTHW or
CHW as required and is designed to be supplied with primary hot or chilled water from a
centralised boiler plant.
The standard DHW / LTHW ‘Minibreeze B’ appliance, where the services enter from below, is
designed so that it can be mounted within a wall cabinet with the following minimum
internal dimensions: 800mm high x 500mm wide x 285mm deep. The appliance can also be
supplied with its own enclosure for mounting locations where the appliance will be sited as a
standalone unit and will not be enclosed in a cabinet or service cupboard.
The standard DHW / LTHW ‘Minibreeze T’ appliance, where the services enter from above, is
designed so that it can be mounted within a wall cabinet with the following minimum
internal dimensions: 850mm high x 500mm wide x 320mm deep. The appliance can also be
supplied with its own enclosure for mounting locations where the appliance will be sited as a
standalone unit and will not be enclosed in a cabinet or service cupboard.
The CHW appliances are designed to be either wall mounted or floor mounted depending on
the sizes of the heat exchanger required for a particular duty, with the services typically
entering the appliance from the top. Minimum dimensions for a wall cabinet or service
cupboard to site the appliance will be dependent on particular duty and should be
determined by reference to appliance design drawings. The appliance can also be supplied
with its own enclosure for mounting locations where the appliance will be sited as a
standalone unit and will not be enclosed in a cabinet or service cupboard.
The appliances should be installed in domestic residential environments only, on fully
pumped sealed systems.
If DHW is provided by an appliance this is produced from the fresh mains supply which is
then heated by a heat exchanger within the appliance.
The supply of DHW from the appliance is fully adjustable up to approximately 60°C.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 7
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
The appliance is protected from overheating of the DHW by means of a temperature sensor
placed inside the DHW heat exchanger. This reduces the risk of scalding by overheated tap
water, and additionally reduces the risk of system calcification. This method also improves
the efficiency of the appliance in standby periods, e.g. during warmer weather.
In standby mode the unit has in-built frost protection to prevent damage to the appliance.
It is possible to mechanically adjust or limit the maximum primary flow of the heating circuit
by adjustment of a limit screw on the control valve.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 8
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
1.2 | Special Features
The appliances have a number of special features, and are fully prepared for a subsequent
change to allow for weather compensation.
Weather compensated control of a heating / cooling circuit:
•
Control of the heating / cooling circuit by two parameter sets stored in the controller
to be selected by a mechanical switch, e.g. one parameter set without weather
compensation and a second set with weather compensation. If an outside
thermostat is installed after initial installation of the appliance the controller can be
switched from one parameter set to the other to allow for weather compensation
without the need to replace the controller.
•
Control of the heating / cooling circuit where the flow temperature is controlled
based on the outdoor temperature over an adjustable heating characteristic.
•
Control of the heating / cooling circuit by an external binary input which allows
switching between rated and reduced operation, or between rated and standby
operation with frost monitoring resulting in a real shut-off of heating / cooling water
and therefore reduced energy consumption.
•
As an alternative to the binary input, control of the heating / cooling circuit where
the gradient or level displacement of the heating / cooling characteristic can be
changed by manual adjustment of a dedicated room sensor.
Fixed set point control function, used to control the heating / cooling circuit to a fixed set
point.
Fixed set point control with a dedicated room sensor where the set point is changed by
variations in the room temperature. A permanently active flash adaption varies the supply of
heating / cooling to the required demand by changing the flow temperature.
A dedicated room sensor can be connected which provides the following features:
•
Convenient wall mounted room panel with various operating mode settings. (Day
mode – Night mode – OFF/Frost Protection)
•
Binary input on the room panel for remote switchover by, for example, room
thermostat.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 9
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
•
Possible override of the flash adaption based on room temperature or heating /
cooling characteristic (gradient or level with outdoor temperature compensated
control) implemented by the controller.
Frost monitoring and automatic initiation of protective action.
Automatic anti-blocking feature prevents circulating pumps from seizing up.
Maintenance friendly controller. Configuration, parameterisation, diagnostic function and
direct connection for monitoring using dedicated software. Allowing a service engineer
direct data transmission via a connecting cable or via a memory pen for easy handling of
multiple similar units, e.g. automatic data transmission of a reviewed temperature set-point
in one easy step by just plugging a memory pen into the controller socket.
Optional priority for DHW circuit, where DHW is provided by the appliance.
Optional electronic domestic hot water control for more comfort, e.g. thermal disinfection
over pre-set periods by separate timer.
Appliances are typically prepared for addition of heating / cooling metering.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 10
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2 | GENERAL LAYOUT
2.1 | With Cover Fitted – DHW / LTHW Appliances
1
2
2
3
1.
2.
3.
4.
Removable cover.
Viewing window.
Service connections, G3/4” BSP Female.
Safety valve discharge pipe, Ø15mm OD Copper Tube.
4
Where the Minibreeze appliance is installed as a standalone unit mounted on a wall it can be
fitted with a removable cover. The cover includes a viewing window to allow the display of
the heat meter to be read (in appliances where the optional heat meter is fitted).
NOTE: The appliance is connected to a local electrical supply. The cover of the appliance
should only be removed by a qualified service engineer. The appliance must be isolated
from the local electrical supply prior to the cover being removed and checks carried out to
ensure that isolation is complete.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 11
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.2 | With Cover Removed – DHW / LTHW Appliances
24
5
23
6
22
21
16
9
20
14
7
19
8
11
18
12
17
15
13
10
5. Expansion Vessel
6. Flow Controller
7. Heat Meter (Mechanical)
8. Terminal Box
9. Filling Loop (temporary)
10. Strainer
11. Safety Valve
12. Flow Switch
13. Drain Cock
14. G1/4” BSP Female, Test Point
15. Cover Retaining Screw
16. Temperature Sensor
17. DHW Heat Exchanger
18. Temperature Controller
19. Pump
20. Temperature/Pressure Gauge
21. Temperature Sensor
22. Mounting Frame
23. Automatic Air Release Valve
24. LTHW Heat Exchanger
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 12
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.3 | Connection Details – Standard DHW / LTHW Minibreeze Appliances with bottom
service connections
Connections from services in to the appliance should be made as indicated above. Actual
operating temperatures supplied to and from the appliance will vary depending on primary
supply, installed location, operating conditions and environmental conditions.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 13
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.4 | Connection Details – CHW Appliances with top service connections
SECONDARY
RETURN TO
APPLIANCE
SECONDARY
FLOW FROM
APPLIANCE
PRIMARY
RETURN FROM
APPLIANCE
PRIMARY
FLOW TO
APPLIANCE
TEMPORARY
FILLING LOOP
CONNECTION
Connections from services in to the appliance should be made as indicated above. Actual
operating temperatures supplied to and from the appliance will vary depending on primary
supply, installed location, operating conditions and environmental conditions.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 14
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.5 | With Cover Fitted – Wall Mounted CHW Appliances with top service connections
2
1
3
1. Removable cover.
2. Service connections.
3. Optional drip tray.
Where the Minibreeze appliance is installed as a standalone unit mounted on a wall it can be
fitted with a removable cover. The cover includes a viewing window to allow the display of
the heat meter to be read (in appliances where the optional heat meter is fitted).
NOTE: The appliance is connected to a local electrical supply. The cover of the appliance
should only be removed by a qualified service engineer. The appliance must be isolated
from the local electrical supply prior to the cover being removed and checks carried out to
ensure that isolation is complete.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 15
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.6 | With Cover Fitted – Wall Mounted CHW Appliances
12
8
8
10
11
5
7
18
13
17
15
9
14
16
4
6
4
5
6
7
8
9
10
11
Expansion Vessel
Flow Controller
Terminal Box
Filling Loop (temporary)
Strainer
Safety Valve
Test Point
Orifice Plate
12
13
14
15
16
17
18
Double Regulation Valve
Temperature Sensor
Heat Exchanger
Pump
Temperature/Pressure Gauge
Mounting Frame
Temperature Gauge
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 16
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.7 | Connection Details – DHW / LTHW Appliances (Primary Take-off for DHW)
PRIMARY RETURN
FROM VESSEL
PRIMARY
RETURN FROM
APPLIANCE
PRIMARY FLOW
TO VESSEL
TEMPORARY
FILLING LOOP
CONNECTION
PRIMARY
FLOW TO
APPLIANCE
SECONDARY
FLOW FROM
APPLIANCE
SECONDARY
RETURN TO
APPLIANCE
Connections from services in to the appliance should be made as indicated above. Actual
operating temperatures supplied to and from the appliance will vary depending on primary
supply, installed location, operating conditions and environmental conditions.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 17
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.8 | Cover Fitted – Wall Mounted DHW/LTHW Appliances (Primary Take-off for DHW)
1
2
2
4
5
3
1. Removable cover.
2. Viewing window.
3. Service connections, G3/4” BSP
Female.
4. Safety valve discharge pipe,
Ø15mm OD Copper Tube.
5. Mains supply cable.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 18
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
2.9 | Cover Fitted – Wall Mounted DHW/LTHW Appliances (Primary Take-off for DHW)
6
17
7
19
9
18
8
20
10
11
15
12
14
13
6
7
8
9
10
11
12
13
Expansion Vessel
Flow Controller
Terminal Box
Filling Loop (temporary)
Strainer
Safety Valve
Test Point
Orifice Plate
14
15
16
17
18
19
20
Double Regulation Valve
Pressure Independent Control Valve
Temperature Sensor (behind 17)
Heat Exchanger
Pump
Temperature/Pressure Gauge
Mounting Frame
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 19
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
3 | APPLIANCE OPERATION
Reference can be made to the DHW / LTHW appliance schematic in Section 13
3.1 | Domestic Hot Water Circuit (DHW)
i.
ii.
iii.
iv.
The supply for domestic hot water (DHW) is taken directly from the fresh mains
supply.
When there is demand for DHW, e.g. a tap is opened; the mains pressure causes
flow of cold water into and through the secondary side of the DHW heat
exchanger.
A temperature sensor on the DHW outlet of the heat exchanger monitors the
temperature of the DHW water being supplied against the current set point.
Where required the temperature controller is actuated by the sensor to increase
or decrease the flow on the primary side and thereby increase or decrease the
temperature of the flow on the secondary side.
3.2 | Central Heating Circuit (LTHW)
i.
ii.
iii.
iv.
v.
The temperature of the flow supplied by the central heating (LTHW) circuit is
monitored by a temperature sensor inside the appliance.
The temperature of the flow supplied by the LTHW circuit may also be monitored
by a dedicated room sensor.
Where there is a demand for heating, the pump circulates water through the
secondary circuit.
The flow controller allows flow through the primary side of the LTHW circuit to
maintain the monitored temperature in the secondary side to the set point level.
When the flow temperature in the secondary side exceeds the set point, the flow
controller will reduce or shut off flow in the primary side of the LTHW circuit,
whilst the pump will continue to circulate water through the secondary side for a
predetermined period of time.
Reference can be made to the CHW appliance schematic in Section 13
3.3 | Cooling Circuit
i.
ii.
The temperature of the flow supplied by the cooling (CHW) circuit is monitored
by a temperature sensor inside the appliance.
The temperature of the flow supplied by the CHW circuit may also be monitored
by a dedicated room sensor.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 20
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
iii.
iv.
v.
Where there is a demand for cooling, the pump circulates water through the
secondary circuit.
The flow controller allows flow through the primary side of the CHW circuit to
maintain the monitored temperature in the secondary side to the set point level.
When the flow temperature in the secondary side exceeds the set point, the flow
controller will reduce or shut off flow in the primary side of the CHW circuit,
whilst the pump will continue to circulate water through the secondary side for a
predetermined period of time.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 21
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
4 | TECHNICAL DATA & SPECIFICATIONS
4.1 | LTHW / DHW Appliances
Nominal Primary Supply Temperature, LTHW (Pri) In
.
.
80°C
Nominal Primary Return Temperature, LTHW (Pri) Out
.
.
53°C
Nominal Secondary Return Temperature, LTHW (Sec) Ret .
.
58°C
Nominal Secondary Flow Temperature, LTHW (Sec) Flow
.
.
78°C
Nominal Cold Feed Temperature, DHW Cold Feed In
.
.
10°C
Nominal Hot Feed Temperature, DHW Hot Feed Out
.
.
60°C
Electrical Supply Voltage*
.
.
.
.
.
.
240 V
.
.
.
.
50 Hz
(* appliance must be connected to an earthed electrical supply)
Electrical Supply Frequency* .
.
(* appliance must be connected to an earthed electrical supply)
External Fuse Rating .
.
.
.
.
.
.
3A
Service Connections .
.
.
.
.
.
.
G3/4” BSP
Safety Valve Discharge Pipe Size
.
.
.
.
.
Ø15 mm OD
Enclosure Height
.
.
.
.
.
.
.
650 mm
Enclosure Width
.
.
.
.
.
.
.
495 mm
Enclosure Depth – Minibreeze B
.
.
.
.
.
279 mm
Enclosure Depth – Minibreeze T
.
.
.
.
.
315 mm
Clearance Above Enclosure .
.
.
.
.
.
20 mm MIN
Clearance Below Enclosure* .
.
.
.
.
.
200 mm MIN
(* sufficient clearance must also be allowed for service pipes coming into the appliance)
Clearance in Front of Enclosure (operating) .
.
.
.
5 mm MIN
Clearance in Front of Enclosure (servicing) .
.
.
.
600 mm MIN
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 22
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Clearance on Left Hand Side of Enclosure
.
.
.
.
5 mm MIN
Clearance on Right Hand Side of Enclosure .
.
.
.
5 mm MIN
Weight, Packed Appliance with Enclosure
.
.
.
.
45 kg
Weight, Installation Lifting Weight
.
.
.
.
35 kg
Appliance Safety Discharge Pressure (LTHW).
.
.
.
4.0 bar
Appliance Maximum Operating Pressure
.
.
.
.
3.0 bar
Appliance Minimum Operating Pressure
.
.
.
.
0.5 bar
Appliance Recommended Operating Pressure
.
.
.
1.0 – 2.0 bar
DHW Maximum Flow Rate @ 50°C Rise
.
.
.
.
12 L/min
DHW Minimum Working Flow Rate .
.
.
.
.
3 L/min
DHW Maximum Supply Pressure
.
.
.
.
.
8.0 bar
DHW Minimum Operating Pressure .
.
.
.
.
0.5 bar
Expansion Vessel Minimum Pre-charge Pressure
.
.
.
0.5 bar
Maximum LTHW System Capacity
.
.
.
100 L
.
.
.
DISCLAIMER: The flow controller operates from a minimum differential pressure of 0.5 barg up to a
maximum differential pressure of 4 barg between the primary flow side and the primary return
side. Where required a pressure controller should be installed on the primary return side of the
system to ensure that there is sufficient pressure in the return line to maintain a suitable pressure
differential between the flow and return lines. For example, in a primary system operating with a
nominal maximum working pressure of 5.2 barg a minimum pressure of 1.2 barg must be
maintained in the primary return line to ensure that the maximum pressure differential between
the primary flow and return lines does not exceed 4 barg.
DISCLAIMER: Stated nominal temperatures are theoretical values only and the actual operating
temperatures of the appliance may differ from these values. Actual operating temperatures will be
affected by local supply conditions for both domestic cold mains water and primary heating fluid,
local environmental conditions and supply demands placed upon the heating appliances.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 23
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
4.2 | CHW Appliances
Typical Primary Supply Temperature, CHW (Pri) In .
.
.
6°C
Typical Primary Return Temperature, CHW (Pri) Out.
.
.
12°C
Typical Secondary Return Temperature, CHW (Sec) Ret
.
.
13°C
Typical Secondary Flow Temperature, CHW (Sec) Flow
.
.
7°C
Electrical Supply Voltage*
.
.
.
.
.
.
240 V
.
.
.
.
50 Hz
(* appliance must be connected to an earthed electrical supply)
Electrical Supply Frequency* .
.
(* appliance must be connected to an earthed electrical supply)
External Fuse Rating .
.
.
.
.
.
.
3A
Typical Service Connections .
.
.
.
.
.
G3/4” BSP
Safety Valve Discharge Pipe Size
.
.
.
.
.
Ø15 mm OD
Typical Appliance Height
.
.
.
.
.
.
1120 mm
Typical Appliance Width
.
.
.
.
.
.
495 mm
Typical Appliance Depth
.
.
.
.
.
.
320 mm
Clearance Above Appliance .
.
.
.
.
.
20 mm MIN
.
.
.
.
200 mm MIN
Clearance in Front of Enclosure (operating) .
.
.
.
5 mm MIN
Clearance in Front of Enclosure (servicing) .
.
.
.
600 mm MIN
Clearance on Left Hand Side of Enclosure
.
.
.
.
5 mm MIN
Clearance on Right Hand Side of Enclosure .
.
.
.
5 mm MIN
Weight, Packed Appliance with Enclosure
.
.
.
.
45 kg
Weight, Installation Lifting Weight
.
.
.
.
35 kg
(* sufficient clearance must also be allowed for service pipes)
Clearance Below Appliance* .
.
(* sufficient clearance must also be allowed for service pipes)
.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 24
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appliance Safety Discharge Pressure (Secondary CHW)
.
.
4.0 bar
Appliance Maximum Operating Pressure
.
.
.
.
3.0 bar
Appliance Minimum Operating Pressure
.
.
.
.
0.5 bar
Appliance Recommended Operating Pressure
.
.
.
1.0 – 2.0 bar
Expansion Vessel Minimum Pre-charge Pressure
.
.
.
0.5 bar
DISCLAIMER: The flow controller operates from a minimum differential pressure of 0.5 barg up to a
maximum differential pressure of 4 barg between the primary flow side and the primary return
side. Where required a pressure controller should be installed on the primary return side of the
system to ensure that there is sufficient pressure in the return line to maintain a suitable pressure
differential between the flow and return lines. For example, in a primary system operating with a
nominal maximum working pressure of 5.2 barg a minimum pressure of 1.2 barg must be
maintained in the primary return line to ensure that the maximum pressure differential between
the primary flow and return lines does not exceed 4 barg.
DISCLAIMER: Stated nominal temperatures are theoretical values only and the actual operating
temperatures of the appliance may differ from these values. Actual operating temperatures will be
affected by local supply conditions for both domestic cold mains water and primary heating fluid,
local environmental conditions and supply demands placed upon the heating appliances.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 25
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
5 | DIMENSIONS & FIXINGS
5.1 | Inlet / Outlet Connections – LTHW / DHW Appliances
All inlet/outlet connections are G3/4” BSP Female.
The safety valve discharge pipe is Ø15mm OD copper tube.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 26
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
5.2 | Overall Dimensions: Minibreeze B (bottom entry services)
Please refer to section 4 to confirm the clearances required around the enclosure of the
appliance where it is installed.
5.3 | Mounting Hole Locations: Minibreeze B (bottom entry services)
The following diagram gives the dimensions of the mounting holes locations within the
mounting frame of the appliance for the Minibreeze B.
The dashed line around the appliance represents the envelope of the enclosure of the
appliance. When measuring and marking the locations of the holes at the site where the
appliance will be installed, please refer to section “4 | Technical Data & Specifications” to
confirm the clearances required around the enclosure of the appliance where it is installed.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 27
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
The double dashed line and dimension
“20 CLEAR” indicates the clearance
required above the level of the
enclosure of the appliance where it is
installed. So, for example, the upper
mounting holes for the mounting
frame of the appliance must be a
minimum of 61mm down from the
ceiling at the location in which the
appliance is installed, i.e. 20mm CLEAR
+ 41mm = 61mm.
The holes in the mounting frame of the
appliance are Ø6.0mm, and therefore
for installation of the appliance a
fastener of up to Ø6.0mm (#12) can be
used to secure the appliance to the wall
on which it is installed.
The upper right hand mounting holes’
location, when viewing the appliance
from the front as in the picture to the
right, is obscured by the pipes from the
heat exchanger. There are a further
three holes at the top of the back plate
to allow the appliance to be securely
attached to a flat vertical surface.
To attach the mounting frame of the appliance to a strong solid vertical wall and to support
the weight of the appliance Ormandy recommends the use of 4 self tapping screws of size
Ø6mm x 60mm long (#12 x 2 ½”) with raw plugs. The screws and raw plugs should be located
into suitable drilled holes in a strong solid vertical wall. It is the responsibility of the installing
engineer to assess the suitability of the location in which the appliance is to be installed and
ensure that this means of the mounting the appliance to the wall is capable of securing the
appliance and of supporting the weight of the appliance when it is operational.
Where the installing engineer deems it to be necessary to ensure a secure installation, they
should use an alternative method of attaching and securing the mounting frame of the
appliance to the wall.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 28
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
5.4 | Overall Dimensions: Minibreeze T (top entry services)
Please refer to section “4 | Technical Data & Specifications” to confirm the clearances
required around the enclosure of the appliance where it is installed.
5.5 | Mounting Hole Locations: Minibreeze T (top entry services)
The following diagram gives the dimensions of the mounting holes locations within the
mounting frame of the appliance for the Minibreeze T.
The dashed line around the appliance represents the envelope of the enclosure of the
appliance. When measuring and marking the locations of the holes at the site where the
appliance will be installed, please refer to section “4 | Technical Data & Specifications” to
confirm the clearances required around the enclosure of the appliance where it is installed.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 29
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Please note that the view shown on the right
is looking on the rear of the appliance.
The double dashed line and dimension “20
CLEAR” indicates the clearance required
above the level of the enclosure of the
appliance where it is installed. So, for
example, the upper mounting holes for the
mounting frame of the appliance must be a
minimum of 76mm down from the ceiling at
the location in which the appliance is
installed, i.e. 20mm CLEAR + 56mm = 76mm.
To allow for the top entry of service pipes in
the Minibreeze T, the appliance has additional
mounting brackets on the rear of the
appliance to offset the main frame from the
wall. It is possible to install the rear brackets if
the service pipes are in location, but it is
preferable to have a clear working area and
install the rear brackets before the service
pipes are installed. Once the rear brackets are
securely attached to the wall the service pipes
can be installed.
To attach the mounting bracket of the appliance to a strong solid vertical wall and to support
the weight of the appliance Ormandy recommends the use of 4 self tapping screws of size
Ø6mm x 60mm long (#12 x 2 ½”) with raw plugs. The screws and raw plugs should be located
into suitable drilled holes in a strong solid vertical wall. It is the responsibility of the installing
engineer to assess the suitability of the location in which the appliance is to be installed and
ensure that this means of the mounting the appliance to the wall is capable of securing the
appliance and of supporting the weight of the appliance when it is operational.
Where the installing engineer deems it to be necessary to ensure a secure installation, they
should use an alternative method of attaching the brackets and securing the mounting
frame of the appliance to the wall.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 30
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Once the rear brackets and
service pipes have been
successfully installed the
appliance may be attached to
the rear brackets.
When viewing the appliance
from the front one of the
upper mounting bolt locations
is likely to be obscured by the
pipework from the heat
exchanger. If this is the case
then there are a further three
holes at the top of the
appliance back plate that can
be used to mount the
appliance to the wall brackets.
The back plate should be
attached to the wall brackets
using M6 hexagonal head
bolts with a minimum length
of 10mm.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 31
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
5.6 | Overall Dimensions: Minibreeze CHW (Top Entry Services)
Please refer to section “4 | Technical Data & Specifications” to confirm the clearances
required around the enclosure of the appliance where it is installed.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 32
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
5.7 | Mounting Hole Locations: Minibreeze CHW (Top Entry Services)
The following diagram gives the
dimensions of the mounting
holes locations within the
mounting frame of the appliance
for the Minibreeze CHW.
The dashed line around the
appliance
represents
the
envelope of the enclosure of the
appliance. When measuring and
marking the locations of the
holes at the site where the
appliance will be installed,
please refer to section “4 |
Technical Data & Specifications”
to confirm the clearances
required around the enclosure
of the appliance where it is
installed.
The double dashed line and
dimension “20 CLEAR” indicates
the clearance required above
the level of the enclosure of the
appliance where it is installed.
So, for example, the upper
mounting
holes
for
the
mounting
frame
of
the
appliance must be a minimum
of 61mm down from the ceiling
at the location in which the
appliance is installed, i.e. 20mm
CLEAR + 41mm = 61mm.
The holes in the mounting frame of the appliance are Ø6.0mm, and therefore for installation
of the appliance a screw of up to Ø6.0mm (#12) can be used to secure the appliance to the
wall on which it is installed.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 33
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
The upper and lower right hand mounting holes’ location, when viewing the appliance from
the front as in the picture on the previous page, may be partially obscured by the pipes or
the expansion vessel.
To attach the mounting frame of the appliance to a strong solid vertical wall and to support
the weight of the appliance Ormandy recommends the use of 4 self tapping screws of size
Ø6mm x 60mm long (#12 x 2 ½”) with raw plugs. The screws and raw plugs should be located
into suitable drilled holes in a strong solid vertical wall. It is the responsibility of the installing
engineer to assess the suitability of the location in which the appliance is to be installed and
ensure that this means of the mounting the appliance to the wall is capable of securing the
appliance and of supporting the weight of the appliance when it is operational.
Where the installing engineer deems it to be necessary to ensure a secure installation, they
should use an alternative method of attaching and securing the mounting frame of the
appliance to the wall.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 34
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
6 | SYSTEM DETAILS
6.1 | Primary & Secondary Heating / Cooling Circuits
The appliance is suitable for use on fully pumped sealed systems only.
All re-circulatory water systems will be subject to corrosion unless an appropriate water
treatment is applied. This means that the efficiency of the system will deteriorate as
corrosion sludge accumulates within the system, risking damage to pump and valves,
appliance noise and circulation problems.
When upgrading existing systems that exhibit evidence of such contamination it is advisable
to clean the system prior to treatment in order to remove any contamination and reduce the
likelihood of these deposits damaging new components.
When fitting new systems flux will be evident within the system, which can lead to damage
of system components.
All systems must be thoroughly drained and flushed out. The recommended flushing and
cleansing agents are Betz-Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal
Cleanser which should be used following the flushing agent manufacturer’s instructions.
System additives - corrosion inhibitors and flushing agents/descalers – should be suitable for
aluminium, stainless steel and copper and should comply with the requirements of BS7593.
The only system additives recommended are Betz-Dearborn Sentinel X100 and Fernox-Copal
which should be used following the inhibitor manufacturer’s instructions.
Failure to flush and add inhibitor to the system will
invalidate the appliance warranty.
It is important to check the inhibitor concentration after installation, system modification
and at every service in accordance with the manufacturer’s instructions. (Test kits are
available from inhibitor stockists.)
6.2 | System Control
The appliance can be installed as a standalone unit that operates without the need for
external controls or inputs from external sources.
The appliance can also be used in a heating / cooling system that incorporates external
controls, i.e. an optional room sensor. For optimum operating conditions and maximum
economy the fitting of a room sensor is recommended.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 35
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
6.3 | System Filling & Pressurisation
The filling method adopted must be in accordance with all relevant water supply regulations.
A temporary filling loop is provided within the appliance to facilitate initial filling and
pressurising and also any subsequent water loss replacement/refilling.
The filling loop is typically initially connected between the mains cold water inlet and the
central heating / cooling return. The filling loop has a stop and double check valve on the
cold water side and an isolation valve on the central heating / cooling return side.
The central heating / cooling circuit may be filled or replenished by means of the temporary
filling loop but the temporary connection must be removed after use.
6.4 | Expansion Vessel
The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill
pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to
100 litres. For greater system capacities an additional expansion vessel must be fitted.
6.5 | Pressure Relief Valve
The pressure relief valve is set at 4 bar therefore all pipework, fittings, etc. should be
suitable for pressures in excess of 4 bar.
The appliance is supplied with a pressure relief discharge pipe of Ø15mm. Where it is
necessary to change this pipe or reduce the pipe for installation, the pressure relief
discharge pipe should be not less than Ø15mm, run continuously downward, and discharge
outside the building, preferably over a drain. It should be routed in such a manner that no
hazard occurs to occupants or causes damage to wiring or electrical components. The end of
the pipe should terminate facing down and towards the wall.
The discharge must not be above a window, entrance or other public access. The installing
engineer should give consideration to the possibility that boiling water/steam could
discharge from the pipe (LTHW appliances).
6.6 | Domestic Hot Water Circuit
All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant
standards, the water supply regulations.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 36
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
6.7 | Showers
If a shower control is supplied from the appliance it should be of the thermostatic or
pressure balanced type. Thermostatic type shower valves provide the best comfort and
guard against water at too high a temperature. Existing controls may not be suitable - refer
to the shower valve manufacturer.
6.8 | Hard Water Areas
If the area of the installation is recognised as a HARD WATER AREA then a suitable device
should be fitted to treat the mains water supply to the appliance. Contact the relevant
Water Distribution Company for the installation area for advice on water quality and suitable
water treatment devices.
6.9 | Flow Controller
The flow controller operates from a minimum difference pressure of 0.5 barg up to a
maximum differential pressure of 4 barg between the primary flow side and the primary
return side. Where required a pressure controller should be installed on the primary return
side of the system to ensure that there is sufficient pressure in the return line to maintain a
suitable pressure differential between the flow and return lines.
For example, in a primary system operating with a nominal maximum working pressure of
5.2 barg a minimum pressure of 1.2 barg must be maintained in the primary return line to
ensure that the maximum pressure differential between the primary flow and return lines
does not exceed 4 barg.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 37
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
7 | INSTALLATION REQUIREMENTS
7.1 | Installed Location
The appliance may be fitted to any suitable wall that is capable of supporting the weight of
installed appliance when it is operation. As the appliance does not require air supply or a
flue to discharge products of combustion, as required by gas fired appliances, it can be
installed in any suitable location within a building provided there are adequate clearances
for installation and servicing of the appliance, service pipes and electrical supply. The
appliance should be fitted within a building unless otherwise protected by a suitable
enclosure i.e. garage or outhouse. (The appliance may be fitted inside a cupboard - see
Section 7.3).
If the appliance is sited in an unheated enclosure or location which may be exposed to
temperatures below 5°C then it is recommended the frost protection facility within the
control system of the appliance is activated.
If the appliance is fitted in a room containing a bath or shower reference must be made to
the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building
Regulations.
7.2 | Clearances
A flat vertical area is required for the installation of the boiler. The may be a wall or other
suitable area that is strong enough to support the appliance when it is operation.
These clearance dimensions specified in section 4 include the necessary clearances around
the appliance for enclosure removal and servicing access. Additional clearances may be
required for the passage of pipes or electrical supply cables around local obstructions, e.g.
such as joists running parallel to the front face of the boiler.
7.3 | Ventilation
As the appliance does not rely upon combustion of any type to supply domestic hot water,
central heating or chilled water it is not necessary to provide a flue.
Where the appliance is installed enclosed in a cupboard or compartment it may be advisable
to provide air vents on the door of the cupboard or compartment to maintain an even
ambient temperature around the appliance.
Care should be taken to ensure that there are no materials within a cupboard or
compartment where the appliance is installed which may be damaged by contact with hot
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 38
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
pipework, or materials which may cause damage to or interfere with the safe operation of
the appliance.
7.4 | Electrical Supply
External wiring must be correctly earthed, polarised and in accordance with the relevant
regulations/rules. In GB this is the current I.E.E. Wiring Regulations.
This appliance requires connection to a suitable electrical supply. Refer to the detailed
appliance specification in section 4 of this manual to ensure that the local supply conditions
are appropriate for this appliance before attempting installation. Where any doubt exists,
DO NOT install the appliance and contact Ormandy Rycroft immediately to confirm the
suitability of the local supply for the appliance.
NOTE: The method of connection to the electricity supply must facilitate complete
electrical isolation of the appliance. Connection may be via a fused double-pole isolator
with a contact separation of at least 3mm in all poles and servicing the appliance and
system controls only.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 39
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
8 | INSTALLATION
8.1 | Preparing for installation
The water supply and pressure and local electrical supply must be checked for suitability
before connection (see section 4 & 7.4).
The locations of the fixing holes for the Minibreeze B (bottom service entry) and Minibreeze
T (top service entry) and Minibreeze CHW appliances are typically different. Please refer to
section 5 to ensure that the correct fixing dimensions are used.
After considering the installation requirements (see section 7.0) mark out the locations of
the fixing holes for the appliance on the wall ensuring they are marked correctly in both the
horizontal and vertical direction.
Drill the wall as marked or install suitable fixings at the marked locations.
Where the Minibreeze T appliance is being installed, the rear brackets of the appliance
should now be fixed to the wall. Use a spirit level to ensure that the brackets are level before
finally tightening the fixing screws.
8.2 | Flushing
Connect a tube to the central heating / cooling flow or return pipe and ensure there is a
means of containing the fluid that is flushed through the system.
Flush the system thoroughly – refer to 6.1 for details of suitable flushing agents.
8.3 | Preparing the appliance
Remove all packaging from the appliance.
Lay the appliance down, with the mounting frame first, onto a level surface. It is advised that
a suitable piece of material is used to protect the surface of the floor before laying the
appliance down.
Note: if the isolation valves on the appliance are opened before the appliance is fully
connected it is common for some water to drain from the appliance. This is water that has
remained in the appliance after final quality testing.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 40
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
8.4 | Installation
It is advised that the installing engineers should wear suitable hand protection whilst lifting
the appliance during installation. The appliance is a heavy object and the installation of the
appliance requires two people to complete. Refer to the guidelines for safe handling given
on page 4 of this manual before attempting installation.
For LTHW / DHW appliances, lift the appliance using the locations indicated below.
For CHW appliances, lift the appliance using from locations where a pipe support clamp is
directly attached to the mounting back plate. Do not lift the appliance from a location where
pipe work is not rigidly secured to the back plate, and do not lift from the connections on the
plate heat exchanger.
Failure to follow these guidelines could result in damage to the CHW appliance.
Minibreeze B / CHW
Align the mounting holes in the main frame of the appliance with the fixing holes and raw
plugs that have been drilled in the wall. Fix the appliance to the wall using suitable screws.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 41
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Minibreeze T
Align the mounting holes in the main frame of the appliance with the mounting hole of the
rear brackets that have been fixed to the wall. Fix the appliance to the rear brackets using
M6 Screws, minimum length 10mm.
Connect all the service pipes to the appropriate point on the appliance. Refer to section 5 for
details of the service pipe arrangement.
Connect the pressure relief valve discharge pipe to an outside discharge point, or connect
the pressure relief valve to a suitable discharge pipe that discharges to an outside discharge
point. All discharge pipework must be Ø15mm minimum and run continuously downwards
to a discharge point outside the building. Refer to section 6.5 for additional information
regarding the pressure relief valve and location of the discharge pipe.
Tighten all the connections.
8.5 | Electrical Connections
Refer to section 7.4 and the safety guidelines on page 2, 3 & 4 of this manual before
proceeding with any electrical work.
To connect the mains electrical supply, proceed as follows. Slacken and remove the 4 screws
from the front cover of the terminal box.
Looking into the terminal box, the connections for the electrical supply are located on the
top right hand corner of the circuit board.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 42
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
LTHW / DHW Appliances
The connection points for Live (L), Neutral (N), and Earth (PE) are clearly marked on the
circuit board. Ormandy recommends the use of a cable gland to securely retain the power
cable where it enters the terminal box.
Where an additional room sensor or external input will be connected to control the
operation of the appliance this can be attached as indicated on the circuit board diagram
above. All other wiring required for standard operation of the Minibreeze appliance is
completed during the manufacturing process. All other wiring required for standard
operation of the Minibreeze appliance is completed during the manufacturing process.
Reference can also be made schematic diagrams in section 13 of this manual.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 43
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
CHW Appliances
The connection points for Live (L), Neutral (N), and Earth (PE) are clearly marked on the
circuit board. Ormandy recommends the use of a cable gland to securely retain the power
cable where it enters the terminal box.
Where an additional room sensor or external input will be connected to control the
operation of the appliance this can be attached as indicated on the circuit board diagram
above. All other wiring required for standard operation of the Minibreeze appliance is
completed during the manufacturing process.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 44
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Reference can also be made schematic diagrams in section 13 of this manual.
Once the supply connections have been made, replace the front cover of the terminal box.
The supply cable for the power should now be securely attached to the appliance using
suitable means to ensure that the power cable cannot be disturbed or accidentally pulled
from the appliance.
Prior to commissioning the appliance preliminary electrical safety checks must be carried
out.
These checks must be performed using a suitable meter and as a minimum must include
checks for Ground Continuity, Resistance to Ground, Short Circuit and Polarity.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 45
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
9 | COMMISSIONING THE APPLIANCE
It has been assumed that the electrical connections required for normal operation of the
appliance have been completed before commissioning of the appliance commences.
Reference should be made to BS 5449 Section 5 when commissioning the appliance.
For DHW appliances, open the mains water supply to the appliance.
For DHW appliances, open all hot water taps temporarily to purge the DHW system.
Ensure that the filling loop is connected and open, then open the heating / cooling flow and
return valves on the appliance.
Where one is fitted, open the screw on the automatic air vent.
The system must be flushed in accordance with BS7593 (see Section 6.1 & 8.2) and the
flushing agent manufacturers’ instructions.
Pressurise the system to 1.0 bar then close and disconnect the temporary filling loop.
Check all connections within and into the appliance for water tightness and ensure the
entire heating / cooling system is sound and leak free.
Check the operation of the central heating / cooling circuit of the appliance. Where a room
sensor (room stat, thermostat) is used within a residence to control the output of the LTHW
Secondary (Central Heating) Circuit or the CHW cooling circuit, ensure the system and
appliance operates as expected and that the set point of the room sensor is adjusted to an
appropriate level. Where the required temperature from the central heating / cooling circuit
is not achieved, adjust the flow restriction screw on the flow control valve to allow more
flow through the LTHW / CHW plate heat exchanger. Refer to the appendices at the end of
this manual for specific instructions regarding adjustment of the flow restriction on the flow
control valve – see Appendix IV, document EB3136 EN, Section 4. Operation – Set Point
Adjustment.
Where appropriate, check the operation of the domestic hot water circuit of the appliance.
Adjust the set point of the temperature controller as necessary to achieve a suitable safe
output temperature for the domestic hot water, which should be measured using a
thermometer at the domestic hot water tap at the point in the circuit nearest to the
appliance. Refer to the appendices at the end of this manual for specific instructions
regarding adjusting the set point of the temperature controller – see Appendix V, document
EB 2430-3 EN, Set Point Adjustment.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 46
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
10 | COMPLETING INSTALLATION
10.1 | LTHW / DHW Bottom Entry Appliance
Where the appliance is installed in a location where it is enclosed within a cupboard or
similar cabinet, and the appliance is not intended to be fitted removable cover, installation
of the appliance is now complete.
Where the appliance is installed in a location where it is intended to have a removable
cover, and the service supply pipes enter the appliance from the bottom, the cover of the
appliance should be fitted as shown below.
Raise the cover so that tab of the cover will clear the hanger on the back plate. Slide the
cover over the over the appliance and lower it into position so that the tab engages the
hanger.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 47
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
10.2 | LTHW / DHW Top Entry Appliance
Where the appliance is installed in a location where it is enclosed within a cupboard or
similar cabinet, and the appliance is not intended to be fitted removable cover, installation
of the appliance is now complete.
Where the appliance is installed in a location where it is intended to have a removable cover
and the service supply pipes run behind the appliance from above, the cover of the
appliance should be fitted as shown below.
Raise the cover so that tab of the cover will clear the hanger on the back plate. Slide the
cover over the over the appliance and lower it into position so that the tab engages the
hanger.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 48
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
When the cover of the appliance has been fitted, fit the retaining screws between the main
frame and the appliance cover. When viewing the appliance from the front, the screws are
located in the lower rear left hand and right hand side of the appliance as indicated.
If it is necessary to secure the cover of the appliance so that it cannot be removed by anyone
except authorised service personnel or engineers, then the right hand side retaining screw
and U-nut can be replaced with a small padlock or seal tag.
Once the cover of the appliance has been fitted, instruct the user in the operation of the
appliance and system, and explain the operational sequence.
Carefully read and complete all sections of the Installation & Commissioning Checklist at the
rear of this manual. These details will be required in the event of any warranty work. This
publication must be handed to the user for safe keeping and each subsequent regular
service visit recorded.
Once the Installation & Commissioning Checklist is complete hand this manual over to the
user, giving advice on the necessity of regular servicing and maintenance.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 49
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
10.3 | CHW Top Entry Appliance
Where the appliance is installed in a location where it is enclosed within a cupboard or
similar cabinet, and the appliance is not intended to be fitted removable cover, installation
of the appliance is now complete.
Where the appliance is installed in a location where it is intended to have a removable cover
and the service supply pipes run behind the appliance from above, the cover of the
appliance should be fitted as shown below.
Raise the cover so that tab of the cover will clear the hanger on the back plate. Slide the
cover over the over the appliance and lower it into position so that the tab engages the
hanger.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 50
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
11 | SERVICING INFORMATION
For reasons of safety and economy, it is recommended that the appliance is serviced annually to
check the pressure within the LTHW / CHW circuit and ensure correct operation of the components
of the appliance. Servicing must be performed by a competent person. After servicing, complete the
relevant Service Interval Record section of the Installation & Commissioning Checklist at the rear of
this publication.
Ensure that the appliance is cool. Ensure that both the water and electrical supplies to the appliance
are isolated. Checks should be carried out to ensure the electrical isolation is complete.
Where a cover is fitted to the appliance, remove any screws securing the cover of the appliance. Lift
the cover so that any locating tabs on the cover clear the back plate of the appliance. Remove the
cover.
Make a thorough visual inspection for outward signs of wear or damage of all the components of the
appliance. Inspect all connections within the appliance and into the appliance for water tightness.
Where required maintain any connection that shows evidence of leakage. Ormandy recommends the
use of Loctite 55 or Loctite 577 for maintenance of threaded connections within and into the
appliance. Where there is leakage from a flat face union which cannot be sealed by tightening,
replacement washers are available from Ormandy where a local supply does not exist.
NOTE: The procedure for relieving internal pressure and draining down of the appliance or system
must be followed before any maintenance of a connection is attempted. Refer to section 12.1 –
12.4
Remove, clean and inspect the strainer on the primary heating / cooling supply (section 2.2, item 9).
Replace the strainer after cleaning and inspection.
Ensure that the system is pressurised to the correct level. Where required, introduce more water
into the system via the temporary filling loop (section 2.2, item 8). Pressurise the system to 1.0 bar
then close and disconnect the filling loop.
Where appropriate, check the operation of the domestic hot water circuit of the appliance. Where
required adjust the appliance controls to ensure correct operation of the domestic hot water circuit.
Check the operation of the central heating / cooling circuit of the appliance. Where required adjust
the appliance controls to ensure correct operation of the central heating / cooling circuit.
Complete the relevant Service Interval Record section at the rear of this manual and hand this
manual to the user.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 51
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
12 | COMPONENT REPLACEMENT
When changing components within the appliance ensure that both the water and electrical
supplies to the appliance are fully isolated before any work is started. Checks should be
carried out to ensure that electrical isolation is complete.
Refer to section 11 for instructions on removal of the appliance cover.
12.1 | Relieving Pressure in the Appliance
Before changing any component, depending on which component is to be replaced, the
internal pressure of the appliance, domestic hot water circuit, central heating or cooling
circuit must be relieved.
Failure to relieve the internal pressure of the system may lead to pressurised fluid escaping
from the system. This escape of pressurised fluid may have the potential to cause injury, to
cause damage to the appliance, or cause damage to the location in which the appliance is
installed.
Before relieving pressure in the appliance ensure that both the water and electrical supplies
to the appliance are isolated.
12.2 | To Relieve Pressure in the Primary Supply Circuit
LTHW Appliance
Connect a suitable flexible hose to the drain cock in the appliance
Put the other end of the flexible hose into a watertight container capable of holding a
minimum of 5 litres of fluid.
Open the tap of the drain cock and allow fluid to drain from the appliance into the container.
When all the fluid has drained from the appliance, close the tap of the drain cock.
CHW Appliance
Close the isolation valves on the primary flow and return lines.
Place a suitable container beneath the heat exchanger of the appliance.
Slowly release the drain plug fitted in the underside of the bottom connection of the primary
circuit on to the exchanger.
12.3 | To Relieve Pressure in the Secondary (Central Heating / Cooling) Circuit
Manually operate the pressure relief valve and allow the pressure in the secondary circuit to
be relieved.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 52
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
The combined temperature / pressure gauge will indicate the pressure within the secondary
circuit.
When the pressure in the secondary circuit has been relieved, close the pressure relief valve.
12.4 | To Relieve Pressure in the Domestic Hot Water Circuit
Close the isolation valve that controls the cold mains feed to the Domestic Hot Water Circuit
(DHW COLD FEED IN).
Check that the isolation valve on the appliance that controls the domestic hot water supply
(DHW HOT FEED OUT) is open.
Open all the hot taps in the system to allow any pressure in the domestic hot water circuit to
be relieved.
Once any pressure in the domestic hot water circuit has been relieved, close all the hot taps.
Close the isolation valve on the appliance that controls the domestic hot water supply.
12.5 | Expansion Vessel
Relieve the pressure in the secondary (central heating) circuit.
Loosen and release the union on the expansion vessel connection.
For LTHW appliances, remove the screws holding the terminal box mounting plate to the
expansion vessel support bracket. Lower the terminal box and mounting plate so they do not
obstruct the expansion vessel. Support the expansions vessel and remove the screw holding
the upper expansion vessel strap to the main back plate of the appliance. Remove the strap.
For CHW appliances, support the expansion vessel and release the retaining strap that holds
the expansion vessel on the main back plate of the appliance.
Remove the expansion vessel from the appliance.
12.6 | Flow Controller
LTHW / DHW Appliances:
Relieve the pressure in the primary supply circuit.
Release the connecting nut between the flow controller actuator and valve body and
remove the actuator.
Loosen and release the union connections on either side of the valve body of the flow
controller
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 53
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Remove the flow controller from the appliance.
CHW Appliances:
Relieve the pressure in the primary supply circuit. Ensure the primary flow and return
isolating valves are shut above the flushing loop, and the isolation valve on the flushing loop
is shut.
Release the connecting nut between the flow controller actuator and valve body and
remove the actuator.
Loosen and release the union connection on to the CHW heat exchanger from the flow
control valve.
Loosen and release the union connection on the primary return line below the flushing loop.
Remove the flow controller and connecting pipe work from the appliance.
12.7 | Heat Meter
Relieve the pressure in the primary supply circuit.
Slacken and release the retaining screw holding the sensor in the sensor pocket on the
primary flow line.
Withdraw the sensor from the sensor pocket.
Slacken and release the unions at the top and bottom of the heat meter and remove the
heat meter taking care not to damage any of the cables or sensors.
NOTE: The sensor may be a tight fit in the sensor pocket. If it cannot be removed easily do
not exert excessive force on the connection cable or sensor, and do not pull on the cable as
this may cause damage to the cable and/or sensor. In this case the sensor pocket complete
with sensor should be unscrewed and removed from the primary flow line.
12.8 | Terminal Box
Ensure the appliance is fully isolated from the electrical supply.
Slacken and remove the screws holding the front cover of the terminal box.
Clearly mark all cables and the connections the cables make within the terminal box so that
they can be identified and re-connected correctly.
Release all cable connections within the terminal box and withdraw the cables.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 54
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Slacken and remove the screws holding the terminal box mounting plate to the expansion
vessel bracket and remove the terminal box and mounting plate.
12.9 | Temporary Filling Loop
The filling loop is intended to be a temporary connection only.
The filling loop is equipped with a double check and isolation valve on the side connected to
the domestic hot water cold feed pipe, and with an isolation valve on the side connected to
the secondary (central heating) circuit.
Ensure that the isolation valves of the filling loop are in the closed position.
Unscrew the fittings connecting the filling loop to the isolation valve and check valve. Do not
slacken the compression fittings on either the isolation valve or check valve.
Remove the filling loop.
12.10 | Strainer
LTHW / DHW Appliances:
Relieve the pressure in the primary circuit of the appliance
Slacken and release the unions on the hexagonal nipples on the strainer.
Remove the strainer.
CHW Appliances:
For CHW appliances it is not possible to fully remove the body of the strainer unless suitable
isolation has been installed in the service pipe work leading into the strainer.
12.11 | Safety Valve [Pressure Relief Valve]
Relieve the pressure in the secondary (central heating) circuit.
Slacken and release the union on the discharge side of the safety valve.
LTHW Appliances: slacken and release the union at the rear of the safety valve between the
valve and the branch off the secondary circuit.
CHW Appliances: unscrew the safety valve from the branch off the secondary circuit
Remove the safety valve from the appliance.
12.12 | Flow Switch
Ensure the appliance is fully isolated from the electrical supply.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 55
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Relieve the pressure in the domestic hot water circuit
Slacken and remove the screw holding the front cover of the terminal box.
Remove the front cover of the terminal box.
Clearly mark the flow switch cable and the connections the cable makes within the terminal
box so that they can be identified and re-connected correctly.
Release the flow switch cable connections within the terminal box and withdraw the cable.
Unscrew the knurled plastic nut connecting the flow switch to the pipe nipple on the
domestic hot water cold feed pipe.
Carefully withdraw the flow switch from the pipe nipple.
12.13 | Drain Cock
The drain cock is an integral part of the pipework in the appliance.
Where it is necessary to remove the drain cock you must slacken and release the union to
the bottom of the heat meter.
Slacken and release the pipe clamp at the bottom of the pipe which includes the drain cock.
Remove the pipework complete with drain cock.
12.14 | G1/4” Test Point
The test points are provided to allow a sensor to be introduced into the service pipes to
monitor heat content of the fluid in the system circuits.
Relieve the pressure in the appropriate circuit.
Unscrew and remove the test point from the appliance.
12.15 | Cover Retaining Screw
Refer to section 10
12.16 | Temperature Sensor
Ensure the appliance is fully isolated from the electrical supply.
Slacken and remove the screw holding the front cover of the terminal box.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 56
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Clearly mark the temperature sensor cable and the connections the cable makes within the
terminal box so that they can be identified and re-connected correctly.
Release the temperature sensor cable connections within the terminal box and withdraw the
cable. Where necessary cut the cable tie which holds the temperature sensor onto the pipe
work. When cutting a cable tie, take care not to damage the insulation on the cable.
Remove the temperature sensor.
12.17 | Domestic Hot Water Heat Exchanger
Relieve the pressure in the primary and domestic hot water circuits.
Slacken and release the unions on the domestic hot water heat exchanger.
Slacken and release the connection nut between the temperature controller spool piece and
the domestic hot water heat exchanger.
Slacken and release the connection nut between the temperature sensor tee piece and the
domestic hot water heat exchanger.
Remove the domestic hot water heat exchanger
12.18 | Temperature Controller
Remove the domestic hot water heat exchanger as described in section 12.17
Slacken and release the union on the temperature sensor tee piece and remove the tee
piece with the temperature sensor.
Slacken and release the union on the left hand side of the temperature controller.
Remove the temperature controller.
12.19 | Pump
Relieve the pressure in the secondary (central heating / cooling circuit).
Slacken and release the unions connecting the pump into the appliance.
Remove the pump.
12.20 | Temperature / Pressure Gauge
The gauge is provided with an adapter that allows the gauge to be removed from the
appliance without the need to relieve the pressure in the circuit to which it is attached. The
gauge and its adapter are screwed into the female branch of a tee connection.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 57
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Unscrew and remove the temperature / pressure gauge from the adapter, taking care not to
disturb the adapter in the branch of the tee connection.
12.21 | Temperature Sensor [temperature controller]
The temperature sensor for the temperature controller is connected to the temperature
controller. The sensor can be removed from the domestic hot water heat exchanger but to
completely remove the sensor it must be removed in conjunction with the temperature
controller. Refer to section 12.17 and 12.18.
12.22 | Mounting Frame
The mounting frame is an integral part of the appliance and is not intended to be a
serviceable or removable item.
12.23 | Automatic Air Release Valve
Relieve the pressure in the secondary (central heating) circuit.
Unscrew the automatic air release valve from the female boss in the pipework.
Remove the automatic air release valve.
12.24 | Low Temperature Hot Water (Central Heating / Cooling) Heat Exchanger
Relieve the pressure in the primary and secondary circuits. (central heating / cooling).
Slacken and release the unions on to the heat exchanger.
Remove the heat exchanger.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 58
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
13 | SCHEMATIC DIAGRAMS
13.1 | Process & Instrumentation Diagrams
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 59
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
13.2 | Electrical Diagrams
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 68
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
14 | TROUBLESHOOTING
14.1 | Initial fault Finding Checks
Before attempting specific fault finding checks on the appliance, the following initial checks
should be completed.
1. Check that the appliance is suitably connected to water and electrical supplies and
that the supplies are available to the appliance.
2. Check that the pressure within the LTHW or CHW Secondary Circuit is at the correct
level.
3. Check that all isolation valves on the service pipes supplying the appliance are in the
open position.
4. Carry out electrical system check, i.e. ground continuity, resistance to ground, short
circuit and polarity with a suitable meter
NOTE: These electrical checks must be repeated after any servicing or fault finding.
5. Ensure all external controls are calling for heat/cooling and check all internal and
external fuses.
6. Before any servicing or replacement of parts, ensure that all electrical and service
supplies are correctly isolated. In the case of electrical services, checks should be
performed to ensure that isolation is complete.
14.2 | Domestic Hot Water
The sequence of operation for the Domestic Hot Water circuit (DHW) is as follows. If at any
point the appliance does not respond as expected the components or parts of the system
relating to that particular step of the process should be investigated further for correct
operation.
1.
2.
3.
4.
5.
6.
7.
8.
Turn on a hot tap to cause flow through the domestic hot water circuit.
Flow switch triggered by flow in domestic hot water circuit.
Flow controller diverts flow through the primary side of the DHW heat exchanger.
Temperature sensor on secondary side of DHW heat exchanger detects temperature
lower than the set point of the temperature controller.
Temperature controller allows full flow through the primary side of the DHW heat
exchanger.
Temperature in the DHW secondary flow from hot tap increases.
As temperature in secondary side of DHW heat exchanger (flow from hot tap) is
raised towards the set point of the temperature controller the flow will be controller
to maintain a constant DHW temperature.
Hot tap is closed; flow controller allows flow through LTHW primary side.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 71
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
14.3 | Central Heating / Cooling
The sequence of operation for the Central Heating (LTHW) / Cooling (CHW) circuit is as
follows. If at any point the appliance does not respond as expected the components or parts
of the system relating to that particular step of the process should be investigated further
for correct operation.
1.
2.
3.
4.
Room thermostat calls for increase (LTHW) or decrease (CHW) in room temperature.
Flow controller opens to allow flow through primary side of heat exchanger.
Pump on secondary circuit operates to create flow around the circuit.
Pump continues to operate and cause flow through the secondary circuit until the
temperature in the room reaches the set point of the room sensor.
5. When set point of the room sensor is reached the pump runs on for a pre-set time.
6. When set point is achieved the flow controller restricts or stops flow through the
primary side of the exchanger unless there are further calls to maintain room
temperature at the set point.
14.4 | Flow Controller
The flow controller is a key component within the appliance. If there is a fault with the
controller it will indicate this with a continuously illuminated red LED on the top of the
controller body.
If the red LED on the flow controller is flashing, this indicates a fault with an external sensor
connected to the controller. In the event that there are several external sensors connected
to the controller the sequence of flashes given off by the LED will indicate which sensor is at
fault.
Where several faults occur, either in the controller itself or in the sensors connected to it,
the LED will indicate the fault with the highest priority.
If the flow rate from the controller deviates considerably from the adjusted set point, first
check the control line for any blockages.
If the valve does not seal properly, this may be because tight shut-off is prevented by dirt
between the seat and plug or due to natural wear. Check the regulator for leaks and replace
it if necessary.
Further details on the controller can be found in the appendices at the end of this manual.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 72
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
14.5 | Temperature Controller
Should the output temperature of the secondary DHW circuit exceed the set point adjusted,
the cause could be either contamination of seat and plug or wear and tear of the seat and
plug no longer ensuring tight shut-off in the Temperature Controller.
For remedy, the valve can be disassembled after shutting down the appliance.
Further details on the controller can be found in the appendices at the end of this manual.
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 73
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
15 | PARTS LIST
LTHW EXPANSION
VESSEL 537EV8L
TEMPERATURE /
PRESSURE GAUGE
WPTG06
1/4” & 1/2”
BLANKING PLUGS
H7PG14 & H7PG12
TEMPERATURE
SENSOR
S663000
3/4” ISOLATION
VALVE 34BBVT
ALPHA 2L PUMP
ALPHA1550
3/4” STRAINER
STR20/47N
1/2” SAFETY VALVE
312405
HEAT EXCHANGERS
(Specify type, duty
and number of
plates)
FILLING LOOP
15MMFLOOP
FLOW SWITCH
VKX20M1
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 74
1/2” AUTO AIR
VALVE 502640
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
TEMPERATURE
CONTROL VALVE
(specify size) (43-2N)
ADAPTER
S14009234
SPOOL PIECE
S14009236
TEMPERATURE
CONTROL SENSOR
(43-2N)
ELECTRONIC FLOW
CONTROLLER
(5757-7)
FLOW CONTROL
VALVE (specify size)
(2488N)
JUNCTION BOARD
SU22PCB
3-WAY CONTROL
VALVE (specify size)
(3226)
CHW EXPANSION
VESSEL PV8W
DOUBLE REGULATING
VALVE (specify size)
(D931)
ORIFICE PLATE
(Specify size) D901
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Page | 75
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix i |
Installation & Commissioning Checklist
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
INSTALLATION DETAILS
Address:
Appliance Serial Number :
Meter Serial Number :
Meter Start Reading :
Meter End Reading :
CONTROLS:
Installed thermostat & programmer / timer
Time & temperature control for heating :
Pump Setting :
Or, installed programmable roomstat
III
Heating zone valves :
Fitted
Thermostatic radiator valves :
Fitted
Automatic system bypass :
Fitted
II
I
PP1
PP2
Not Required
Not Required
Not Required
FOR ALL APPLIANCE INSTALLATIONS CONFIRM THE FOLLOWING:
The system has been flushed in accordance with the appliance manufacturers’ instructions
(This includes that the system has been flushed with an appropriate cleaner prior to commissioning and then
commissioned using an appropriate inhibitor and strainers have been inspected and cleaned.)
CP1
CP2
FOR THE CENTRAL HEATING / COOLING MODE, MEASURE AND RECORD THE FOLLOWING:
Primary Flow Temp. (°C) :
Secondary Flow Temp. (°C) :
Primary Return Temp. (°C) :
Secondary Return Temp. (°C) :
Primary Flow Rate (l/hr) :
Secondary Flow Rate (l/min) :
FOR THE DOMESTIC HOT WATER MODE, MEASURE AND RECORD THE FOLLOWING:
Primary Flow Temp. (°C) :
Cold Water Inlet Temp. (°C) :
Primary Return Temp. (°C) :
Hot Water Outlet Temp. (°C) :
Primary Flow Rate (l/hr) :
Hot Water Flow Rate (l/min) :
Please note: for normal operation of the appliance a minimum primary supply differential pressure of 0.4 bar is required.
FOR APPLIANCE INSTALLATIONS CONFIRM THE FOLLOWING:
The heating/cooling and hot water system complies with the current Building Regulations
The appliance and associated equipment has been installed & commissioned in accordance
with the manufacturers’ instructions
The manufacturers’ literature has been left in the dwelling
APPLIANCE COMMISSIONED BY:
Company Name :
Commissioning Engineer :
Sign :
Date :
Additional Notes :
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix ii |
Appliance Service Interval Record
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
It is recommended that to keep your heating/cooling system in optimum condition it is
serviced periodically and an entry is made in the appropriate Service Interval Record below.
For the attention of the Servicing Engineer: Before completing the appropriate Service
Interval Record below, please ensure that you have serviced the appliance in accordance
with the manufacturers’ instructions. Always replace a component with the manufacturers’
recommended spare part when servicing this appliance.
SERVICE 1
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 2
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 3
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 4
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 5
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 6
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 7
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
SERVICE 8
Date: . . . . . . . . . . . . . . . . . .
Engineer Name:
..................
Company Name:
..................
Tel No:
........................
CORGI ID Card Serial: . . . . . . . . . . . . . . . . . .
Comments: . . . . . . . . . . . . . . . . . . . . . . . .
....................................
Signature:
........................
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix iii |
Manual Handling Guidance & Assessment Charts
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Health and Safety
Executive
Manual handling at work
A brief guide
Introduction
This leaflet describes what you, as an employer, may need to do to protect
your employees from the risk of injury through manual handling tasks in
the workplace. It will also be useful to employees and their representatives.
The Manual Handling Operations Regulations 1992, as amended in 2002
(‘the Regulations’) apply to a wide range of manual handling activities,
including lifting, lowering, pushing, pulling or carrying. The load may be
either animate, such as a person or an animal, or inanimate, such as a box
or a trolley.
What’s the problem?
This is a web-friendly version
of leaflet INDG143(rev3),
published 11/12
Incorrect manual handling is one of the most common causes of injury at work. It
causes work-related musculoskeletal disorders (MSDs) which account for over a
third of all workplace injuries. (For the latest statistics, visit the HSE web page,
www.hse.gov.uk/statistics/causdis/musculoskeletal/index.htm.)
Manual handling injuries can happen anywhere people are at work – on farms and
building sites, in factories, offices, warehouses, hospitals, banks, laboratories, and
while making deliveries. Heavy manual labour, awkward postures, manual materials
handling, and previous or existing injury are all risk factors in developing MSDs.
There is more information and advice on MSDs on the HSE website, including
advice on managing back pain at work.
Taking the action described here will help prevent these injuries and is likely to be
cost effective. But you can’t prevent all MSDs, so it is still essential to encourage
early reporting of symptoms.
What should I do about it?
Consider the risks from manual handling to the health and safety of your
employees – this guidance will help you to do this. If there are risks, the Regulations
apply.
Consult and involve the workforce. Your employees and their representatives
know first hand what the risks in the workplace are. They can probably offer
practical solutions to controlling them.
The Regulations require employers to:
■■ avoid the need for hazardous manual handling, so far as is reasonably
■■
■■
practicable;
assess the risk of injury from any hazardous manual handling that can’t be
avoided; and
reduce the risk of injury from hazardous manual handling, so far as is
reasonably practicable.
Page 1 of 10
Health and Safety
Executive
These points are explained in detail under ‘Avoiding manual handling’ and
‘Assessing and reducing the risk of injury’.
Employees have duties too. They should:
■■
■■
■■
■■
■■
follow systems of work in place for their safety;
use equipment provided for their safety properly;
cooperate with their employer on health and safety matters;
inform their employer if they identify hazardous handling activities;
take care to make sure their activities do not put others at risk.
Avoiding manual handling
Check whether you need to move it at all
For example:
■■ Does a large workpiece really need to be moved, or can the activity
■■
(eg wrapping or machining) be done safely where the item already is?
Can raw materials be delivered directly to their point of use?
Consider automation, particularly for new processes
Think about mechanisation and using handling aids. For example:
■■
■■
■■
■■
a conveyor;
a pallet truck;
an electric or hand-powered hoist;
a lift truck.
But beware of new hazards from automation or mechanisation.
For example:
■■ automated plant still needs cleaning, maintenance etc;
■■ lift trucks must be suited to the work and have properly trained operators.
Controlling the risks
As part of managing the health and safety of your business, you must control the
risks in your workplace. To do this you need to think about what might cause harm
to people and decide whether you are doing enough to prevent harm. This process
is known as a risk assessment and it is something you are required by law to carry
out.
A risk assessment is about identifying and taking sensible and proportionate
measures to control the risks in your workplace, not about creating huge amounts of
paperwork. You are probably already taking steps to protect your employees, but
your risk assessment will help you decide whether you should be doing more.
Think about how accidents and ill health could happen and concentrate on real risks
– those that are most likely and which will cause the most harm. The following might
help:
■■ Think about your workplace activities, processes and the substances used that
could injure your employees or harm their health.
Manual handling at work: A brief guide Page 2 of 10
Health and Safety
Executive
■■ Ask your employees what they think the hazards are, as they may notice things
■■
■■
that are not obvious to you and may have some good ideas on how to control
the risks.
Check manufacturers’ instructions or data sheets for chemicals and equipment,
as they can be very helpful in spelling out the hazards.
Some workers may have particular requirements, for example new and young
workers, migrant workers, new or expectant mothers, people with disabilities,
temporary workers, contractors, homeworkers and lone workers may be at
particular risk.
Having identified the hazards, you then have to decide how likely it is that harm will
occur. Risk is a part of everyday life and you are not expected to eliminate all risks.
What you must do is make sure you know about the main risks and the things you
need to do to manage them responsibly. Generally, you need to do everything
reasonably practicable to protect people from harm.
Make a record of your significant findings – the hazards, how people might be
harmed by them and what you have in place to control the risks. Any record
produced should be simple and focused on controls. If you have fewer than five
employees you do not have to write anything down. But it is useful to do this so you
can review it at a later date, for example if something changes. If you have five or
more employees, you are required by law to write it down.
Few workplaces stay the same, so it makes sense to review what you are doing
regularly.
Table 1 Making an assessment
Problems to look for when making an
assessment
Ways of reducing the risk
of injury
The tasks, do they involve:
Can you:
■■ holding loads away from the body?
■■ twisting, stooping or reaching upwards?
■■ large vertical movement?
■■ long carrying distances?
■■ strenuous pushing or pulling?
■■ repetitive handling?
■■ insufficient rest or recovery time?
■■ a work rate imposed by a process?
■■ use a lifting aid?
■■ improve workplace layout to improve efficiency?
■■ reduce the amount of twisting and stooping?
■■ avoid lifting from floor level or above shoulder The loads, are they:
Can you make the load:
■■ heavy or bulky?
■■ difficult to grasp?
■■ unstable or likely to move unpredictably
■■ lighter or less bulky?
■■ easier to grasp?
■■ more stable?
■■ evenly stacked?
(like animals)?
■■ harmful, eg sharp or hot?
■■ awkwardly stacked?
■■ too large for the handler to see over?
height, especially heavy loads?
■■ reduce carrying distances?
■■ avoid repetitive handling?
■■ vary the work, allowing one set of muscles to rest while another is used?
■■ push rather than pull?
If the load comes in from elsewhere, have you asked
the supplier to help, eg by providing handles or
smaller packages?
Manual handling at work: A brief guide Page 3 of 10
Health and Safety
Executive
Table 1 Making an assessment (continued)
Problems to look for when making an
assessment
Ways of reducing the risk
of injury
The working environment, are there:
Can you:
■■ restrictions on posture?
■■ bumpy, obstructed or slippery floors?
■■ variations in floor levels?
■■ hot/cold/humid conditions?
■■ gusts of wind or other strong air movements?
■■ poor lighting conditions?
■■ restrictions on movements from clothes or ■■ remove obstructions to free movement?
■■ provide better flooring?
■■ avoid steps and steep ramps?
■■ prevent extremes of hot and cold?
■■ improve lighting?
■■ provide protective clothing or PPE that is less personal protective equipment (PPE)?
restrictive?
■■ ensure your employees’ clothing and footwear is suitable for their work?
Individual capacity, does the job:
Can you:
■■ require unusual capability, eg above average ■■ pay particular attention to those who have a Handling aids and equipment:
Can you:
■■ is the device the correct type for the job?
■■ is it well maintained?
■■ are the wheels on the device suited to the floor ■■ adjust the work rate?
■■ provide equipment that is more suitable for the ■■
■■
strength or agility?
■■ endanger those with a health problem or learning/
physical disability?
■■ endanger pregnant women?
■■ call for special information or training?
■■
■■
surface?
do the wheels run freely?
is the handle height between the waist and shoulders?
are the handle grips in good condition and comfortable?
are there any brakes? If so, do they work?
physical weakness?
■■ take extra care of pregnant workers?
■■ give your employees more information, eg about the range of tasks they are likely to face?
■■ provide more training (see ‘What about training?’)
■■ get advice from an occupational health advisor if you need to?
■■
■■
■■
■■
task?
carry out planned preventive maintenance to prevent problems?
change the wheels, tyres and/or flooring so that equipment moves easily?
provide better handles and handle grips?
make the brakes easier to use, reliable and effective?
Work organisation factors:
Can you:
■■ is the work repetitive or boring?
■■ is work machine or system-paced?
■■ do workers feel the demands of the work are ■■
■■
■■
■■
■■
■■
■■
■■
excessive?
have workers little control of the work and working methods?
is there poor communication between managers and employees?
Manual handling at work: A brief guide change tasks to reduce the monotony?
make more use of workers’ skills?
make workloads and deadlines more achievable?
encourage good communication and teamwork?
involve workers in decisions?
provide better training and information?
Page 4 of 10
Health and Safety
Executive
How far must I reduce the risk?
To the balancing the level ‘reasonably practicable’. This means balancing the level
of risk against the measures needed to control the risk in terms of money, time and
trouble.
Do I have to provide mechanical aids in every case?
You should definitely provide mechanical aids if it is reasonably practicable to do so
and the risks identified in your risk assessment can be reduced or eliminated by this
means. But you should consider mechanical aids in other situations as well – they
can improve productivity as well as safety. Even something as simple as a sack
truck can make a big improvement.
What about training?
Training is important but remember that, on its own, it can’t overcome:
■■ a lack of mechanical aids;
■■ unsuitable loads;
■■ bad working conditions.
Training should cover:
■■ manual handling risk factors and how injuries can occur;
■■ how to carry out safe manual handling, including good handling technique (see
■■
■■
■■
‘Good handling technique for lifting’ and ‘Good handling technique for pushing
and pulling’);
appropriate systems of work for the individual’s tasks and environment;
use of mechanical aids;
practical work to allow the trainer to identify and put right anything the trainee is
not doing safely.
Good handling technique for lifting
Here are some practical tips, suitable for use in training people in safe manual
handling.
Think before lifting/handling. Plan the lift. Can
handling aids be used? Where is the load going to be
placed? Will help be needed with the load? Remove
obstructions such as discarded wrapping materials.
For a long lift, consider resting the load midway on a
table or bench to change grip.
Adopt a stable position. The feet should be apart
with one leg slightly forward to maintain balance
(alongside the load, if it is on the ground). The worker
should be prepared to move their feet during the
lift to maintain their stability. Avoid tight clothing or
unsuitable footwear, which may make this difficult.
Manual handling at work: A brief guide Page 5 of 10
Health and Safety
Executive
Get a good hold. Where possible, the load should be
hugged as close as possible to the body. This may be
better than gripping it tightly with hands only.
Start in a good posture. At the start of the lift, slight
bending of the back, hips and knees is preferable to
fully flexing the back (stooping) or fully flexing the hips
and knees (squatting).
Keep the load close to the waist. Keep the load
close to the body for as long as possible while lifting.
Keep the heaviest side of the load next to the body.
If a close approach to the load is not possible, try to
slide it towards the body before attempting to lift it.
Don’t flex the back any further while lifting. This
can happen if the legs begin to straighten before
starting to raise the load.
Avoid twisting the back or leaning sideways,
especially while the back is bent. Shoulders should be
kept level and facing in the same direction as the hips.
Turning by moving the feet is better than twisting and
lifting at the same time.
Keep the head up when handling. Look ahead, not
down at the load, once it has been held securely.
Move smoothly. The load should not be jerked or
snatched as this can make it harder to keep control
and can increase the risk of injury.
Don’t lift or handle more than can be easily
managed. There is a difference between what people
can lift and what they can safely lift. If in doubt, seek
advice or get help.
Manual handling at work: A brief guide Page 6 of 10
Health and Safety
Executive
Put down, then adjust. If precise positioning of the load
is necessary, put it down first, then slide it into the
desired position.
Good handling technique for pushing and pulling
Here are some practical points to remember when loads are pushed or pulled.
Handling devices. Aids such as barrows and trolleys should have handle heights
that are between the shoulder and waist. Devices should be well maintained with
wheels that run smoothly. The law requires that equipment is maintained. When you
buy new trolleys etc, make sure they are good quality with large diameter wheels
made of suitable material and with castors, bearings etc which will last with
minimum maintenance. Consulting your employees and safety representatives will
help, as they know what works and what doesn’t.
Force. As a rough guide the amount of force that needs to be applied to move a
load over a flat, level surface using a well-maintained handling aid is at least 2% of
the load weight. For example, if the load weight is 400 kg, then the force needed to
move the load is 8 kg. The force needed will be larger, perhaps a lot larger, if
conditions are not perfect (eg wheels not in the right position or a device that is
poorly maintained). The operator should try to push rather than pull when moving a
load, provided they can see over it and control steering and stopping.
Slopes. Employees should get help from another worker whenever necessary, if
they have to negotiate a slope or ramp, as pushing and pulling forces can be very
high. For example, if a load of 400 kg is moved up a slope of 1 in 12 (about 5°), the
required force is over 30 kg even in ideal conditions – good wheels and a smooth
slope. This is above the guideline weight for men and well above the guideline
weight for women.
Uneven surfaces. Moving an object over soft or uneven surfaces requires higher
forces. On an uneven surface, the force needed to start the load moving could
increase to 10% of the load weight, although this might be offset to some extent by
using larger wheels. Soft ground may be even worse.
Stance and pace. To make it easier to push or pull, employees should keep their
feet well away from the load and go no faster than walking speed. This will stop
them becoming too tired too quickly.
Manual handling at work: A brief guide Page 7 of 10
Health and Safety
Executive
How do I know if there’s a risk of injury?
It’s a matter of judgement in each case, but there are certain things to look out for,
such as people puffing and sweating, excessive fatigue, bad posture, cramped
work areas, awkward or heavy loads or people with a history of back trouble.
Operators can often highlight which activities are unpopular, difficult or hard work.
It is difficult to be precise – so many factors vary between jobs, workplaces and
people. But the general risk assessment guidelines in the next section should help
you identify when you need to do a more detailed risk assessment.
General risk assessment guidelines
There is no such thing as a completely ‘safe’ manual handling operation. But
working within the following guidelines will cut the risk and reduce the need for a
more detailed assessment.
■■ Use Figure 1 to make a quick and easy assessment. Each box contains a
■■
■■
■■
guideline weight for lifting and lowering in that zone. (As you can see, the
guideline weights are reduced if handling is done with arms extended, or at
high or low levels, as that is where injuries are most likely to happen.)
Observe the work activity you are assessing and compare it to the
diagram. First, decide which box or boxes the lifter’s hands pass through when
moving the load. Then, assess the maximum weight being handled. If it is less
than the figure given in the box, the operation is within the guidelines.
If the lifter’s hands enter more than one box during the operation, use the
smallest weight. Use an in-between weight if the hands are close to a boundary
between boxes.
The guideline weights assume that the load is readily grasped with both hands
and that the operation takes place in reasonable working conditions, with the
lifter in a stable body position.
Women
Men
10 kg
3 kg
7 kg
Shoulder height
Elbow height
Knuckle height
Mid lower leg height
7 kg
13 kg
10 kg
16 kg
7 kg
13 kg
3 kg
5 kg
7 kg
Shoulder height
20 kg
10 kg
Elbow height
25 kg
15 kg
Knuckle height
20 kg
10 kg
10 kg
5 kg
Mid lower leg height
Figure 1 Lifting and lowering
Manual handling at work: A brief guide Page 8 of 10
Health and Safety
Executive
Twisting
Reduce the guideline weights if the handler twists to the side during the operation.
As a rough guide, reduce them by 10% if the handler twists beyond 45°, and by
20% if the handler twists beyond 90°.
Frequent lifting and lowering
The guideline weights are for infrequent operations – up to about 30 operations per
hour – where the pace of work is not forced, adequate pauses to rest or use
different muscles are possible, and the load is not supported by the handler for any
length of time. Reduce the weights if the operation is repeated more often. As a
rough guide, reduce the weights by 30% if the operation is repeated once or twice
a minute, by 50% if it is repeated 5–8 times a minute, and by 80% where it is
repeated more than 12 times a minute.
Pushing and pulling
The task is within the guidelines if the figures in Table 2 are not exceeded:
Table 2
Men Force to stop or start the load 20 kg Sustained force to keep the load in motion 10 kg
Women
15 kg
7 kg
See ‘Good handling technique for pushing and pulling’ for some examples of forces
required to push or pull loads.
Using the results: Do I need to make a more detailed assessment?
Using Figure 1 is a first step. If it shows the manual handling is within the guideline
figures (bearing in mind the reduced limits for twisting and frequent lifts) you do not
need to do any more in most cases. But you will need to make a more detailed
assessment if:
■■ the conditions given for using the guidelines (eg that the load can be readily
■■
■■
■■
grasped with both hands) are not met;
the person doing the lifting has reduced capacity, eg through ill health or pregnancy;
the handling operation must take place with the hands beyond the boxes in the
diagram; or
the guideline figures in the diagram are exceeded.
For pushing and pulling, you should make a more detailed assessment if:
■■ there are extra risk factors like uneven floors or constricted spaces;
■■ the worker can’t push or pull the load with their hands between knuckle and
■■
■■
shoulder height;
the load has to be moved for more than about 20 m without a break; or
the guideline figures in Table 2 are likely to be exceeded.
See the HSE guidance Manual handling (see ‘Further reading’) for more advice on
how to make a more detailed assessment.
HSE has also developed a tool called the Manual Handling Assessment Chart
(MAC), to help you assess the most common risk factors in lifting, carrying and
team handling. You may find the MAC useful to help identify high-risk manual
handling operations and to help complete detailed risk assessments. It can be
downloaded from www.hse.gov.uk/msd.
Manual handling at work: A brief guide Page 9 of 10
Health and Safety
Executive
Does this mean I mustn’t exceed the guidelines?
No. The risk assessment guidelines are not ‘safe limits’ for lifting. But work outside
the guidelines is likely to increase the risk of injury, so you should examine the task
closely for possible improvements. You should remember that you must make the
work less demanding, if it is reasonably practicable to do so.
Your main duty is to avoid lifting operations that have a risk of injury. Where it is not
practicable to do this, assess each lifting operation and reduce the risk of injury to
the lowest level reasonably practicable. Look carefully at higher risk operations to
make sure they have been properly assessed.
Further reading
HSE’s website on musculoskeletal disorders: www.hse.gov.uk/msd
Manual handling. Manual Handling Operations Regulations 1992 (as amended).
Guidance on Regulations L23 (Third edition) HSE Books 2004
ISBN 978 0 7176 2823 0 www.hse.gov.uk/pubns/books/l23.htm
This book gives comprehensive guidance, including:
■■ the full text of the Manual Handling Operations Regulations 1992 (as amended
■■
■■
■■
in 2002) with detailed advice on each regulation;
guidelines for assessing risk while lifting, carrying, pushing and pulling, and
handling while seated;
practical advice on measures to reduce the risk of injury; and
an example of an assessment checklist.
Manual handling: Solutions you can handle HSG115 HSE Books 1994
ISBN 978 0 7176 0693 1 www.hse.gov.uk/pubns/books/hsg115.htm
Getting to grips with hoisting people Health Services Information Sheet HSIS3
HSE Books 2011 www.hse.gov.uk/pubns/hsis3.pdf
More guidance on risk assessment can be found at www.hse.gov.uk/risk.
Further information
For information about health and safety, or to report inconsistencies or inaccuracies in
this guidance, visit www.hse.gov.uk/. You can view HSE guidance online and order
priced publications from the website. HSE priced publications are also available from
bookshops.
This guidance is issued by the Health and Safety Executive. Following the guidance
is not compulsory, unless specifically stated, and you are free to take other action.
But if you do follow the guidance you will normally be doing enough to comply with
the law. Health and safety inspectors seek to secure compliance with the law and
may refer to this guidance.
This leaflet can be found at www.hse.gov.uk/pubns/indg143.htm.
© Crown copyright If you wish to reuse this information visit
www.hse.gov.uk/copyright.htm for details. First published 11/12.
Published by the Health and Safety Executive
11/12
INDG143(rev3)
Page 10 of 10
Health and Safety
Executive
Manual handling assessment
charts (the MAC tool)
Introduction
Work-related musculoskeletal disorders (MSDs), including manual handling
injuries, are the most common type of occupational ill health in the UK. It is
important to remember that:
■■
■■
■■
This is a web-friendly
version of leaflet
INDG383(rev2),
published 06/14
there is a lot you can do to prevent them;
preventative measures are often simple and cost-effective;
you cannot prevent all MSDs, but where they occur, early reporting of
symptoms, proper treatment and suitable rehabilitation are essential.
The Manual Handling Assessment Charts (MAC) is a tool aimed at employers,
health and safety managers and safety representatives and is used by
health and safety inspectors. The tool will help individuals to assess the most
common risk factors in lifting (and lowering), carrying and team handling
operations and was developed to identify high-risk manual handling.
What does the law say?
The Manual Handling Operations Regulations 1992 set out a clear hierarchy of
measures for dealing with risk likely to cause harm from manual handling. These are:
■■
■■
■■
avoid hazardous manual handling operations so far as reasonably practicable;
assess any manual handling operations that cannot be avoided;
reduce the risk of injury to as low as reasonably practicable.
Structure of the MAC
There are three types of assessment that can be carried out with the MAC:
■■
■■
■■
lifting operations (pages 3–6);
carrying operations (pages 7–10);
team handling operations (pages 11–13).
For each type of assessment there is an assessment guide and a flow chart. There is
a score sheet (the ‘MAC: Score sheet’) to complete on page 14.
Note
The MAC is not appropriate for some manual handling operations, for example
those that involve pushing and pulling. Its use does not comprise a full risk
assessment (see Manual handling in ‘Further reading’). Always consider individual
and psychosocial issues when completing the ‘MAC: Score sheet’. Also, the MAC
is not designed to assess risks associated with workplace upper limb disorders
(see Upper limb disorders in the workplace and Assessment of Repetitive Tasks of
the upper limbs (the ART tool) in ‘Further reading’).
Page 1 of 15
Health and Safety
Executive
How to complete a MAC assessment
G = GREEN - Low level of risk
Although the risk is low, consider the exposure levels for vulnerable groups such as
pregnant women or young workers, where appropriate.
A = AMBER - Medium level of risk
Examine tasks closely.
R = RED - High level of risk
Prompt action needed. This may expose a significant proportion of the working
population to risk of injury.
P = PURPLE - Very high level of risk
Such operations may represent a serious risk of injury and should come under close
scrutiny, particularly when the entire weight of the load is supported by one person.
■■
■■
■■
■■
■■
■■
Spend some time observing the task (videoing may help) to ensure that what
you are seeing is representative of normal working procedures. You should
involve your employees and safety representatives during the assessment
process. Where several people do the same task, make sure you have some
insight into the demands of the job from all employees’ perspective.
Select the appropriate type of assessment (ie lifting, carrying or team handling).
If a task involves lifting and carrying, consider both.
Follow the appropriate assessment guide and flow chart to determine the level
of risk for each risk factor. Information on risk reduction can be found on the
HSE website at www.hse.gov.uk/msd and in the HSE publication Manual
handling at work (see ‘Further reading’).
Enter the colour band and corresponding numerical score on the ‘MAC: Score
sheet’. The colour bands help determine which elements of the task require
attention.
Enter the remaining task information and use the scores to help identify which
risk factors need to be examined and the total level of exposure to risk.
If the individual does a number of tasks, assess each one separately and
prioritise action to address the highest scoring task.
Further guidance on using the MAC tool can be accessed online at
www.hse.gov.uk/msd/mac.
Remember
The purpose of the assessment is to identify and then reduce the overall
level of risk of the task.
Manual handling assessment charts (the MAC tool)
Page 2 of 15
Health and Safety
Executive
Assessment guide for lifting
operations
A Load weight/frequency
Note the weight of the load and the repetition rate of the lifting operation. Take note
of the risk banding from the graph below and enter the colour band and numerical
score onto the ‘MAC: Score sheet’. If the colour band is purple, the task should be
examined very closely, as such operations may represent a serious risk of injury
and should come under close scrutiny, particularly when the entire weight of the
load is supported by one person. Note: High frequency handling operations of
light weights will fall within the green zone, but may be associated with upper limb
problems. Please refer to Upper limb disorders in the workplace and Assessment of
Repetitive Tasks of the upper limbs (the ART tool) (see ‘Further reading’) for advice
on further assessment.
Load weight/frequency graph for lifting operations
P=10
Weight of load (kg)
50
40
50
40
R=6
30
30
A=4
20
10
20
10
G=0
0
0
One lift per
day
30 minutes
(2)
5 minutes
(12)
2 minutes
(30)
1 minute
(60)
14 seconds
(250)
9 seconds
(400)
5 seconds
(720)
One lift every
(lifts per hour)
Manual handling assessment charts (the MAC tool)
Page 3 of 15
Health and Safety
Executive
B Hand distance from the lower back
Observe the task and examine the horizontal distance between the operative’s
hands and their lower back. Always assess the ‘worst case scenario’. Use the
following to guide your assessment:
Close: Upper arms
aligned vertically
and upright
torso
G/0
Moderate: Upper
arms angled away
from body
Moderate:
Torso bent
forward
A/3
A/3
Far: Upper arms
angled away from
body and torso
bent forward R/6
C Vertical lift region
Observe the position of the operative’s hands at the start of the lift and as the lift progresses.
Always assess the ‘worst case scenario’. Use the following illustrations as a guide:
Above knee and/or
below elbow height
G/0
Below knee and/or
above elbow height
A/1
Floor level
or below
At head height
or above
R/3
D Torso twisting and sideways bending
Observe the operative’s torso as the load is lifted. If the torso twists in relation to the
hips and thighs or the operative leans to one side as the load is lifted, the colour
band is amber and the numerical score is 1. If the torso both twists and bends to
the side as the load is lifted the colour band is red and the numerical score is 2.
Little or no torso twisting
or sideways bending
G/0
Torso twisting
or
sideways bending
Torso twisting
and
sideways bending
A/1
Manual handling assessment charts (the MAC tool)
R/2
Page 4 of 15
Health and Safety
Executive
E Postural constraints
If the movements of the operative are unhindered, the colour band is green and the
numerical score is 0. If the operative adopts restricted postures during the lift because of
the space available (eg a narrow gap between pallet load and hopper) or the workstation
design (eg an excessively high monorail conveyor), the colour band is amber and the
numerical score is 1. If the posture is severely restricted, the colour band is red and the
numerical score is 3 (eg work in confined areas such as baggage holds).
No postural constraints
Restricted posture
A/1
G/0
Severely restricted
posture
R/3
F Grip on the load
Good grip
Reasonable grip
G/0
Poor grip
A/1
R/2
Containers with welldesigned handles or
handholds, fit for purpose
Containers with poor
handles or handholds
Containers of poor design.
Loose parts, irregular
objects, bulky or difficult
to handle
Loose parts enabling
comfortable grip
Fingers to be clamped
at 90 degrees under the
container
Non-rigid sacks or
unpredictable loads
Dry floor but in poor
condition, worn or
uneven
Contaminated/wet or
steep sloping floor or
unstable surface or
unsuitable footwear
G Floor surface
Dry and clean floor in
good condition
G/0
A/1
R/2
H Other environmental factors
Observe the work environment and score if the lifting operation takes place:
in extremes of temperature; with strong air movements; or in extreme lighting
conditions (too dark or bright). If one of the risk factors is present score 1, if two
or more of the risk factors are present score 2.
No factors present
One factor present
G/0
Two or more factors
present
A/1
Manual handling assessment charts (the MAC tool)
R/2
Page 5 of 15
Health and Safety
Executive
Lifting
operation
A
Load weight/
frequency (see
graph on p3)
B
Hand distance
from lower
back
C
Vertical lift
region
D
Torso twisting
and sideways
bending
Please insert the colour and
NOTE THE COLOUR AND NUMERICAL
SCORE
numerical
scores on the
AND INSERT ON SCORE SHEET ‘MAC: Score sheet’
See graph on p3
G
See graph on p3
A
See graph on p3
R
50 kg or more
P
0
4
6
H
Other
environmental
factors
G
Moderate: upper
arms angled or
torso bent forward
A
Far: upper arms
angled and torso
bent forward
R
Above knee and/or
below elbow
height
G
Below knee and/or
above elbow
height
A
Floor level or below
and/or above
head height
R
Little or no torso
twisting or
sideways bending
G
Torso twisting
or
sideways bending
A
Torso twisting
and
sideways bending
R
0
G
Floor
surface
6
Grip on
the load
Reasonable
E
Manual handling assessment charts (the MAC tool)
G
0
R
None
2
2
Contaminated,
wet, sloping or
unstable
Poor
Postural
constraints
R
A
F
3
1
1
Dry but in poor
condition or
uneven
Good
1
0
A
One factor
present
Dry and in good
condition
3
0
0
Two or more
factors present
10
Close: upper arms
vertical/torso
upright
G
No factors
present
Restricted
Severely
restricted
1
2
G
0
A
1
R
2
G
0
A
1
R
3
Page 6 of 15
Health and Safety
Executive
Assessment guide for carrying
operations
A Load weight/frequency
Note the weight of the load and the frequency of the carrying operation. Take note
of the risk banding on the graph below and enter the colour band and numerical
score on the ‘MAC: Score sheet’. If the colour band is purple the task should be
examined very closely, as such operations may represent a serious risk of injury
and should come under close scrutiny, particularly when the entire weight of the
load is carried by one person.
Load weight/frequency graph for carrying operations
P=10
Weight of load (kg)
50
40
50
40
R=6
30
30
A=4
20
10
20
10
G=0
0
0
One carry per
day
30 minutes
(2)
5 minutes
(12)
2 minutes
(30)
1 minute
(60)
12 seconds
(300)
One carry every
(carries per hour)
B Hand distance from the lower back
Observe the task and examine the horizontal distance between the operative’s
hands and their lower back. Always assess the ‘worst case scenario’. Use the
following illustrations to guide your assessment:
Close: Upper arms
aligned vertically
and upright
torso
G/0
Moderate: Upper
arms angled away
from body
Moderate:
Torso bent
forward
A/3
Manual handling assessment charts (the MAC tool)
A/3
Far: Upper arms
angled away from
body and torso
bent forward R/6
Page 7 of 15
Health and Safety
Executive
C Asymmetrical torso/load
The operative’s posture and the stability of the load are risk factors associated with
musculoskeletal injury. The following illustrations should guide your assessment.
Load and hands
symmetrical in
front of the
torso
G/0
Load and hands
asymmetrical,
upright body
position
A/1
One handed
carrying to the
individual’s
side
R/2
D Postural constraints
If the operative’s movements are unhindered, the colour band is green and the
numerical score is 0. If the operative adopts restricted postures during the carry
(eg a narrow doorway making the operative turn or move the load to get through)
the colour band is amber and the numerical score is 1. If the posture is severely
restricted, the colour band is red and the numerical score is 3 (eg carrying loads in
a forward bent posture in areas with low ceilings such as cellars).
No postural constraints
Restricted posture
A/1
G/0
Severely restricted
posture
R/3
E Grip on load
Good grip
Reasonable grip
G/0
Poor grip
A/1
R/2
Containers with welldesigned handles or
handholds, fit for purpose
Containers with poor
handles or handholds
Containers of poor design.
Loose parts, irregular
objects, bulky or difficult
to handle
Loose parts enabling
comfortable grip
Fingers to be clamped
at 90 degrees under the
container
Non-rigid sacks or
unpredictable loads
Dry floor but in poor
condition, worn or
uneven
Contaminated/wet or
steep sloping floor or
unstable surface or
unsuitable footwear
F Floor surface
Dry and clean floor in
good condition
G/0
A/1
R/2
G Other environmental factors
Observe the work environment and score if the carrying operation takes place:
in extremes of temperature; with strong air movements; or in extreme lighting
conditions (dark, bright or poor contrast). If one of the risk factors is present
score 1, if two or more of the risk factors are present score 2.
No factors present
One factor present
G/0
Two or more factors
present
A/1
Manual handling assessment charts (the MAC tool)
R/2
Page 8 of 15
Health and Safety
Executive
H Carry distance
Observe the task and estimate the total distance that the load is carried (not the
distance ‘as the crow flies’).
2 m—4 m
4 m—10 m
G/0
10 m or more
A/1
R/3
I Obstacles en route
Observe the route. If the operator has to carry a load up a steep slope, up steps, through
closed doors or around tripping hazards, the colour band is amber and the numerical
score is 2. If the task involves carrying the load up ladders, enter ‘R’ (red) for the colour
band and 3 for the numerical score. If the task involves more than one of the risk factors
(eg a steep slope and then up ladders) total the scores on the score sheet. Enter the
ladder height data and/or the angle in the task description box on the score sheet.
No obstacles
and
carry route is flat
Steep slope or up steps
or through closed doors
or trip hazards
G/0
A/2
Manual handling assessment charts (the MAC tool)
Ladders
R/3
Page 9 of 15
Health and Safety
Executive
Please insert the colour and
numerical scores on the
‘MAC: Score sheet’
Carrying
operation
A
Load weight/
frequency (see
graph on p7)
B
Hand distance
from lower
back
C
Asymmetrical
torso/load
See graph on p7
G
See graph on p7
A
See graph on p7
R
50 kg or more
P
Close: upper arms
vertical/torso
upright
G
0
R
Asymmetrical or
offset load/hands
D
Restricted
Severely
restricted
Good
E
Reasonable
Poor
Obstacles
en route
10
Far: upper arms
angled and torso
bent forward
Load symmetrical
in front/two hands
I
6
A
None
Grip on
the load
4
Moderate: upper
arms angled or
torso bent forward
One-handed to
side or twisting/
back bent
Postural
constraints
0
H
Carry
distance
3
6
G
0
A
1
G
Steep slope or up
steps or through
closed doors or
trip hazards
A
G
Other
environmental
factors
2 m—4 m
G
4 m—10 m
A
10 m or more
R
0
A
1
R
Floor
surface
3
0
1
3
G
0
A
One factor
present
1
Dry and in good
condition
F
2
R
Two or more
factors present
2
0
Ladders
No factors
present
R
G
No obstacles
and
carry route is flat
R
2
G
0
Dry but in poor
condition or
uneven
A
Contaminated,
wet, sloping or
unstable
R
1
2
3
G
0
A
1
R
2
Manual handling assessment charts (the MAC tool)
Page 10 of 15
Health and Safety
Executive
Assessment guide for team handling
operations
A Load weight
Note the weight of the load and the number of operatives performing the task.
Enter the colour band and numerical score on the ‘MAC: Score sheet’. If the colour
band is purple the task should be examined very closely. Such operations may
represent a serious risk of injury and should come under close scrutiny, particularly
when the entire weight of the load is supported by the team.
2 person<35 kg
3 person<40 kg
2 person 35—50 kg
3 person 40—75 kg
4 person 40—100 kg
2 person 50—85 kg
3 person 75—125 kg
4 person 100—170 kg
R/6
A/4
G/0
2 person>85 kg
3 person>125 kg
4 person>170 kg
P/10
B Hand distance from the lower back
Observe the task and examine the horizontal distance between each operative’s
hands and their lower back. Always assess the ‘worst case scenario’. Use the
following illustrations to guide your assessment:
Close: Upper arms aligned
vertically and upright
torso
G/0
Moderate: Torso bent forward
or upper arms angled away from
body
A/3
Far: Upper arms angled away
from body and torso
bent forward
R/6
C Vertical lift region
Observe the position of the operatives’ hands at the start of the lift and as the lift
progresses. Always assess the ‘worst case scenario’. Use the following illustrations
as a guide:
Above knee and/or
below elbow height
G/0
Below knee and/or above elbow
height
Manual handling assessment charts (the MAC tool)
A/1
At head height or above, or floor
level or below
R/3
Page 11 of 15
Health and Safety
Executive
D Torso twisting and sideways bending
Observe the operatives’ torsos as they lift the load. If the torso twists in relation to the
hips and thighs or if the operatives lean to one side as the load is lifted, the colour
band is amber and the numerical score is 1. If the torso both twists and bends to the
side as the load is lifted, the colour band is red and the numerical score is 2.
Little or no torso twisting
or sideways bending
Torso twisting
or
sideways bending
G/0
Torso twisting
and
sideways bending
A/1
R/2
E Postural constraints
If the movements of the operatives are unhindered, the colour band is green and the
numerical score is 0. If the operatives adopt restricted postures during the lift because
of the space available (eg narrow space between team members) or the workstation
design (eg an excessively high monorail conveyor), the colour band is amber and the
numerical score is 1. If the postures are severely restricted, the colour band is red and
the numerical score is 3 (eg work in confined areas such as baggage holds).
No postural constraints
Restricted posture
A/1
G/0
Severely restricted
posture
R/3
F Grip on load
Good grip
Reasonable grip
G/0
Poor grip
A/1
R/2
Containers with welldesigned handles or
handholds, fit for purpose
Containers with poor
handles or handholds
Containers of poor design.
Loose parts, irregular
objects, bulky or difficult
to handle
Loose parts enabling
comfortable grip
Fingers to be clamped
at 90 degrees under the
container
Non-rigid sacks or
unpredictable loads
Dry floor but in poor
condition, worn or
uneven
Contaminated/wet or
steep sloping floor or
unstable surface or
unsuitable footwear
G Floor surface
Dry and clean floor in
good condition
G/0
A/1
R/2
H Other environmental factors
Observe the work environment and score if the lifting operation takes place:
in extremes of temperature; with strong air movements; or in extreme lighting
conditions (dark, bright or poor contrast). If one of the risk factors is present score 1,
if two or more of the risk factors are present score 2.
No factors present
One factor present
G/0
Two or more factors
present
A/1
R/2
I Communication, co-ordination and control
Communication between the operatives is essential when lifting as part of a team.
Examples of good communication would be that you may hear the operatives
counting ‘one, two, three’ etc before the lift. Look to see if the team have control of
the load, that it is lifted smoothly, and that all members lift together. An
unco-ordinated team lift may leave one member of the team bearing the entire weight.
Good
G/0
Reasonable
A/1
Manual handling assessment charts (the MAC tool)
Poor
R/3
Page 12 of 15
Health and Safety
Executive
Please insert the colour and
numerical scores on the
‘MAC: Score sheet’
Team
handling
operation
A
Load weight
B
Hand distance
from lower
back
C
Vertical lift
region
D
Torso twisting
and sideways
bending
2 person < 35 kg
3 person < 40 kg
G
2 person 35—50 kg
3 person 40—75 kg
4 person 40—100 kg
A
2 person 50—85 kg
3 person 75—125 kg
4 person 100—170 kg
R
2 person >85 kg
3 person >125 kg
4 person >170 kg
P
Close: upper arms
vertical/torso
upright
G
Moderate: upper
arms angled or
torso bent forward
A
Far: upper arms
angled and torso
bent forward
R
4
6
3
Below knee and/or
above elbow
height
A
Floor level or below
and/or above
head height
R
A
Torso twisting
and
sideways bending
R
Restricted
Severely
restricted
R
3
G
0
A
One factor
present
1
Dry and in good
condition
G
Floor
surface
0
1
Grip on
the load
2
G
0
A
Contaminated,
wet, sloping or
unstable
R
GOOD
Good
F
R
Dry but in poor
condition or
uneven
3
Torso twisting
or
sideways bending
1
Two or more
factors present
1
G
A
REASONABLE
Reasonable
No factors
present
Other
environmental
factors
0
Little or no torso
twisting or
sideways bending
0
Poor
6
G
E
I
Communication,
co-ordination
and control
H
0
G
Good
10
Above knee and/or
below elbow
height
None
Postural
constraints
0
Reasonable
Poor
1
2
G
0
A
1
R
2
2
G
0
A
1
R
3
Manual handling assessment charts (the MAC tool)
Page 13 of 15
Good
Manual handling assessment charts (the MAC tool)
Signature: ______________________________________________________________________
Date: ______________________________________________________________________________
Other indications, if so, what? __________________________________________________
Employees doing the work show signs that they are finding it hard work (eg breathing
heavily, red-faced, sweating).
Task is known to be hard work or high risk.
Task has a history of manual handling incidents (eg company
accident book, RIDDOR reports).
Are there indications that the task is high risk?
(Tick the appropriate boxes)
Task description:
Company name:_________________________________________________________________
MAC: Score sheet
Carry
Total score:
Lift
Team
Colour band (G, A, R or P)
Lift
Carry
Team
Numerical score
Other risk factors: Record individual and psychosocial factors etc (see website –
address on page 15)
Communication and co-ordination
(team handling only)
Obstacles en route (carrying only)
Carry distance
Other environmental factors
Floor surface
Grip on the load
Postural constraints
Torso twisting/sideways bending
Asymmetrical torso/load (carrying)
Vertical lift region
Hand distance from the lower back
Load weight and lift/carry frequency
Risk factors
Insert the colour band and numerical score for each of the risk factors in
the boxes below, referring to your assessment, using the tool.
Health and Safety
Executive
Page 14 of 15
Health and Safety
Executive
Further reading
Assessment of Repetitive Tasks of the upper limbs (the ART tool): Guidance for
health and safety practitioners, consultants, ergonomists and large organisations
Leaflet INDG438 HSE Books 2010 www.hse.gov.uk/pubns/indg438.pdf
Managing upper limb disorders in your business: A brief guide
for employers Leaflet INDG171(rev2) HSE Books 2013
www.hse.gov.uk/pubns/indg171.htm
Manual handling at work. A brief guide Leaflet INDG143(rev3)
HSE Books 2012 www.hse.gov.uk/pubns/indg143.htm
Manual handling. Manual Handling Operations Regulations 1992 (as amended).
Guidance on Regulations L23 (Third edition) HSE Books 2004
ISBN 978 0 7176 2823 0 www.hse.gov.uk/pubns/books/l23.htm
Upper limb disorders in the workplace HSG60 (Second edition) HSE Books 2002
ISBN 0 978 0 7176 1978 8 www.hse.gov.uk/pubns/books/hsg60.htm
Further guidance on using the MAC tool can be accessed online at
www.hse.gov.uk/msd/mac.
Further information
For information about health and safety, or to report inconsistencies or inaccuracies
in this guidance, visit www.hse.gov.uk. You can view HSE guidance online and
order priced publications from the website. HSE priced publications are also
available from bookshops.
This guidance is issued by the Health and Safety Executive. Following the guidance
is not compulsory, unless specifically stated, and you are free to take other action.
But if you do follow the guidance you will normally be doing enough to comply with
the law. Health and safety inspectors seek to secure compliance with the law and
may refer to this guidance.
This leaflet is available at: www.hse.gov.uk/pubns/indg383.htm.
© Crown copyright If you wish to reuse this information visit www.hse.gov.uk/
copyright.htm for details. First published 06/14.
Published by the Health and Safety Executive
06/14
INDG383(rev2)
Page 15 of 15
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix iv |
Flow Regulator with Electric Controller 2488N / 5757-7
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Flow Regulator with Electric Actuator
Type 2488 N/5857
Type 2488 N/5857 Flow Regulator with Electric Actuator
Mounting and Operating
Instructions
EB 3136 EN
Edition March 2008
Contents
Page
Contents
1
Design and principle of operation . . . . . . . . . . . . . . . . . . . 4
2
2.1
2.2
2.3
2.4
Installation . . . . . . . . . . .
Mounting position . . . . . . .
Strainer . . . . . . . . . . . .
Shut-off valves, pressure gauges.
Mounting the actuator . . . . .
3
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4
Operation · Set point adjustment . . . . . . . . . . . . . . . . . . . . 7
5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7
Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
EB 3136 EN
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
5
5
5
5
5
Safety instructions
General safety instructions
4 The flow regulator with electric actuator must be installed, started up and
serviced only by skilled or semi-skilled staff in accordance with good
engineering practice so that employees and third persons are not exposed
to danger.
All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up and
maintenance, must be strictly observed.
4 The regulator complies with the requirements of the European Pressure
Equipment Directive 97/23/EC. The declaration of conformity issued for a
valve bearing the CE marking includes information on the applied
conformity assessment procedure and will be provided on request.
4 To ensure appropriate use, only use the regulator in applications where the
operating pressure and temperatures do not exceed the operating values
specified in the order.
Note that the manufacturer does not assume any responsibility for damage
caused by external forces or any other external factors.
Take appropriate safety precautions to prevent hazards that may be caused
in the regulator by the process medium, operating pressure, signal pressure,
or moving parts.
4 Make sure the regulator is shipped and stored properly.
4 Depending on the field of application, allow the regulator to cool down or
warm up to reach ambient temperature prior to starting any work.
Always depressurize the relevant section of the plant and, if necessary, also
drain the pipeline prior to installing or servicing the regulator.
4 The electric actuator has been designed for use in electrical power
installations. Strictly observe the relevant safety regulations for wiring and
maintenance work.
4 Only use disconnect devices that are protected against accidental or
unintentional reconnection.
Take special care when making adjustments on live parts.
Do not remove the covers under any circumstances.
EB 3136 EN
3
Design and principle of operation
1
Design and principle of
operation
The device combines a Type 2488 N Flow
Regulator and a Type 5857 Electric Actuator. The electric actuator is attached to the
valve by means of the connecting piece and
allows also the temperature to be controlled
by changing the position of the restriction in
response to the control signal received from
an electric control device. The medium flows
through the valve in the direction indicated
by the arrow on the valve body. The flow
rate depends on the flow passage defined by
the valve plug (3) and the restriction (11).
The integral positioning spring (5) determines
the upper differential pressure (0.2 bar). The
1
Valve body
2
Seat
3
Valve plug
4
Plug stem
5
Positioning spring
6
Diaphragm actuator
7
High-pressure control line
8
High-pressure side
9
Operating diaphragm
10
Low-pressure side
11
Restriction
12
Restriction stem
13
Set point screw
14
Connecting piece
15
Spring
16
Electric actuator
17
Coupling nut
18
Intermediate piece
Fig. 1 · Principle of operation
4
EB 3136 EN
high pressure upstream of the restriction (11)
is transmitted to the high-pressure side of the
diaphragm actuator through the control line
(7). The low pressure downstream of the restriction acts on the low-pressure side of the
operating diaphragm (9) via a bore in the
valve plug. The differential pressure
generated by the restriction (special differential pressure) is converted into a positioning
force by the operating diaphragm. This force
is used to position the valve plug against the
force of the positioning spring (5). The flow
rate can be adjusted by turning the set point
screw (13).
16
18
17
15
14
13
12
11
2
1
10
9
8
3
4
5
6
7
Installation
2
Installation
2.1
Mounting position
4 Install the flow regulator in a horizontal
pipeline with its diaphragm actuator vertically suspended. Make sure that the electric actuator is above the valve body.
4 Make sure that the medium flows through
the regulator in the direction indicated by
the arrow on the valve body.
Note!
Choose a point of installation which will provide easy access to the regulator after completion of the plant.
Flush the pipeline thoroughly before installation.
4 Install the strainer with the filter element
vertically suspended. Ensure that ample
space is available to remove the filter.
2.3
Ideally, hand-operated shut-off valves should
be installed both upstream of the strainer
and downstream of the flow regulator. This
allows the plant to be shut down
(depressurized) for cleaning and maintenance routines, or when it is not operated for
long periods of time.
To monitor the pressures prevailing in the
plant, install pressure gauges both upstream
and downstream of the flow regulator.
Caution!
When carrying out a pressure test on
the section of the plant equipped with
a pressure regulator, prevent the diaphragm actuator from being damaged by the test pressure by using a
test pressure which does not exceed
the maximum permissible pressure Δp
of the actuator.
Make sure the permissible ambient temperature will not be exceeded. If the valve is to be
insulated, do not insulate the actuator and
the coupling nut. If necessary, use an extension piece (order no. 1690-6975). The valve
should not be insulated more than approx.
25 mm above the top edge of its body.
2.2
Shut-off valves, pressure
gauges
Strainer
Install a strainer (SAMSON Type 1 NI) upstream of the regulator to prevent sealing
particles, weld spatter, pipe scale, and other
impurities carried along by the process medium from impairing the proper operation,
especially the tight shut-off of the valve.
4 Make sure that the medium flows through
2.4
Mounting the actuator
First insert the intermediate piece (18), which
comes with the actuator, into the actuator.
Then place the actuator onto the valve connection and manually fasten it using the
coupling nut (17).
the strainer in the direction indicated by
the arrow on the strainer body.
EB 3136 EN
5
L
eL
Ce
Electrical connection
3
Ce
N
aL
eL
wh
br
gr
aL
24 V, 50 Hz
L
N
br
bl
0...10 V
_
+
0...10 V
_
+
ye
rd
gr
or
Electrical connection
L
Warning!
When laying electric lines, strictly
observe the regulations governing the
erection of power installations
defined by DIN VDE 0100 as well as
the regulations specified by your
local power supply company.
Use a suitable power supply which
guarantees that no dangerous voltages will reach the device in standard operation or in case of a fault in
the system or any system parts.
Warning!
Always switch off the power supply
first prior to connecting the actuator
to the electrical network. Make sure
the power cannot be switched on unintentionally.
Use the three-wire connecting cable attached
to the actuator to establish the electrical connection (Fig. 2).
If a voltage is applied between the white and
the green cable, the motor will retract the actuator stem into the actuator. The restriction
stem will be pushed upward by the spring
(15) and the flow rate will increase.
If, however, a control signal is applied to the
white and the brown cable, the actuator stem
will be extended. The restriction stem will be
pushed downward and the flow rate will decrease.
6
EB 3136 EN
eL
Ce
eL
aL
Ce
N
aL
eL
wh
br
gr
aL
Actuator stem retracts
Actuator stem extends
Note!
Decoupling capacitors Ce in the output circuit of
the connected controller must not exceed a value of
2.5 nF in order to guarantee the proper functioning
of the actuator.
Fig. 2 · Electrical connection
Operation · Set point adjustment
4
4 Determine the number of turns required
Operation · Set point
adjustment
to set the desired flow rate from the diagram (Fig. 3).
The flow rate can be adjusted, both with and
without the electric actuator mounted. Prior
to adjusting the flow rate on a regulator with
the electric actuator mounted, make sure the
actuator stem is retracted.
Important!
Prior to starting up or pressurizing the regulator, make sure that the restriction for limiting the flow is open.
To adjust or alter the flow set point, proceed
as follows:
4 Turn the set point screw (13) clockwise
until the restriction (11) stops in the seat
using a 4 mm Allen key.
4 Turn set point screw (11) counterclockwise the required number of turns.
For exact adjustment, check the set value
using a flow meter.
4 Turn the set point screw (13) clockwise to
close the restriction and decrease the flow
rate.
4 Turn the set point screw counterclockwise
to open the restriction and increase the
flow rate.
5
Troubleshooting
If the flow rate deviates considerably from
the adjusted set point, first check the control
line for any blockages.
If the valve does not seal properly, this may
be because tight shut-off is prevented by dirt
between the seat and plug or due to natural
wear. Check the regulator for leaks and replace it if necessary.
Turns
5
Kvs 1.0
4
2.5
Caution!
Prior to starting any work on the regulator or removing it from the pipeline, allow the relevant section of the
plant to cool down to working temperature if high temperatures prevail
and make sure that the pipeline concerned is depressurized and drained.
3
2
1
V˚
0
0.1
0.2
0.5
1
2 m3/h
Fig. 3 · Adjustment diagram for flow rate
EB 3136 EN
7
Nameplates
6
Nameplates
7
Should you have any inquiries, please submit
the following details:
Nameplate of Type 2488 N Valve
1
2
2
6
7
8
9
Description of the nameplate:
1 Model number with index
2 Year of manufacture
3 Type
4 Flow set point range in m3/h
5 Upper differential pressure in bar
6 Max. perm. differential pressure in bar
7 Flow coefficient KVS
8 Max. perm. temperature in °C
9 Nominal pressure PN
Nameplate of Type 5857 Electric Actuator
SAMSON 5857
Electric Actuator
1
2
3
Made in Germany
Description of the nameplate:
1 Nominal thrust, rated travel
actuating time, electrical connection
2 Configuration ID
3 Serial number
8
EB 3136 EN
4 Type and nominal size of the flow
regulator
3
5
Customer inquiries
4 Order and model numbers
(see nameplate)
4 Upstream and downstream pressures
4 Flow rate in m³/h
4 Has a strainer been installed?
4 Installation drawing
Dimensions
8
Dimensions
114
32
70
Ø12
11
55
80
120
ISO 228/1-G ¾ B
80
~65
65
Ø95
~70
Intermediate
insulating piece
L
SW30
Welding ends
SW30
di
Ø21.3
129
G½
Ø21.3
210
SW30
Soldering ends
Threaded ends
Soldering ends · Dimensions in mm
Internal ∅ di
15
18
Length L
107
103
Fig. 4 · Dimensional drawings (dimensions in mm)
EB 3136 EN
9
Technical data
9
Technical data
Type 5857 Actuator
Type 2488 N Valve
Rated travel
6 mm
Actuating time for rated travel
20 s
Nominal thrust
300 N
Supply voltage
230 V/24 V (±10 %)
50 Hz
Power consumption
Approx. 3 VA
Perm. ambient temperature
0 to 50 °C
Perm. storage temperature
–20 to 70 °C
Degree of protection
IP 42
Noise immunity
EN 61000-6-3
Noise emission
EN 61000-6-4
Weight
Approx. 0.7 kg
Materials
Nominal size
DN 15
Nominal pressure
PN 10
Max. perm. diff. pressure Δp
4 bar
Flow coefficient KVS
Standard version
Special version
2.5
1.0
Max. perm. temperature
Treated water
Non-flammable gases
110 °C
80 °C
Flow set point range / flow limitation for water at upper differential pressure of 0.2 bar
3
Standard version
0.3 to 1m /h
3
0.1 to 0.5 m /h
Special version
Body
CC491K
Upper differential pressure
Plug
1.4301 with EPDM
sealing ring
Materials
Restriction
Brass resistant to
dezincification
Diaphragm
EPDM without fabric
10
EB 3136 EN
0.2 bar
Body
Plastic PPO
Coupling nut
Brass
Intermediate insulating piece
1.4306, CW617N,
PTFE, EPDM, FPM
EB 3136 EN
11
EB 3136 EN
S/Z 2008-04
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
Type 5757-7 Controller with Electric Actuator
Quick Guide: Applications and Configuration
Note! The warnings and safety instructions specified in the
Mounting and Operating Instructions EB 5757-7 EN apply to
mounting, electrical connection and operation.
Scope of application
The Type 5757-7 Controller with Electric Actuator is suitable for
installations in small to medium-sized buildings for outdoor
temperature compensated control, fixed set point control or
control with a reference variable (room temperature).
Sectional drawing
2
8
1
1.1
3
5
4
7
6
1
1.1
2
3
4
Controller with electric
actuator
Connecting lead
Handwheel
Only to be used when
power is disconnected
Actuator stem
Coupling nut
5
6
7
8
Travel indicator
Plug stem
Valve spring
Cover with serial interface
connection underneath
(RJ-12 jack), slide switch
and LEDs
• Manual operating mode function
The controller with electric actuator can be set to the manual operating mode by the memory pen while the control operation is
running.
The actuator stem is retracted or extended depending on the
command stored in the memory pen.
After removing the memory pen from the actuator, the actuator
returns to its normal control state.
• Data transmission
After inserting the memory pen into the actuator, data are transferred depending on how the memory pen is configured:
(A) Data are uploaded automatically onto the pen
– Function: All the data in the controller (settings #1 and #2)
are uploaded onto the pen.
– Indication: The yellow LED blinks several times
(B) Data are downloaded automatically from the pen
– Function: All the data in the memory pen (settings #1 and #2)
are downloaded onto the controller. Any existing settings are
overwritten.
– Indication: The yellow LED blinks twice several times
(C) Copy function
After function (A) is completed, the pen is automatically configured (B), allowing data in the pen to be copied to other actuators of the same type and version.
Note: If a memory pen, which is empty or containing data from
another version of the same type of actuator, is inserted into an
actuator, data are uploaded onto the pen regardless of the
read/write status of the memory pen.
______________________________________________________
Attachment
The controller with electric actuator may not be installed in a
suspended position.
Ready for operation
As soon as the actuator is connected to the power supply, the
initialization procedure starts. The actuator stem extends and
the red and yellow LEDs are illuminated.
When the actuator stem has reached the final position, the red
LED is turned off. The yellow LED remains illuminated and indicates that the actuator is ready for operation.
____________________________________________________
Using the memory pen (order no. 1400-7697)
Data are transferred between
the memory pen and the actuator at the serial interface
(RJ-12 jack) underneath the
cover (8).
Faults
An illuminated red LED indicates a fault in the actuator.
A sensor cable breakage is indicated by the red LED blinking.
Each sensor is assigned a different blinking sequence.
When several sensors malfunction, the fault with the highest priority is indicated first (highest priority = flow sensor).
Sensor
Flow sensor
Outdoor sensor
Return flow sensor
Blinking sequence
1
0
1
0
1
0
Room sensor/
Potentiometer
Edition October 2007
1
0
3s
3s
3s
3s
3s
3s
3s
Time
Zeit
3s
3s
3s
Time
Zeit
3s
Time
Zeit
3s
Time
Zeit
KA 5757-7 EN
Explanation
Function
Note: A function is activated when the setting of the function blocks (F) is consistent with
the specifications listed under “Customer data”.
Control principle
The controller with electric actuator functions with a PI algorithm (three-point stepping
control). The valve reacts to pulses, which the electric actuator receives from the integrated digital controller when a system deviation occurs. The length of the first pulse, in
particular, depends on the system deviation and the selected gain Kp flow temperature
control (P09) (the length of the pulse increases, the larger the Kp gets). The length of the
pulses as well as the interval between them changes until the system deviation is at zero
again. The interval between individual pulses is influenced by the reset time Tn flow temperature control (P10) (the interval rises as Tn rises). The valve transit time Ty actuator
transit time for valve travel (P11) reflects the time that the valve needs to move through its
travel range from 0 to 100 % without stopping. Its default setting is optimally tuned in
this device and therefore should not be changed (Ty = 24 s).
The Dead band (P12) determines the reaction to the controlled state, i.e. the actuator is
not active if the controlled variable moves within the dead band.
Customer data
Level
F/P
#1
#2
P09 [–]
P10 [s]
P11 [s]
P12 [%]
Fixed set point control
The flow temperature is controlled to a fixed value. The following parameters are used as F01 - 0
the reference variable:
P01 [°C]
• Flow temperature set point (P01) in rated operation and
P02 [K]
• Flow temperature set point (P01) – Flow temperature set-back in reduced
operation (P02) in reduced operation
Control with reference
variable (room
temperature)
(connected to Type 5257-7
Room Panel)
The predetermined Flow temperature set point (P01) is influenced by the room temperature: The heat supply is matched to the required amount over a permanently active flash
adaptation. This is achieved by comparing the room temperature at regular Time intervals (P22) with the room temperature set point valid for the current operating mode
(rated or reduced operation):
F01 - 1
Note: The function is not
active with setting
P22 = 0.
• Room temperature limit at rated operation (P19)
• Room temperature limit at reduced operation (P20)
P19 [°C]
The flow temperature is raised based on the Flow temperature set point (P01) when it
falls below the valid room temperature set point.
F02 - 1
F05 - 1
F06 - 0
P20 [°C]
P21 [K]
The heating is switched off when the room temperature exceeds the room temperature set P22 [min]
point by the amount in Maximum room temperature boost for deactivation (P21).
P23 [min]
When the flow temperature falls below 15 °C, frost protection measures are started, i.e.
the circulation pump is switched on and the flow temperature is regulated to 20 °C.
Outdoor temperature compensated control
t VL
[°C]
120
The flow temperature set point is determined in rated operation depending on the outdoor temperature by using a heating characteristic stored in the controller. By varying
the Gradient (P05) and Level (P06) parameters, the characteristic can be adapted to individual requirements. In reduced operation, the flow temperature is reduced by the
amount set in Flow temperature setback in reduced operation (P02).
3.2 2.9 2.4
2.0
1.6
100
80
1.2
0.8
0.4
60
40
tA
20
20 12
4 0 -4 -12 -20 [°C]
The Maximum flow temperature and Minimum flow temperature parameters (P03/04)
limit the flow temperature range.
When the outdoor temperature falls below 3 °C, frost protection measures are started,
i.e. the circulation pump is switched on and the flow temperature is regulated to 20 °C.
F01 - 1
F02 - 0
P02 [K]
P03 [°C]
P04 [°C]
P05 [–]
P06 [K]
Summer mode
Should the outdoor temperature exceed the Outdoor temperature limit value (rated oper- P17 [°C]
ation/reduced operation) (P17/18), the controller switches off the heating, i.e. the valve
P18 [°C]
is closed and the circulation pump is switched after the Pump lag time (P23) has elapsed.
The heating is switched on again when the outdoor temperature falls below the set point. P23 [min]
Heating characteristic
gradient shift
The potentiometer input changes the heating characteristic gradient. The range that can
be changed is determined by the Gradient shift range via potentiometer (P07) parameter. The mid-position of the relevant potentiometer is also the zero position.
Heating characteristic gradient (P05) = 1.6
Gradient shift range via potentiometer (P07) = 1.0
→ The gradient can be changed between 0.6 and 2.6.
Example:
Heating characteristic
level shift
The potentiometer input changes the heating characteristic level. The range that can be
changed is determined by the Level shift range via potentiometer (P08) parameter. The
mid-position of the relevant potentiometer is also the zero position. The base level of the
characteristic can be set by Heating characteristic level (P06).
Heating characteristic level (P06) = 0 K
Level shift range via potentiometer (P08) = 15 K
→ The level can be changed between –15 K and +15 K.
The limits for flow temperature (P03/04) still apply.
Example:
2
F05 - 1
F06 - 0/1
F07 - 1
P07 [–]
F05 - 1
F06 - 0/1
F07 - 0
P08 [K]
KA 5757-7 EN
Function
Customer data
Explanation
Note: A function is activated when the setting of the function blocks (F) is consistent with
the specifications listed under “Customer data”.
F/P
Level
#1
#2
Change of operation modes
Change rated oper. – BE1 open:
OFF/frost protec. (BE1) BE1 closed:
Rated operation
OFF/frost protection
Change rated oper.–
reduced oper. (BE1)
Rated operation
Reduced operation
BE1 open:
BE1 closed:
F05 - 0
F08 - 0
Note: The combined configuration of F05 - 0 and
F11 - 0 makes BE2 react to
BE1similar to a NO contact
connected in parallel.
Change rated oper.–
BE2 open:
OFF/frost protec. (BE2) BE2 closed:
Rated operation
OFF/frost protection
Change rated oper.–
reduced oper. (BE2)
BE2 open:
BE2 closed:
Rated operation
Reduced operation
Change by
Type 5257-7 Room
Panel
The operation mode of the controller is determined at the room panel:
F05 - 0
F08 - 1
F11 - 0
F12 - 0
F11 - 0
F12 - 1
F05 - 1
Rated operation
F06 - 0
Reduced operation
OFF/frost protection
Change by binary
input (BE) in
Type 5257-7 Room
Panel
When the mode switch is set to reduced operation or
Note: Terminals 1 to 4 are
OFF/frost protection, the operation mode is changed by the to be bridged with an exbinary input in the room panel.
ternal floating contact (e.g.
BE open:
Operation mode is the same as set at by a timer with downstream contactor relay and
the mode switch
with floating NO contact):
Rated operation
Reduced operation
Rated operation
F02 - 1
F05 - 1
F06 - 0
Type 5257-7
OFF/frost protection
BE closed:
F01 - 1
1
2
3
4
Pump forced operation
Note: The function is
only active with
F10 - 1.
A deactivated circulation pump is forced-operated every 24 hours for one minute.
F09 - 0
F10 - 1
Manual operating mode (over configuration)
In manual operating mode, the pump output (with F09 - 0)
is switched ON.
• With the setting F05 - 0, the actuator stem movement is
controlled over binary input BE1: For globe valves
(F03 - 0) the following applies:
BE1 closed
Actuator stem retracts
BE1 open
Actuator stem extends
• With the setting F05 - 1, the actuator stem movement is
controlled over the connected potentiometer.
For globe valves (F03 - 0) the following applies:
0%
Actuator stem extends
100 %
Actuator stem retracts
Note: The slide switch (underneath the cover (8)) can
be used to change over
into manual operating
mode only if one level is
used for control, provided
the setting of F13 in levels
#1 and #2 is not the same.
F13 - 1
The slide switch in position
#1 points away from the
device and towards the device in position #2.
A detailed list of all functions that can be configured in Type 5757-7 Controller with Electric Actuator can be found in the
Mounting and Operating Instructions EB 5757-7 EN.
KA 5757-7 EN
3
Summary of all functions and parameters
F Function
Comment, [WE]
01 Control mode
P
0 – Fixed set point control
Parameters
01 Flow temperature set point
[1] – Control with reference variable
02
02 Selecting the ref- [0] – Outdoor sensor
erence variable
1 – Room sensor
Flow temperature set-back in reduced
operation
WE
Range
70 °C
0…150 °C
15 K
0…50 K
03 Minimum flow temperature
20 °C
0…150 °C
03 Direction of stem [0] – SAMSON globe valve
action
1 – SAMSON three-way mixing valve
04 Maximum flow temperature
120 °C
0…150 °C
04 Delayed outdoor [0] – Without delay
temperature
1 – With delay
05 Heating characteristic gradient
1.6
06 Heating characteristic level
0K
05 Potentiometer
input
07 Gradient shift range via potentiometer
[0] – Inactive, binary input BE1 active
06 Resistance range [0] – Type 5257-7 Room Panel
of potentiometer
(1000 … 1100 Ω)
1 – Type 5257-2 with remote adjuster
(1000 … 2000 Ω)
07 Function of
potentiometer
[0] – Heating characteristic level shift
1 – Gradient shift
08 Function of
binary input 1
[0] – BE1 short-circuited: OFF/frost protect.
09 Function of
binary output
[0] – BA as circulation pump control
1 – BE1 short-circuited: Reduced operation
K
1.0
0.0…1.5
15 K
0…30 K
09 Kp flow temperature control
2.0
0.1…50.0
10 Tn flow temperature control
120 s
0…999 s
08 Level shift range via potentiometer
1 – Active
0.2…3.2
–30…30
11 Ty actuator transit time for valve travel
24 s
10…240 s
12 Dead band (switching range)
2.0 %
0.5…5.0 %
13 Max. return flow temperature
50 °C
10…90 °C
1.0
0.1…50.0
14 Kp return flow temperature limitation
15 Tn return flow temperature limitation
400 s
16 Delayed time for outdoor temperature
1 – BA as heat demand
3.0
°C
0…999 s
1.0…6.0
h
°C
h
17
Outdoor temperature limit at rated
operation
22 °C
0…50 °C
18
15 °C
0…50 °C
11 Return flow tem- 0 – Inactive; Binary input 2 active
perature sensor [1] – Active
Outdoor temperature limit at reduced
operation
19
20 °C
10…40 °C
12 Function of
binary input 2
[0] – BE2 short-circuited: OFF/frost protect.
Room temperature set point at rated
operation
20
15 °C
10…40 °C
13 Manual mode
1) WE for #1
2) WE for #2
[0] 1) – Inactive
Room temperature set point at reduced
operation
0 – No anti-block protection
10 Anti-block
protection of
pumps
[1] – When pumps deactivated: switched on
every 24 h for 1 min.
1 – BE2 short-circuited: Reduced operation
[1]
2)
– Man. operation: Control via BE1/
potentiometer
22 Time interval for flash adaption
2K
1…6 K
10 min
0…100 min
5 min
1…999 min
23 Pump lag time
Note! Manual operating mode has absolute priority over all other
functions.
Applications and wiring plan
21 Room temperature boost for deactivation
(bl = blue · br = brown · ye = yellow · gr = green · or = orange · blk = black · rd = red)
Terminals at the point of installation, not included in the scope of the delivery
Control with reference variable (room temperature) with flow sensor VS (Type 5267-2) and room panel RS (Type 5257-7)
VL RL
RS
VS
Type 3222N/ 5757-7
BE2
230 V, 50 Hz
Type 5257-7
1
2
3
4
Pt 1000
VS
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
UP
Outdoor temperature compensated flow control with flow sensor VS (Type 5267-2) and outdoor sensor AS (Type 5227-2)
_
+
VS
Type 3222N/ 5757-7
AS
UP
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
KA 5757-7 EN
2007-11
VL RL
Type 5757-7 Electric Actuator
with Process Controller
for heating and cooling applications
Mounting and
Operating Instructions
EB 5757-7 EN
Firmware version 2.0x
Edition July 2009
Definition of the signal words used in these mounting and operating instructions DANGER!
indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
WARNING!
indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
2
NOTICE
indicates a property damage message.

Note:
Supplementary explanations, information and tips
EB 5757-7 EN
Contents
1
General safety instructions..............................................................................5
2
Design and principle of operation...................................................................6
2.1Accessories....................................................................................................7
2.2
Technical data................................................................................................8
2.3
LED blinking pattern........................................................................................8
3
Attachment to the valve................................................................................10
3.1
Mounting position.........................................................................................10
4
Electrical connection.....................................................................................10
5
Dimensions in mm........................................................................................15
6Functions.....................................................................................................17
6.1
6.1.1
6.1.2
6.1.3
Outdoor-temperature-compensated control.....................................................17
Override using potentiometer.........................................................................19
Summer mode..............................................................................................19
Delayed outdoor temperature adaptation........................................................20
6.2
6.2.1
Fixed set point control...................................................................................20
Control with reference variable (room temperature)..........................................21
6.3
6.3.1
6.3.2
6.3.3
Changing the operating modes......................................................................22
Switchover using binary input........................................................................22
Switchover using room panel.........................................................................23
Switchover using binary input in room panel...................................................24
6.4
Frost protection.............................................................................................24
6.5
Return flow temperature limitation..................................................................24
6.6
Pump forced operation..................................................................................25
6.7
External heat demand...................................................................................25
6.8
Control principle...........................................................................................25
6.9
Operating direction.......................................................................................26
6.10
Manual mode...............................................................................................27
6.10.1Handwheel...................................................................................................27
6.10.2
Command mode...........................................................................................27
6.10.3
Function block F13 for manual mode..............................................................28
6.10.4
Manual level in TROVIS-VIEW.......................................................................28
EB 5757-7 EN
3
Contents
7
Device-specific readings and functions of the TROVIS-VIEW software..............30
7.1
Operation values..........................................................................................30
7.2Diagnostics...................................................................................................31
7.2.1
Additional diagnostics folders in the “Specialist” user level...............................32
7.3
SAMSON memory pen.................................................................................33
7.4
Functional test assistant..................................................................................34
8
Appendix.....................................................................................................35
8.1
Function block list..........................................................................................35
8.2
Parameter list................................................................................................36
8.3
Resistance values with Pt 1000 resistors..........................................................37
8.4
Customer settings..........................................................................................38
4
EB 5757-7 EN
General safety instructions
1 General safety instructions
For your own safety, follow these instructions concerning the mounting, start up and operation of the electric actuator:
−− The actuator is to be mounted, started up or operated only by trained and experienced personnel familiar with the product.
−− According to these mounting and operating instructions, trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible dangers
due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards.
−− Any hazards that could be caused in the valve by the process medium and the operating
pressure or by moving parts are to be prevented by taking appropriate precautions.
−− The electric actuator is designed for use in low voltage installations.
−− For wiring and maintenance, you are required to observe the relevant safety regulations.
Only use protective equipment in which the power supply cannot be reconnected inadvertently.
−− Before wiring the actuator, disconnect it from the power supply.
To avoid damage to any equipment, the following also applies:
−− Proper shipping and storage are assumed.

Note:
Devices with a CE marking fulfill the requirements of the Directives 2004/108/EC and
2006/95/EC. The Declaration of Conformity is available on request.
EB 5757-7 EN
5
Design and principle of operation
2 Design and principle of operation
The Type 5757-7 Electric Actuator with Process Controller consists of a digital controller integrated into the housing of an electric
actuator. The combination is especially designed for heating applications as well as
for fixed set point control of heating systems
in small to medium-sized buildings. It is particularly suitable for mounting to SAMSON
Types 3222, 3222 N, 2488 and 3267 Valves
(DN 15 to 25) as well as to special versions of
Type 3226 and Type 3260 Valves.
The actuator is mounted onto the valve using
a coupling nut (4).
When the actuator stem extends, the valve is
closed, opposing the force of the valve spring
(7). When the actuator stem retracts, the valve
is opened as the plug stem (6) follows the motion of the return spring.
The valve can be moved to any position in
the de-energized state by the handwheel (2).
2
8
Travel and direction of action can be read off
the travel indicator (5) on the side of the actuator housing.
Retracted
The digital controller is connected to a flow
sensor on the input side, which can be optionally upgraded by a return flow, outdoor
or room sensor. In addition to the Pt 1000 input, the digital controller has a potentiometer
input (1000 to 1100 Ω or 1000 to 2000 Ω)
to measure the flow temperature. This input influences the heating characteristic in the case
of outdoor-temperature-compensated control
and the room temperature set point in the case
of fixed set point control with room temperature influence. The heating characteristic and
set point can be changed over the TROVISVIEW configuration software.
The output signal of the integrated digital
controller functions as a three-step signal on
the synchronous motor of the actuator and is
transferred over the connected gear to the actuator stem (3) and used as the positioning
force.
The motor is switched off by torque-dependent
switches when an end position is reached or
in case the motor is overloaded.
6
1
Actuator stem
Extended
2
5
8
1
3
1.1
4
7
3
5
4
6
7
6
1
Electric actuator
1.1 Connecting cable
2 Handwheel (only
use when power is
disconnected)
3 Actuator stem
4
5
6
7
8
Coupling nut
Travel indicator
Plug stem
Valve spring
Cover, serial
interface
connection, slider
switch and LEDs
Fig. 1: Functional diagram
EB 5757-7 EN
5
Design and principle of operation
Slider switch
Slider switch (red)
Fig. 2: Position of the slider switch
The slider switch allows you to switch between
two different configurations #1 and #2. In position #1, the slider switch points away from
the housing and in position #2 towards the
middle of the housing. In both levels #1 and
#2, the functions described in section 6 can
be activated and the associated parameter
settings made. The default settings is the same
for both levels #1 and #2, except for function
block F13. Changes to functions and parameters can be made over the TROVIS-VIEW software. Refer to EB 6661 EN available in [?]
menu of the software.
The position of the slider switch determines
which function and parameter settings (level
#1 or #2) is used for closed-loop operation.
2.1 Accessories
Heating applications, refer to section 6
−− Type 5267-2 Contact Sensor (Pt 1000)
Configuration ID (Var.-ID): 1058683
Permissible temperatures:
Medium
–20 to 120 °C
Ambient
–20 to 120 °C
Degree of protection IP 42
EB 5757-7 EN
−− Type 5257-2 Pt 1000 Room Sensor with
potentiometer (remote adjuster)
Configuration ID (Var.-ID): 1072581
Permissible temperatures:
Medium
–35 to 70 °C
Ambient
–35 to 70 °C
Degree of protection IP 20
−− Type 5257-7 Room Panel (Pt 1000) with
potentiometer and mode selector switch
Configuration ID (Var.-ID): 1180319
Permissible temperatures:
Medium
–20 to 60 °C
Ambient
–20 to 60 °C
Degree of protection IP 30
−− Type 5227-2 Outdoor Sensor (Pt 1000)
Configuration ID (Var.-ID): 1043862
Permissible temperatures:
Medium
–35 to 85 °C
Ambient
–35 to 85 °C
Degree of protection IP 44
Communication, refer to section 7
−− TROVIS-VIEW software for Type 5757-7
Electric Actuator with Process Controller
−− Hardware package with accessories for
direct and indirect data transmission (including memory pen (1400-9753), connecting cable and modular adapter), order no. 1400-9998
−− Memory pen – 64 for indirect data transmission and data logging, order no.
1400-9753

Note:
The TROVIS-VIEW software is available for downloading from our website (www.samson.de).
7
Design and principle of operation
2.2 Technical data
Type 5757-7 Electric Actuator with Process
Controller
Temperature sensor
Operating temperature range
Max. 3 x Pt 1000
–40 to 150 °C
The device has a red and a yellow LED which
indicate the operating states of the device.
The LEDs are located underneath the cover on
top of the circuit board.
Blinking pattern of the yellow LED
Binary inputs
BI1 (instead of
potentiometer)
Floating contact
BI2 (instead
of return flow
sensor)
Floating contact
−− Device switched off or command mode
ON
Potentiometer input
1000 to 1100 Ω or
1000 to 2000 Ω
Switching output
230 V/50 Hz/1 A
Circulation pump or
external demand
Rated travel
2.3 LED blinking pattern
OFF
Time [s]
−− Device switched on or memory pen
action completed
ON
6 mm
Transit time for rated
20 s
travel
OFF
Time [s]
Thrust
300 N
Power supply
230 V (±10 %)/50 Hz
Power consumption
Approx. 3 VA
−− Active return flow temperature limitation
or plausibility error in memory pen
Class of protection
II
ON
Permissible temperatures
Ambient
0 to 50 °C
Storage
–20 to 70 °C
Degree of protection IP 42
Mounting position
Any position except
suspended
Electromagnetic
compatibility
According to
EN 61000-6-2,
EN 61000-6-3 and
EN 61326
Weight
8
OFF
Time [s]
−− Preparing to read data from memory pen
ON
OFF
Time [s]
Approx. 0.7 kg
EB 5757-7 EN
Design and principle of operation
−− Preparing to write data to memory pen
−− Device is starting up or limit switch error
ON
ON
OFF
Time [s]
−− Preparing data logging
OFF
Time [s]
−− Exceptional error or sensor line breakage
ON
ON
OFF
Time [s]
−− Data logging in progress
OFF
Time [s]
−− EEPROM error in device
ON
ON
OFF
Time [s]
−− EEPROM error in memory pen
OFF
Time [s]
−− Stem synchronization
ON
ON
OFF
Time [s]
Blinking pattern of the red LED
−− Device switched off, normal operation or
command mode
ON
OFF
OFF
−− Internal transit time measurement
ON
OFF
Time [s]
Time [s]
Time [s]
−− Flow sensor defective
ON
OFF
EB 5757-7 EN
Time [s]
9
Attachment to the valve
3 Attachment to the valve
−− Outdoor/room sensor defective
ON
OFF
The actuator has a force-locking connection to
the valve in de-energized state.
NOTICE
Turning the handwheel beyond the
end position will destroy the actuator.
Time [s]
−− Return flow sensor defective
ON
OFF
Time [s]
−− Place the actuator on the valve connection
and screw coupling nut (4, Fig. 3) tight
(tightening torque 20 Nm).
−− Potentiometer defective
ON
OFF
−− Turn the handwheel (2, Fig. 3) counterclockwise to retract the actuator stem as
far as it will go.
2
Time [s]
3
4
2
3
4
Handwheel
Actuator stem
Coupling nut
Fig. 3: Attachment to the valve
3.1 Mounting position
Any mounting position may be used, however, the actuator must not be installed in a suspended position.
10 EB 5757-7 EN
Electrical connection
4 Electrical connection
Risk of electric shock!
−−Upon installation of the electric cables, you are required to observe
the regulations concerning lowvoltage installations according to
DIN VDE 0100 as well as the regulations of your local power supplier.
−−Use a suitable power supply which
guarantees that no dangerous voltages reach the device in normal operation or in the event of a fault in
the system or any other system parts.
−−Connect the actuator to the electrical
network only after the power supply
is first switched off. Make sure the
power cannot be switched on unintentionally!
−−The pump output L’ is non-floating
(230 V~).
The actuator requires a Pt 1000 temperature
sensor (e.g. Type 5267-2) to be connected to
measure the flow temperature.
Depending on the control task, an outdoor
sensor (e.g. Type 5227‑2) or a room sensor (e.g. Type 5257-2) or room panel (e.g.
Type 5257-7) can be connected. They can all
be combined with a return flow sensor (e.g.
Type 5267-2).
an outdoor sensor, it can change the adjusted heating characteristic (see section 6.1). The
non-floating switching output can alternatively be used as an output for an external demand for heat.
The connected sensors are monitored for line
breakages. A fault in the line of a sensor is indicated by the red LED blinking (underneath
the cover on top of the circuit board). Each
sensor has its own blinking pattern (see section 2.3). In the event that several sensors are
defective, the LED blinks using the sequence
for the sensor with the highest priority:
Highest priority
Flow sensor
Outdoor sensor or
room sensor
Return flow sensor
Lowest priority
Potentiometer
Example: In the event that the flow sensor and
outdoor sensor are defective, the LED initially blinks to indicate that the flow sensor is defective. When this fault is eliminated, the LED
then blinks to indicate that the outdoor sensor is defective.
Additionally, the actuator has a potentiometer
input 1000 to 1100 Ω (e.g. Type 5257-7) or
1000 to 2000 Ω (e.g. Type 5257-2). This input is used to correct the room set point (±5 K)
in case of fixed set point control with room temperature influence (see section 6.2). On using
EB 5757-7 EN
11
Electrical connection
ÎÎ Perform the electrical connection depending on the heating application according
to one of the following wiring diagrams
(Fig. 4 to Fig. 6). As soon as the actuator
is connected to the power supply, the initialization procedure starts.
The actuator stem extends and the red and
yellow LEDs located under the cover on top of
the circuit board are illuminated.
As soon as the actuator stem has reached the
final position, the red LED is turned off. The
yellow LED remains illuminated and indicates
that the actuator is ready to operate.
e.g. Type 5257-2 Room Sensor
100/
1000 Ω
AS
Pt 1000
Pt 1000
Pt 1000
RüS
230 V, 50 Hz
1000 Ω
VS
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
NOTICE!
Live wires
Application with flow sensor (VS), return flow sensor (RüS) and outdoor sensor (AS)
and potentiometer functioning as set point adjuster
or
Orange
br
Brown
br
Brown
ye
Yellow
blk
Black
bl
Blue
rd
Red
gr
Green
blk
Black
Fig. 4: Electrical connections
12 Note: Terminals at point of installation, not included in the
scope of supply!
EB 5757-7 EN
Electrical connection
100/
1000 Ω
AS
Pt 1000
Pt 1000
BE2
230 V, 50 Hz
1000 Ω
VS
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
NOTICE!
Live wires
Application with flow sensor (VS), outdoor sensor (AS), binary input (BI2) to switch between
operating mode and potentiometer for adjusting the set point
VS
BE1
230 V, 50 Hz
Pt 1000
AS
Pt 1000
Pt 1000
RüS
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
NOTICE!
Live wires
Application with flow sensor (VS), return flow sensor (RüS), outdoor sensor (AS) and binary input
(BI1) to switch between operating modes
or
Orange
br
Brown
br
Brown
ye
Yellow
blk
Black
bl
Blue
rd
Red
gr
Green
blk
Black
Fig. 5: Electrical connections
EB 5757-7 EN
Note: Terminals at point of installation, not included in the
scope of supply!
13
Electrical connection
VS
AS
BE1
230 V, 50 Hz
Pt 1000
Pt 1000
BE2
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
NOTICE!
Live wires
Application with flow sensor (VS) and outdoor sensor (AS)
VS
Type 5257-7 Room Panel
1
2
3
230 V, 50 Hz
4
Pt 1000
Pt 1000
RüS
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
NOTICE!
Live wires
Application with flow sensor (VS), return flow sensor (RüS) and room sensor
with mode selector switch and set point adjuster
or
Orange
br
Brown
br
Brown
ye
Yellow
blk
Black
bl
Blue
rd
Red
gr
Green
blk
Black
Fig. 6: Electrical connections
14 Note: Terminals at point of installation, not included in the
scope of supply!
EB 5757-7 EN
Dimensions in mm
5 Dimensions in mm
11
Ø 12
80
55
2.5 m
32
70
aL Stem extends
70
114
eL Stem retracts
Fig. 7: Type 5757-7 Electric Actuator with Process Controller
EB 5757-7 EN
15
Dimensions in mm
84
50
36
+
Ø4
22
60
75
84
_
23
21
28
Type 5227-2 Outdoor Sensor (Pt 1000)
Configuration ID (Var-ID): 1043862
Color: RAL 9016
30
Type 5257-2 Room Sensor (Pt 1000) with remote
adjuster
Configuration ID (Var-ID): 1072581
Color: RAL 9010
50
20
32
2
86
30
82
Type 5267-2 Contact Sensor (Pt 1000)
(flow and return flow temperature
measurement)
Configuration ID (Var-ID): 1058683
32
Type 5257-7 Room Panel (Pt 1000)
Configuration ID (Var-ID): 1180319
Color: Cover and knobs RAL 9016 · Base RAL 7047
Continuous day mode (rated operation)
Continuous night mode (reduced operation)
Off/frost protection
Fig. 8: Accessories for heating applications
16 EB 5757-7 EN
Functions
6 Functions
Functions and parameters are entered in the TROVIS-VIEW Operator Interface separately for
level #1 and level #2 (see section 7).
6.1 Outdoor-temperature-compensated control
When outdoor-temperature-compensated control is used, the flow temperature (tA) is controlled
according to the outdoor temperature. The heating characteristic in the controller defines the
flow temperature set point as a function of the outdoor temperature (Fig. 9).
Basically, the following rule applies: a decrease in the outdoor temperature causes the flow
temperature to increase. By varying the Gradient and Level parameters, the characteristic can
be adapted to individual requirements: An increased Gradient causes an increase in flow temperature, whereas a reduced Gradient causes a lower flow temperature. The Level parameter
shifts the heating characteristic parallel upwards or downwards. In reduced operation, the flow
temperature is reduced by the amount set in Flow temperature set-back in reduced operation.
The Max. flow temperature and Min. flow temperature parameters limit the flow temperature
range. Return flow temperature limitation (see section 6.5) is an exception as it can reduce
the flow temperature without restriction down to 20 °C flow temperature set point.
tVL [˚C]
3.2 2.9
130
2.6
2.4
120
2.2
110
2.0
100
1.8
1.6
90
1.4
80
1.2
70
1.0
60
0.8
50
0.6
0.4
40
0.2
30
20
20
tA
16
12
8
4
0
-4
-8 -12 -16 -20
tVL
tA
Flow temperature
Outdoor temperature
[˚C]
Fig. 9: Heating characteristics
EB 5757-7 EN
17
Functions
Functions
WE
Configuration
F01 – Control mode
1
F01 - 1
F02 – Selecting the reference variable
0
F02 - 0
Parameters
WE
P02 – Flow temperature set-back in reduced
operation
15 K
P03 – Min. flow temperature
20 °C
P04 – Max. flow temperature
120 °C
Value range
0 to 50 K
0 to 150 °C
0 to 150 °C
P05 – Heating characteristic gradient
1.6
0.2 to 3.2
P06 – Heating characteristic level
0K
–30 to 30 K
Examples for adjusting the characteristic:
−−
−−
−−
−−
Old building, radiator design 90/70:
New building, radiator design 70/55:
New building, radiator design 55/45:
Underfloor heating depending on arrangement:
Gradient approx. 1.8
Gradient approx. 1.4
Gradient approx. 1.0
Gradient smaller than 0.5
VL RL
VS
BE1
AS
RüS
UP
AS
UP
Circulation pump (heating)
RüS Return flow sensor
Outdoor sensor
RL
District heating return flow
VS
VL
District heating supply
Flow sensor
Fig. 10:Typical application: Outdoor-temperature-compensated flow temperature control with return
flow temperature limitation; with binary contact (BI1) to switch between operating modes
18 EB 5757-7 EN
Functions
6.1.1 Override using potentiometer
The potentiometer input (e.g. by connecting a Type 5257-2 Room Panel with remote adjustment) can change either the heating characteristic level or gradient, depending on the configuration. The Gradient shift range via potentiometer and Level shift range via potentiometer parameters are used to adjust the range (±) in which the override is to take place.
Functions
WE
Configuration
F05 – Potentiometer input
0
F05 - 1
F06 – Resistance range of potentiometer
0
F06 - 0: 1000 to 1100 Ω
F06 - 1: 1000 to 2000 Ω
F07 – Function of potentiometer
0
F07 - 0: Level shift
F07 - 1: Gradient shift
Parameters
P07 – Gradient shift range via potentiometer
P08 – Level shift range via potentiometer
WE
Value range
1.0
0.0 to 1.5 (only with F07 - 1)
15 K
0 to 30 K (only with F07 - 0)
Examples:
−− Function of potentiometer F07 - 0
Heating characteristic gradient P05 = 1.6
Gradient shift range via potentiometer P07 = 1.0
à The gradient can be shifted between 0.6 and 2.6 (±1.0).
−− Function of potentiometer F07 - 1
Heating characteristic level P06 = 0 K
Level shift range via potentiometer P08 = 15 K
à The level can be shifted between –15 K and +15 K (±15 K).
The limits adjusted for the flow temperature still apply.
6.1.2 Summer mode
If the outdoor temperature exceeds the Outdoor temperature limit value (rated operation/reduced operation), the controller switches off the heating, i.e. the valve is closed and the circulation pump is switched off after the Pump lag time (P23) has elapsed. The heating is switched
on again when the outdoor temperature falls below the limit.
Parameters
WE
Value range
P17 – Outdoor temperature limit value at rated operation
22 °C
0 to 50 °C
P18 – Outdoor temperature limit value at reduced operation
15 °C
0 to 50 °C
P23 – Pump lag time
5 min
1 to 999 min
EB 5757-7 EN
19
Functions
6.1.3 Delayed outdoor temperature adaptation
The calculated outdoor temperature is used to determine the flow temperature set point. The
heat response is delayed when the outdoor temperature either increases or decreases.
If the outdoor temperature varies by, for example, 12 °C within a very short period of time, the
calculated outdoor temperature is adapted to the actual outdoor temperature in small steps.
Assuming a Delay time for outdoor temperature of 3 °C/h, the linear adaptation would take
12 ° C
t = 3 ° C / h = 4 h.

Note:
The delayed outdoor temperature adaptation helps avoid unnecessary overloads of central heating stations in combination with either overheated buildings occurring, for example, due to warm winds, or temporarily insufficient heating due to the outdoor sensor being exposed to direct sunshine.
Functions
F04 – Delayed outdoor temperature
Parameters
P16 – Delay time for outdoor temperature
WE
0
WE
3 °C/h
Configuration
F04 - 1
Value range
1 to 6 °C/h
6.2 Fixed set point control
The flow temperature is controlled to the fixed value in Flow temperature set point. In reduced
operation, the flow set point is used for the control reduced by the amount in Flow temperature set-back in reduced operation. A connected outdoor sensor does not have any affect on
the control.
Functions
F01 – Control mode
Parameters
P01 – Flow temperature set point
P02 – Flow temperature set-back in reduced
operation

20 WE
1
WE
70 °C
15 K
Configuration
F01 - 0
Value range
0 to 150 °C
0 to 50 K
Note:
The return flow limitation and the potentiometer override are still active when configured correspondingly.
EB 5757-7 EN
Functions
VL RL
RS
VS
RüS
UP
AS
Outdoor sensor
UP
Circulation pump (heating)
RüS Return flow sensor
RL
District heating return flow
VS
VL
District heating supply
Flow sensor
Fig. 11:Typical application: Control with reference variable (room temperature) and return flow temperature limitation; switching between operating modes at room panel RS (Type 5257-7)
6.2.1 Control with reference variable (room temperature)
On connecting a Type 5257-7 Room Panel, the Flow temperature set point is influenced by the
room temperature: A permanently active flash adaptation adapts the supply of heat to the required demand by changing the flow temperature. The room sensor is polled at regular intervals (Time interval flash adaptation). If the room temperature is lower than the Room temperature set point at rated operation or Room temperature set point at reduced operation, the flow
temperature is raised based on the Flow temperature set point.
If the room temperature exceeds the room temperature set point (rated operation/reduced operation) by the amount in Room temperature boost for switch-off, the heating is switched off, i.e.
the valve is closed and the circulation pump is switched off after the Pump lag time has elapsed.
The set point of the flow temperature is not affected when the P22 parameter (Time interval
flash adaptation) is set to 0. The heating deactivation remains active when the room temperature exceeds the value in Room temperature set point (P19/P20) plus Room temperature boost
for switch-off (P21).
EB 5757-7 EN
21
Functions

Note:
−−We recommend not to select a value that is too low for parameter P22. In particular,
in cases where cooling loads, such as drafts or open windows, affect the control process, short cycles usually have a negative effect. The heating is directly switched off
after the cooling stops.
−−The set points for room temperature entered in TROVIS-VIEW can be reduced or
raised by 5 K at the room panel (F05 - 1).
Functions
WE
F01 – Control mode
1
Configuration
F01 - 1
F02 – Selecting the reference variable
0
F02 - 1
F05 – Potentiometer input
0
F05 - 1
Parameters
WE
Value range
P01 – Flow temperature set point
70 °C
0 to 150 °C
P19 – Room temperature set point at rated operation
20 °C
10 to 40 °C
P20 – Room temperature set point at reduced
operation
15 °C
10 to 40 °C
P21 – Room temperature boost for switch-off
P22 – Time interval for flash adaptation
P23 – Pump lag time
2K
1 to 6 K
10 min
0 to 100 min
5 min
1 to 999 min
6.3 Changing the operating modes
6.3.1 Switchover using binary input
The electric actuator with process controller can be configured to allow one of two active binary inputs to determine which operating mode is used. Depending on the configuration, the
following applies:
Binary input BI1
22 F08 - 0
Open binary input BI1 – Rated operation
Closed binary input BI1 – OFF/Frost protection
F08 - 1
Open binary input BI1 – Rated operation
Closed binary input BI1 – Reduced operation
EB 5757-7 EN
Functions
Binary input BI2

F12 - 0
Open binary input BI2 – Rated operation
Closed binary input BI2 – OFF/Frost protection
F12 - 1
Open binary input BI2 – Rated operation
Closed binary input BI2 – Reduced operation
Note:
A Type 5257-7 Room Panel cannot be connected when binary input BI1 is active (see
section 6.3.3). The binary input BI2 can be used, provided a return flow sensor is not
activated.
Functions
WE
Configuration
Binary input BI1:
F05 – Potentiometer input
F08 – Function of binary input BI1
0
F05 - 0
0
F08 - 0: Rated operation and OFF/
Frost protection
F08 - 1: Rated and reduced operation
1
F11 - 0
0
F12 - 0: Rated operation and OFF/
Frost protection
F12 - 1: Rated and reduced operation
Binary input BI2
F11 – Return flow temperature sensor
F12 – Function of binary input BI2
6.3.2 Switchover using room panel
The operating mode is determined at the mode selector switch on the Type 5257-7 Room Panel:
Rated operation (day mode)
Reduced mode (night mode)
OFF/frost protection
Functions
WE
Configuration
F05 – Potentiometer input
0
F05 - 1
F06 – Resistance range of potentiometer
0
F06 - 0 (Type 5257-7 Room Panel)
EB 5757-7 EN
23
Functions
6.3.3 Switchover using binary input in room panel
The terminals 1 and 4 of the Type 5257-7 Room Panel can be bridged by means of an external floating contact (e.g. by a time switch with downstream contactor relay with floating make
or break contact). This enables the controller to switch to the rated operation mode when the
mode selector switch is set to reduced operation
or OFF/Frost protection .
The following applies:
−− BI break contactOperating mode is the same as the mode set at the mode selector switch
−− BI make contact Operating mode is rated operation, regardless of the mode set at the
mode selector switch
Functions
WE
Configuration
F05 – Potentiometer input
0
F05 - 1
F06 – Resistance range of potentiometer
0
F06 - 0 (Type 5257-7 Room Panel)
6.4 Frost protection
If the controller is in the operating mode OFF/Frost protection (see section 6.3), frost protection
measures are initiated if the following applies:
−− Outdoor temperature < 3 °C (outdoor-temperature-compensated control)
The flow set point is set to 20 °C. The binary output remains activated until the outdoor temperature rises above 3.5 °C.
−− Flow temperature < 15 °C (control with reference variable (room temperature))
The flow set point is set to 20 °C. The binary output remains activated for 5 minutes. After
that, the heating is deactivated when the flow temperature is higher than 15° C.
6.5 Return flow temperature limitation
The temperature difference between the flow and return flow in a network indicates how well
the energy is used: the greater the difference, the higher the efficiency.
A return flow sensor is sufficient to evaluate the temperature difference when the network flow
temperatures are predetermined. The flow temperature set point is reduced when the Max. return flow temperature measured at the return flow sensor exceeds the Flow temperature set
point. The reduction amount is calculated from the deviation of the return flow temperature
multiplied by the factor Kp return flow temperature limitation. The rate at which the return flow
temperature is reduced by the calculated amount is determined by Tn return flow temperature
limitation.
24 EB 5757-7 EN
Functions
The yellow LED blinks slowly if the flow temperature is reduced due to the Return flow temperature limitation function
Functions
WE
F11 – Return flow temperature sensor
1
Parameters
WE
P13 – Max. return flow temperature
Configuration
F11 - 1
Value range
50 °C
10 to 90 °C
P14 – Kp return flow temperature limitation
1.0
0.1 to 50.0
P15 – Tn return flow temperature limitation
400 s
0 to 999 s
6.6 Pump forced operation
A deactivated circulation pump is forced-operated every 24 hours for one minute. This function is deactivated by selecting F10 - 0 or F09 - 1.
Functions
WE
Configuration
F09 – Function of switching output
0
F09 - 0
F10 – Anti-block protection of pump
1
F10 - 1
6.7 External heat demand
The electric actuator can issue a heat demand to a higher-level controller over the binary output BO in rated or reduced operation. In this case, a coupling relay (contactor relay with floating contact) must be used to adapt the electrical connection.
This function is only possible when the switching output is not configured as a pump output.
Functions
F09 – Function of switching output
WE
0
Configuration
F09 - 1
6.8 Control principle
The electric actuator functions with a PI algorithm. The valve reacts to pulses which the actuator receives from the integrated digital controller when a system deviation occurs. In particular, the length of the first pulse depends on the system deviation and the selected gain Kp flow
temperature control (P09) (the pulse length increases as the Kp rises). Pulse lengths and intervals change until the system deviation is zero again. The interval between individual pulses is
influenced considerably by the reset time Tn flow temperature control (P10) (the interval time
increases as the Tn rises).
EB 5757-7 EN
25
Functions
The valve transit time Ty actuator transit time for valve travel (P11) reflects the time that the valve
needs to move through the range from 0 to 100 % without stopping. Its default setting is optimally tuned in this device and therefore should not be changed (Ty = 24 s).
The Dead band (P12) determines the reaction in steady state, i.e. the actuator is not active if
the controlled variable moves within the dead band.
Parameters
WE
Value range
P09 – Kp flow temperature control
2.0
0.1 to 50.0
P10 – Tn flow temperature control
120 s
0 to 999 s
24 s
10 to 240 s
P11 – Ty actuator transit time for valve travel
P12 – Dead band (switching range)
2.0 %
0.5 to 5.0 %
6.9 Operating direction
Increasing/increasing (F03 - 0)
−− Actual value < Set point: Actuator stem retracts
−− Actual value > Set point: Actuator stem extends
Increasing/decreasing (F03 - 1)
−− Actual value < Set point: Actuator stem extends
−− Actual value > Set point: Actuator stem retracts
Actuator stem extended
For globe valves: Valve CLOSED
With three-way mixing valves:
With three-way diverting valves:
Port A -> AB open, B -> AB closed (see Fig. 12)
Port AB -> A closed, AB -> B open
Actuator stem retracted
For globe valves: Valve OPEN
With three-way mixing valves:
With three-way diverting valves:
Functions
F03 – Direction of stem action
26 Port A -> AB closed, B -> AB open (see Fig. 12)
Port AB -> A open, AB -> B closed
WE
0
Configuration
F03 - 0: Increasing/increasing >>
F03 - 1: Increasing/decreasing <>
EB 5757-7 EN
Functions
Mixing valve for:
Mixing service
Diverting service
Flow
Flow
AB
A
B
Return flowAB
Return flow
A
AB
B
B
Diverting valve for:
Mixing service
Diverting service
Flow
Flow
Return flow
B
A
AB
Fig. 12:Type 3226 Three-way Mixing Valve mounted onto Type 5757-7 Electric Actuator with Process
A
AB
Controller
B
Return flow
6.10Manual mode
6.10.1 Handwheel
The handwheel (red knob, 2, Fig. 1 on page 6) is used to move the actuator stem when
the power has been disconnected. Do not use the handwheel while the actuator is running.
6.10.2 Command mode
A memory pen can be configured in TROVIS-VIEW to be a command pen. The command pen
allows the actuator stem to be moved to the open and closed positions.

Note:
The action of retracting/extending the actuator stem on inserting the command pen has
absolute priority. The input signal is overridden.
The configuration of the memory pen is explained in u EB 6661 EN.
EB 5757-7 EN
A
27
Functions
6.10.3 Function block F13 for manual mode
The electric actuator can be transferred into the manual operation mode while the actuator is
closed loop operation over function block F13. In manual operation mode, the switching output (with F09 - 0) can be switched to “I“ (ON) and the position of the actuator stem can be
controlled, depending on the configuration of function block F05 over the binary input BI1 or
over the potentiometer.
Open loop control with binary input BI1 (F05 - 0)
−− Increasing/increasing (F03 - 0): BI closedThe actuator stem retracts.
BI open The actuator stem extends.
−− Increasing/decreasing (F03 - 1): BI closedThe actuator stem extends.
BI open The actuator stem retracts.
Open loop control with potentiometer (F05 - 1)
−− Increasing/increasing (F03 - 1): 0 %
The actuator stem extends.
100 % The actuator stem retracts.
−− Increasing/decreasing (F03 - 1): 0 %
The actuator stem retracts.
100 % The actuator stem extends.

Note:
If just one level is used for closed loop control, the slider switch (Fig. 2 on page 7)
can be used to switch over to manual operation mode, provided the setting of function
F13 varies in level #1 and level #2. For example, if the function block F13 - 0 is configured for level #1, the closed loop control is performed according to the specifications in level #1 when the slider switch is positioned at #1. When the slider switch is
positioned at #2, the electric actuator moves to manual operation, provided the function block F13 - 1 is configured in level #2.
Functions
WE
Configuration
F13 Manual operation
0 1)
F13 - 1
1)
The default setting of F13 - 1 in level #2 is different.
6.10.4 Manual level in TROVIS-VIEW
The manual level can only be entered when “Specialist” is selected as the user level. See
u EB 6661 EN.
28 EB 5757-7 EN
Functions
You can switch the actuator to the manual mode using the TROVIS-VIEW Configuration and
Operator Interface if the manual level is enabled in online mode (Release for manual level parameter = ON (
icon)).
The following actions are possible in the manual level:
−− Retract actuator stem
−− Extend actuator stem
−− Move the stem to position selected in manual mode
(first enter the required value in Stem position in manual mode)
−− LED operation
−− Switching output
The electric actuator leaves the manual operation mode as soon as you exit the manual level
or the online mode in TROVIS-VIEW.
EB 5757-7 EN
29
Device-specific readings and functions of the TROVIS-VIEW software
7 Device-specific readings and functions of the TROVIS-VIEW software
The TROVIS-VIEW software is explained in detail in the Operating Instructions u EB 6661 EN.
Select [?] menu in the software to access these instructions or download them from the SAMSON
website (www. samson.de).
This section describes the device-specific readings and functions which are not covered in the
Operating Instructions EB 6661 EN.
7.1 Operation values
Operation values (for example, the flow temperature or the switching output state) can be read
in the Operation values folder in the TROVIS-VIEW software

30 Note:
−−The user level is set to “Customer” by default in TROVIS-VIEW. The current user level is displayed on the status bar. When the user level is set to “Specialist”, additional data points are displayed in the Operation and Diagnostics folders as well as the
Test functions, Calibration and Status messages subfolders.
−−Change the user level to “Specialist” by selecting User Level in Device menu. See
u EB 6661 EN.
EB 5757-7 EN
Device-specific readings and functions of the TROVIS-VIEW software
7.2 Diagnostics
The Diagnostics folder contains the Information and Error subfolders.
Information
Error

Note:
In the “Specialist” user level, the EEPROM error, Motor data and Elapsed hours meter
are additionally displayed.
EB 5757-7 EN
31
Device-specific readings and functions of the TROVIS-VIEW software
7.2.1 Additional diagnostics folders in the "Specialist" user level
Test functions
Manual level
Refer to section 6.10.4 for description.
Calibration
Status messages
32 EB 5757-7 EN
Device-specific readings and functions of the TROVIS-VIEW software
7.3 SAMSON memory pen
The SAMSON memory pen serves as a data carrier and is able to load and store data in its
non-volatile memory.
Used in conjunction with the Type 5757-7 Electric Actuator with Process Controller, various
functions of the memory pen are avaiable:
−− Reading data from the memory pen
−− Writing data to the memory pen
−− Command mode (retract actuator stem, extend actuator stem, manual operation using potentiometer or binary input)
−− Data logging to save the following data:
• Flow temperature
• Return flow temperature
• Binary input state
• Switching output state
• Position of the slider switch
• Flow temperature set point
• Set point reduction
• Operating status
• Cause for operating status
• Remaining time for pump lag
• Remaining time until anti-block protection of pump
• Limit switch status
• Current actuator stem position
• Current correction value for closed loop control
• P component from closed loop control
• I component from closed loop control
• Temperature inside device
The data are logged until the memory capacity of the memory pen is full.
Data in the memory pen can be saved as a data logging file using the TROVIS-VIEW software.
The configuration and handling of the memory pen is explained in u EB 6661 EN.
EB 5757-7 EN
33
Device-specific readings and functions of the TROVIS-VIEW software
7.4 Functional test assistant
To establish communication, the serial interface of the computer must be connected to the serial interface port of the electric actuator using the SAMSON connecting cable.
The functional test is performed with the help of an online wizard.
The following functions can be executed by selecting Functional test in Device menu or by clicking
in the device toolbar:
−−
−−
−−
−−
The actuator stem extends
The actuator stem retracts
LEDs, pump or switching output can be checked
Measured data are shown
34 EB 5757-7 EN
Appendix
8 Appendix
8.1 Function block list

Note:
There are separate two configuration levels #1 and #2. Both configuration levels contain the functions F01 to F13 with the specified default settings and meanings.
The function blocks F01 to F13 have the following listed functions.
F = Function block
F
WE = Default setting
Function
WE
01 Control mode
1
02 Selecting the reference variable (only effective when
F01 - 1)
0
03 Direction of stem action
0
04 Delayed outdoor
temperature (only effective
when F01 - 1 and F02 - 0)
0
05 Potentiometer input
0
06 Resistance range of
potentiometer (only effective
when F05 - 1)
0
07 Function of potentiometer
(only effective when F02 - 0
and F05 - 1)
0
08 Function of binary input BI1
(only effective when F05 - 0)
0
0 = OFF, 1 = ON
Meaning
0 – Fixed set point control à Section 6.2
1 – Control with reference variable à Section 6.1
0 – Outdoor sensor à Section 6.1
1 – Room sensor à Section 6.2.1
0 – Increasing/increasing >> à Section 6.9
1 – Increasing/decreasing <> à Section 6.9
0 – Without delay
1 – With delay à Section 6.1.3
0 – Inactive, binary input active à Section 6.3.1
1 – Active à Sections 6.1.1, 6.3.2, 6.3.3
09 Function of switching output
EB 5757-7 EN
0 – Type 5257-7 Room Panel (1000-1100 ohm) à
Sections 6.3.2, 6.3.3
1 – Type 5257-2 with remote adjuster (1000-2000 ohm)
à Section 6.1.1
0 – Heating characteristic level shift à Section 6.1.1
1 – Gradient shift à Section 6.1.1
0
0
BI1 short-circuited: OFF with frost protection à
Section 6.3.1
1
BI1 short-circuited: Reduced operation à Section 6.3.1
0
BO as circulation pump control à Section 6.6
1
BO as heat demand (ON in rated operation) à
Section 6.7
35
Appendix
F
Function
WE
10 Anti-block protection of
pumps (only effective when
F09 - 0)
1
11 Return flow temperature
sensor
1
12 Function of binary input BI2
(only effective when F11 - 0)
0
13 Manual mode
Meaning
0 – No anti-block protection
1 – When pumps are deactivated: switched on every 24 h
for 1 min. à Section 6.6
0 – Inactive, binary input 2 active à Section 6.3.1
1 – Active, with return flow temperature limitation
à Section 6.5
0 1)
0
BI2 short-circuited: OFF with frost protection
à Section 6.3.1
1
BI2 short-circuited: Reduced operation à Section 6.3.1
0 – Inactive
1 – Manual mode (absolute priority)
1)
The default setting F13 - 1 applies for level #2.
8.2 Parameter list

Note:
There are separate two parameter levels #1 and #2. Both parameter levels contain the
functions P01 to P23 with the specified default settings and setting ranges.
The parameters have the setting ranges as listed below.
P = Parameter
WE = Default setting
P
Parameters
WE
Adjustment
range
01
Flow temperature set point
70 °C
0 to 150 °C
02
Flow temperature set-back in reduced operation
15 K
0 to 50 K
03
Min. flow temperature
20 °C
0 to 150 °C
04
Max. flow temperature
120 °C
0 to 150 °C
05
Heating characteristic gradient
1.6
0.2 to 3.2
06
Heating characteristic level
0K
–30 to 30 K
07
Gradient shift range via potentiometer
1.0
0.0 to 1.5
08
Level shift range via potentiometer
15 K
0 to 30 K
09
Kp flow temperature control
2.0
0.1 to 50.0
36 EB 5757-7 EN
Appendix
P
Parameters
WE
Adjustment
range
10
Tn flow temperature control
120 s
0 to 999 s
11
Ty actuator transit time for valve travel
24 s
10 to 240 s
12
Dead band (switching range)
2.0 %
0.5 to 5.0 %
13
Max. return flow temperature
50 °C
10 to 90 °C
14
Kp return flow temperature limitation
1.0
0.1 to 50.0
15
Tn return flow temperature limitation
400 s
0 to 999 s
16
Delay time for outdoor temperature
3.0 °C/h
1.0 to 6.0 °C/h
17
Outdoor temperature limit value at rated operation
22 °C
0 to 50 °C
18
Outdoor temperature limit value at reduced operation
15 °C
0 to 50 °C
19
Room temperature set point at rated operation
20 °C
10 to 40 °C
20
Room temperature set point at reduced operation
15 °C
10 to 40 °C
21
Max. room temperature boost for switch-off
2K
1 to 6 K
22
Time interval for flash adaptation
10 min
0 to 100 min
23
Pump lag time
5 min
1 to 999 min
8.3 Resistance values with Pt 1000 resistors
°C
–35
–30
–25
–20
–15
–10
–5
Ω
862.5
882.2
901.9
921.6
941.2
960.9
980.4
15
20
25
30
35
40
45
°C
Ω
°C
Ω
°C
Ω
0
5
10
1000.0 1019.5 1039.0
50
55
60
1058.5 1077.9 1097.3 1116.7 1136.1 1155.4 1174.7 1194.0 1213.2 1232.4
65
70
75
80
85
90
95
100
105
110
1251.6 1270.7 1289.8 1308.9 1328.0 1347.0 1366.0 1385.0 1403.9 1422.9
115
120
125
130
135
140
145
150
1441.7 1460.6 1479.4 1498.2 1517.0 1535.8 1554.5 1573.1
EB 5757-7 EN
37
Appendix
8.4 Customer settings
Function blocks
Parameters
Setting
performed
F
WE
01
1
01
70 °C
   0 to 150 °C
02
0
02
15 K
   0 to 50 K
03
0
03
20 °C
   0 to 150 °C
04
0
04
120 °C
   0 to 150 °C
05
0
05
1.6
  0.2 to 3.2
06
0
06
0K
–30 to 30 K
07
0
07
1.0
   0.0 to 1.5
08
0
08
15 K
   0 to 30 K
09
0
09
2.0
   0.1 to 50.0
10
1
10
120 s
   0 to 999 s
11
1
11
24 s
  10 to 240 s
12
0
12
2.0 %
0.5 to 5.0 %
13
50 °C
  10 to 90 °C
14
1.0
0.1 to 50.0
15
400 s
   0 to 999 s
16
3.0 °C/h
1.0 to 6.0 °C/h
13
0
#1
#2
Setting
performed
1)
The default setting F13 - 1
applies for level #2.
1)
38 P
WE
#1
#2
Adjustment range
17
22 °C
   0 to 50 °C
18
15 °C
   0 to 50 °C
19
20 °C
  10 to 40 °C
20
15 °C
  10 to 40 °C
21
2K
   1 to 6 K
22
10 min
   0 to 100 min
23
5 min
   1 to 999 min
EB 5757-7 EN
EB 5757-7 EN
39
40 EB 5757-7 EN
Index
Index
A
Accessories
communication.............................. 7
heating applications...................... 7
Actuator stem.................. 6, 10, 26, 28
Anti-block protection of pump.......... 25
Attachment..................................... 10
B
Blinking pattern
red LED........................................ 9
yellow LED.................................... 8
C
Cable breakage.............................. 11
Calibration..................................... 32
Command mode............................. 27
Control
fixed set point............................. 20
outdoor-temperaturecompensated............................... 17
with reference variable
(room temperature)...................... 21
Coupling nut..................................... 6
Customer settings............................ 38
D
Delayed outdoor temperature
adaptation...................................... 20
Design.............................................. 6
Diagnosistics................................... 31
Diagnostics folder
Calibration................................. 32
Error.......................................... 31
Information................................. 31
Test functions............................... 33
Digital controller................................ 6
Dimensions
accessories................................. 16
electric actuator with process
controller.................................... 15
E
Electrical connection........................ 11
wiring diagrams.............. 12, 13, 14
Errors............................................. 31
External heat demand................ 11, 25
F
Fixed set point control...................... 20
Flash adaptation............................. 21
Flow temperature............................ 17
Forced operation of pump................ 25
Frost protection............................... 24
Functional test assistant.................... 34
Function block list............................ 35
Data transmission
with memory pen........................ 33
EB 5757-7 EN
41
Index
H
Handwheel........................... 6, 10, 27
Hardware package........................... 7
Heating characteristics..................... 17
gradient...................................... 17
level........................................... 17
I
Information..................................... 31
Initialization.................................... 12
M
Manual level................................... 32
Manual mode................................. 27
Memory pen..................................... 7
Mounting position........................... 10
O
Operating direction
globe valve................................. 26
three-way diverting valve............. 26
three-way mixing valve................ 26
Operating mode switchover
binary input................................ 22
binary input at room panel........... 23
room panel................................. 24
Outdoor-temperature-compensated
control............................................ 17
outdoor temperature adaptation... 20
potentiometer override................. 19
42 summer mode............................. 19
Outdoor temperature limit................ 19
P
Parameter list.................................. 36
Potentiometer.................................. 19
Potentiometer input.... 6, 11, 12, 13, 19
Principle of operation........................ 6
Pump anti-block protection............... 25
R
Ready to operate............................. 12
Resistance values............................. 37
Return flow temperature limitation..... 24
S
Sensor failure.................................. 11
Serial interface connection................. 6
Set point of room temperature.......... 22
Slider switch..................................... 7
Status messages.............................. 32
Summer mode................................. 19
T
Technical data................................... 8
Test functions................................... 32
Three-step signal............................... 6
Travel indicator................................. 6
TROVIS-VIEW................................. 30
EB 5757-7 EN
Index
Type 5227-2 Outdoor Sensor........... 11
dimensional drawing................... 16
permissible temperatures/
degree of protection...................... 7
Type 5257-2 Room Sensor............... 11
dimensional drawing................... 16
electrical connection.................... 12
permissible temperatures/
degree of protection...................... 7
Type 5257-7 Room Panel..... 11, 19, 21
dimensional drawing................... 16
electrical connection.................... 14
permissible temperatures/
degree of protection...................... 7
Type 5267-2 Contact Sensor
dimensional drawing................... 11
permissible temperatures/
degree of protection...................... 7
U
User level
Customer.................................... 30
Specialist............ 28, 30, 31, 32, 33
EB 5757-7 EN
43
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
EB 5757-7 EN
2014-02-14
SAMSON AG · MESS- UND REGELTECHNIK
Controller with Electric Actuator
Type 5757-7
for heating applications
Application
Electric actuator with integrated digital controller used to
position force-locking valves in nominal sizes DN 15 to 25.
Designed for installations in small to medium-sized buildings
for outdoor temperature compensated control, fixed set point
control, or fixed set point control with room temperature
sensors.
The Type 5757-7 is a combination of a linear actuator and an
integrated digital controller. It is particularly suitable for mounting to SAMSON Types 3222, 3222 N, 2488 and 3267 Valves
(DN 15 to 25) as well as to special versions of Type 3226 and
Type 3260 Valves.
Special features
• Outdoor temperature compensated control of a heating
circuit:
The flow temperature is controlled based on the outdoor
temperature over an adjustable heating characteristic.
An external binary contact allows switching between rated
and reduced operation or between rated and stand-by
operation with frost monitoring. As an alternative to the
binary input, the gradient or a level displacement of the
heating characteristic can be changed by the adjustment
knob of the Type 5257-2 Room Sensor.
• Fixed set point control · This function is used to control the
heating circuit to a fixed set point.
• Fixed set point control with room sensor · The set point is
changed by the room temperature. A permanently active
flash adaptation adapts the supply of heat to the required
demand by changing the flow temperature.
• Return flow temperature limitation · The temperature of the
return flow is monitored. When an adjustable maximum limit
is exceeded, the flow temperature is reduced until it remains
below the limit.
• Type 5257-7 Room Panel can be connected:
– Convenient room panel with various operating mode settings (Day mode · Night mode · OFF/frost protection)
– Binary input on room panel for remote switchover
– Possible override of the flash adaptation based on the
room temperature or heating characteristic (gradient or
level with outdoor temperature compensated control)
implemented by the controller
• Frost monitoring and automatic initiation of protective action
• Automatic anti-blocking function prevents circulating pumps
from seizing up
• Configuration, parameterization, diagnostic function, and
direct connection for monitoring over TROVIS-VIEW software:
– Direct data transmission over a connecting cable (direct
connection with PC)
– Data transmission over a memory pen
Fig. 1 · Type 5757-7 Controller with Electric Actuator
for heating applications
Accessories
– TROVIS-VIEW Configuration and Operator Interface software (6661-1066) for Type 5757-7 Controller with Electric
Actuator
– Hardware package with a memory pen, a connecting
cable, and a modular adapter, order no. 1400-7704
– Memory pen, order no. 1400-7697
– Type 5267-2 Pt 1000 Contact Sensor
– Type 5257-2 Pt 1000 Room Sensor with potentiometer
– Type 5257-7 Room Panel with potentiometer and mode
selector switch
– Type 5227-2 Pt 1000 Outdoor Sensor
Note:
Refer to Data Sheets T 5766 EN, T 5767 EN, T 5794 EN,
T 5763 EN and T 5761 EN for details on Type 3222,
Type 3222 N, Type 3267, Type 3226 and Type 3260 Valves.
Edition August 2005
Data Sheet
T 5757-7 EN
Principle of operation (Fig. 2)
The Type 5757-7 consists of a digital controller integrated into
the housing of an electric actuator.
The digital controller is connected to a flow temperature sensor
on the input side, which can optionally be upgraded by a return
flow sensor, outdoor sensor, or a room sensor. In addition to the
Pt 1000 flow temperature sensor input, the actuator has a potentiometer input (1000 to 1100 Ω/2000 Ω). This changes the
heating characteristic when outdoor temperature compensated
control is used. Alternatively, the room set point is changed
when a fixed set point control with room sensor is used.
The heating characteristic and set point can be changed over
the TROVIS-VIEW configuration software.
The output signal of the digital controller is applied as a
three-point stepping signal to the synchronous motor of the actuator. The signal is transferred over the connected gear to the
actuator stem (3) and used as the positioning force. The motor is
switched off by torque-dependent switches when an end positions is reached or in case of overload.
The actuator is mounted onto the valve using a coupling nut (4).
When the actuator stem extends, the valve is closed, opposing
the force of the valve spring (7). When the actuator stem retracts, the valve is opened as the plug stem (6) follows the motion of the return spring.
The valve can be moved to any position by the handwheel (2)
when the power supply is disconnected. Travel and direction of
action can be read off the travel indicator (5) on the side of the
actuator housing.
tVL [˚C]
3.2 2.9
130
2.6
2.4
120
2.2
110
2.0
100
1.8
1.6
90
1.4
80
1.2
70
1.0
60
0.8
50
0.6
0.4
40
0.2
30
20
20
tA
16
12
8
4
0
-8 -12 -16 -20
-4
[˚C]
tA Outdoor temperature
tVL Flow temperature
Fig. 3 · Heating characteristics:
Correlation between outdoor temperature (tA) and flow
temperature (tVL) in the outdoor temperature compensated
control
Electrical equipment
The actuator requires a Pt 1000 temperature sensor to be connected to measure the flow temperature. Depending on the control task, an outdoor sensor or a room sensor or room panel
(Type 5257-7 only) can be connected. They can all be combined with a return flow sensor.
The control circuit can be influenced over the potentiometer input. The non-floating pump output can alternatively be used as
a binary output for a demand for an externally required signal.
8
Type 5267-2 Pt 1000 Contact Sensor (see Data Sheet T 5220 EN)
Perm. medium temperature –20 to 120 °C
Perm. ambient temperature –20 to 120 °C
Degree of protection
IP 42
Type 5257-2 Room Sensor with potentiometer (see T 5220 EN)
Perm. medium temperature –35 to 70 °C
Perm. ambient temperature –35 to 70 °C
Degree of protection
IP 20
Type 5257-7 Room Panel with potentiometer and mode selector
switch (see Data Sheet T 5220 EN)
Operating mode switch
Day mode, night mode, OFF/frost
protection
Measuring range
–20 to 60 °C
Perm. ambient temperature –20 to 60 °C
Degree of protection
IP 30
1
Controller with electric
actuator
5
Travel indicator
6
Plug stem
Type 5227-2 Pt 1000 Outdoor Sensor (see T 5220 EN)
1.1
Connecting cable
7
Valve spring
Measuring range
–35 to 85 °C
2
Handwheel
8
Serial interface
Perm. ambient temperature –35 to 85 °C
3
Actuator stem
Degree of protection
4
Coupling nut
IP 44
Fig. 2 · Principle of operation
2
T 5757-7 EN
Mounting
Before connecting the actuator to the valve, the actuator stem
must be retracted. The coupling nut can only be tightened after
the stem has been retracted.
Any mounting position may be used, however, the actuator
must not be installed suspended downwards.
Electrical connection
2 cables both 2.5 m in length; cable ends fitted with wire-end
ferrules
Ordering text
Type 5757-7 Controller with Electric Actuator
Technical data
Type 5757-7 Controller with Electric Actuator
Temperature sensor
Setting range
Max. 3 x Pt 1000
0 to 150 °C
Potentiometer input
1000 to 1100 Ω or
1000 to 2000 Ω
Binary output
230 V/50 Hz/1 A
Circulating pump or demand for
externally required signal
Connection to the valve
Force-locking
Rated travel
6 mm
Transit time for rated travel
20 sec
Nominal thrust
300 N
Supply voltage
230 V (±10 %) / 50 Hz
Power consumption
Approx. 3 VA
Perm. ambient temperature
0 to 50 °C
Perm. storage temperature
–20 to 70 °C
Degree of protection
IP 42
Mounting position
Any, but not suspended
Noise immunity
EN 61000-6-2
Noise emission
EN 61000-6-3
Weight
Approx. 0.7 kg
Outdoor temperature compensated flow temperature control with
return flow temperature limitation;
with binary contact to switch between operating modes
AS
Outdoor sensor
RS
Room sensor/room panel
RüS Return flow sensor
VS
Flow sensor
UP
Circulating pump
RL
Return flow to district
heating network
VL
Supply from district
heating network
Fixed set point control with room sensor with return flow temperature limitation;
Operating mode switchover at room panel (Type 5257-7)
Fig. 4 · Typical applications
3
T 5757-7 EN
Electrical connection
100/
1000 Ω
Note:
Terminals at point of installation
not included in the scope of
delivery
230 V, 50 Hz
1000 Ω
Pt 1000
AS
Pt 1000
RüS
VS
Pt 1000
Application with
flow, return flow
and outdoor
sensors and
potentiometer
functioning as set
point adjuster
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
or Orange
br Brown
ye Yellow
bl Blue
rd Red
blk Black
br Brown
blk Black
gr Green
Caution!
Live wires
VS
AS
230 V, 50 Hz
Pt 1000
Pt 1000
RüS
Pt 1000
Application with
flow, return flow
and outdoor
sensors and binary
input to switch
between operating
modes
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
Caution!
Live wires
AS
230 V, 50 Hz
Pt 1000
VS
Pt 1000
Application with
flow and return
flow sensors
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
Caution!
Live wires
Type 5257-7
Room Panel
RüS
1
2
3
230 V, 50 Hz
4
Pt 1000
VS
Pt 1000
Application with
flow, return flow
and room sensors
with mode selector
switch and room set
point adjuster
1
2
3
4
5
6
L
N
L´
or
ye
rd
br
blk
gr
br
bl
blk
Caution!
Live wires
4
T 5757-7 EN
Dimensions in mm
11
Ø 12
80
55
2.5 m
70
32
aL Stem extends
70
114
eL Stem retracts
Type 5757-7 Controller with Electric Actuator
Accessories for heating applications
Type 5227-2 Outdoor Sensor,
Pt 1000
Type 5257-2 Room Sensor with potentiometer, Pt 1000
Type 5267-2 Contact Sensor, Pt 1000
(flow and return flow temperature
measurement)
Type 5257-7 Room Panel, Pt 1000
Continuous day mode (rated operation)
Continuous night mode (reduced operation)
Off/frost protection
Specifications subject to change without notice.
5
T 5757-7 EN
T 5757-7 EN
2007-01
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
Combined Self-operated Regulators
Flow Regulators with Additional Electric Actuator
Type 2488 N/5857
Application
Self-operated regulator for flow rate control in heat supply
networks, combined with an electric actuator to apply a control
signal of an electric control device.
Especially suitable for local heat supply networks and large
heating networks.
Globe valve in nominal size DN 15 · Nominal pressure
PN 10 · Flow set point ranges from 0.3 to 1.0 m³/h or 0.1 to
0.5 m³/h with a differential pressure created at the restriction of
0.2 bar · For treated water up to 110 °C and non-flammable
gases up to 80 °C.
The valve closes when the flow rate or the output signal of the
electric control device increases.
The combined regulators consist of a valve with integrated diaphragm actuator and an additional Type 5857 Electric Actuator.
Special features
• Low-maintenance, medium-controlled flow regulators requiring no auxiliary energy
• Single-seated globe valve
• Optionally with threaded ends, welding ends or soldering
ends
• Valve plug with soft sealing
• With adapter for the attachment of an electric actuator
Versions
Type 2488 N/5857 Flow Regulator
Type 2488 N Valve with connecting threads according to
ISO 228/1-G ¾ B on both sides for attachment of threaded
ends G ½, welding ends or soldering ends · Type 5857 Electric
Actuator
Fig. 1 · Type 2488 N/5857 Flow Regulator with
Electric Actuator
Accessories
– Threaded ends G ½, welding ends or soldering ends
(inside diameter = 15 mm or 18 mm)
– Intermediate insulating piece
ANSI versions available on request
Associated Information Sheet
T 3120 EN
Edition March 2008
Data Sheet
T 3136 EN
Principle of operation
The medium flows through the valve (1) in the direction indicated by the arrow on the body. The areas released by the restriction (11) and the valve plug (3) determine the flow rate.
Type 5857
Electric Actuator
The flow rate is controlled either by the connected Type 5857
Actuator or the diaphragm actuator (6).
The Type 5857 Electric Actuator reacts to the control signal of
an electric control device. As a result, the position of the restriction (11) and the flow rate are changed.
The continuously adjustable restriction (11) is installed above
the valve seat (2) as an orifice plate assembly and set point adjuster. Use the adjusting screw (13) to limit the cross section of
the restriction and the flow rate as well.
The valve plug (3) is located beneath the valve seat. The plug is
connected directly to the diaphragm actuator (6). The operating
diaphragm (9) and the positioning spring (5) determine the special differential pressure of 0.2 bar at the restriction.
Type 2488 N
Valve
The pressure upstream of the valve is transmitted to the
high-pressure side (8) of the operating diaphragm (9) through
an external control line (7). The low pressure directly downstream of the restriction is transmitted to the low-pressure side
(10) of the diaphragm through a hole in the valve plug. If the
pressure difference across the operating diaphragm exceeds
the adjusted special differential pressure set point of 0.2 bar,
the diaphragm moves the plug stem (4) and the flow cross-section of the valve is reduced in proportion to the differential pressure.
The actuator (6) adjusts the valve plug until the pressure drop
across created at the restriction in the valve and the fixed differential pressure are identical.
Differential pressure across the valve
The minimum required differential pressure Δpmin across the
valve is calculated from:
⎛ V& ⎞ 2
⎟
Δpmin = Δprestriction + ⎜
⎝ K VS ⎠
Δpmin
Minimum differential pressure across the valve in bar
Δprestriction Special differential pressure specially created
at the restriction to measure the flow rate
&V
Fixed flow rate in m³/h
KVS
2
Valve flow coefficient in m³/h
Fig. 2 · Sectional diagram
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Valve body
Valve seat
Plug
Plug stem
Positioning spring
Actuator
Control line for high-pressure
High-pressure side
Operating diaphragm
Low-pressure side
Restriction (orifice plate)
Restriction stem
Flow limiter (adjusting screw)
Adapter
Actuator stem
T 3136 EN
Table 2 · Materials · Material number acc. to DIN EN
Table 1 · Technical data
Type 2488 N Valve
Type 2488 N Valve
Nominal size
Connection
Type of connection
DN 15
ISO 228/1- G ¾ B
Threaded ends G ½ · Welding
ends · Soldering ends
KVS value
Standard version
Special version
2.5
1.0
Nominal pressure
Max. perm. diff. pressure Δp
Max. perm. temperature
Treated water
Non-flammable gases
Flow set point range/limit for
water at upper differential
pressure of 0.2 bar
Standard version
Special version
1.4301 with EPDM sealing
Restriction
Brass, resistant to dezincification
Plug stem
1.4305
Seat
CC491K (red brass, Rg 5)
1.4310 K
PN 10
Diaphragm
EPDM without fabric reinforcement
4 bar
Threaded ends
CW617N (brass)
Soldering ends
CC491K (red brass, Rg 5)
Welding ends
1.0037 (St 37)
0.43
Upper differential pressure
CC491K (red brass, Rg 5)
Plug
Valve spring
110 °C
80 °C
z value
Valve body
0.2 bar
Intermediate insulating
piece
Type 5857 Electric Actuator
Housing
Plastic (PPO)
Coupling nut
0.3 to 1 m³/h
0.1 to 0.5 m³/h
Type 5857 Electric Actuator
Power supply
Supply voltage
230 V/24 V ±10 %, 50 Hz
Power consumption
Approx. 3 VA
Rated travel
6 mm
Transit time per rated travel
22 s
Nominal thrust
1.4305, CW617N (brass),
PTFE, EPDM, FPM
Brass
Typical application
300 N
Perm. ambient temperature range
0 to 50 °C
Perm. temperature range at the
actuator stem
0 to 110 °C
Storage temperature range
–20 to 70 °C
Degree of protection
(installed upright) 1)
IP 42
Noise immunity
EN 61000-6-3
Noise emission
EN 61000-6-2
Weight, approx.
0.7 kg
Additional electrical equipment
Type 2488 N/5857
Positioner (for 24 V AC only)
Input signal
Position feedback
1)
0 (2) to 10 V
0 to 10 V
Actuator mounted above the valve
Installation
– The regulator is especially suitable for
installation in horizontal pipelines.
– Direction of flow must match the direction
indicated by the arrow on the body.
– The electric actuator must be mounted
above the valve body.
– Prior to mounting the actuator on the
valve: Retract the actuator stem.
3
Fig. 3 · Indirect local heating supply connection
with Type 2488 N/5857 Flow Regulator
– If the control device is insulated, do not insulate actuator
and coupling nut.
– Observe permissible temperature ranges!
Use an intermediate insulating piece if the permissible
temperature at the actuator stem is exceeded.
T 3136 EN
Dimensions
114
32
70
Ø12
11
55
80
120
ISO 228/1-G ¾ B
80
~65
65
Ø95
~70
Intermediate
insulating piece
Type 2488 N Valve with Type 5857 Actuator
210
SW30
Threaded ends
L
SW30
di
Ø21.3
G½
Ø21.3
129
SW30
Welding ends
Soldering ends
Soldering ends · Dimensions in mm
Inside Ø di
15
18
Length L
107
103
Fig. 4 · Dimensions in mm
Ordering text
Flow Regulator Type 2488 N/5857
With Type 2488 N Valve and Type 5857 Actuator
Flow set point range with an upper differential pressure of
0.2 bar:
0.3 to 1.0 m³/h (standard version) or 0.1 to 0.5 m³/h
(special version)
Accessories
Threaded ends G ½, welding ends or soldering ends
(inside diameter di = 15 mm or 18 mm)
Intermediate insulating piece
Specifications subject to change without notice.
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
T 3136 EN
Combined Self-Operated Regulators for
Differential Pressure or Flow Rate
with additional electric actuator
Application
Self-operated regulators for controlling the differential pressure
and/or the flow rate in district heating systems. Combined with
an electric actuator used to transmit the control signal of an
electric controller. Valve sizes DN 15 to DN 50 · Nominal
pressure PN 16/25 for liquids up to 150 °C
The valve closes when the differential pressure, flow rate or the
output signal issued of the electric controller increase.
These combined regulators consist of a valve, a diaphragm
actuator and a Type 5824 or Type 5825 Electric Actuator (with
fail-safe action) or Type 5857 or Type 5757 Electric Actuator.
Special features
• Low-maintenance regulators requiring no auxiliary energy
• Single-seated valve with a balanced valve plug
• Suitable for water and other liquids, provided these do not
cause the materials used to corrode
• Available with adapter for attachment of the electric actuator
to the valve and for adjustment of the flow rate
Versions (Figs. 1 to 3)
Valve body made of red brass with screwed ends DN 15 to 50,
DN 32 to 50 also available with flanged body made spheroidal
graphite iron.
Type 2488/5824(25) (Fig. 3.1), Type 2488/5857 or
Type 2488/5757 Flow Regulator
with either a Type 5824, Type 5825, Type 5857 or Type 5757
Electric Actuator · Type 5857 or Type 5757 Actuator for DN 15
to 32 only
Type 2489/582.. Flow Regulator (Fig. 3.5)
with either a Type 5824 or Type 5825 Electric Actuator and an
additional Type 2430 K Control Thermostat
Type 2491/582.. Flow and Differential Pressure or Pressure
Regulator (Fig. 3.3)
with adjustable differential pressure or pressure set point and
either a Type 5824 or Type 5825 Electric Actuator
Type 2494/582.. Flow and Differential Pressure or Pressure
Regulator (Fig. 3.4)
with fixed differential pressure or pressure set point and either a
Type 5824 or Type 5825 Electric Actuator
Type 2487/582.. Flow and Differential Pressure Regulator
(Fig. 3.2) · With internal force limiter and overload protection
(excess pressure limiter) in the actuator · With adjustable differential pressure set point and either a Type 5824 or Type 5825
Electric Actuator
Type 2495/582.. Flow and Differential Pressure Regulator
With internal force limiting device and overload protection (excess pressure limiter) in the actuator · With fixed differential
pressure or pressure set point and either a Type 5824 or Type
5825 Electric Actuator
Typetested control equipment with Type 5825 Actuator
according to DIN 32730 are available.
Associated Information Sheet
T 3120 EN
Edition July 2006
Associated Data Sheet for accessories
T 3095 EN
Data Sheet
Fig. 1 · Type 2488/5824 Flow Regulator with electric actuator
(DN 15 to 25 version)
Fig. 2 · Type 2487/5825 Differential Pressure and Flow
Regulator with electric actuator (DN 32 to 50 only)
T 3135 EN
1 Valve body
1.1 Connection nut with seal
and welding end
1.2 Orifice to adjust the flow rate
set point
2 Valve seat
3 Plug
10 4 Plug stem
5 Positioning springs
6 Diaphragm actuator (housing)
6.1 Operating diaphragm
12 6.3 Operating diaphragm
8 Set point spring (assembly)
1
10 Electric actuator
11 Control line
12 Set point adjuster with
lead-seal (DN 32 to 50)
13 Set point adjustment screw
(DN 15 to 25)
16 Internal excess pressure limiter
(overload protection)
20 Control thermostat
21 Spring
22 Set point adjuster
23 Bellows with actuator stem
24 Capillary tube
25 Temperature sensor
13
1.1
1
1.2
2
3
4
5
P2
P1
6.3
1.2
11
3
out-of-line
4
5
6.1
6.1
6
16
8
11
6
Fig. 3.1 · Type 2488/5825, PN 25
(flow regulator)
Fig. 3.2 · Type 2487/5825, PN 25
(flow and differential pressure regulator)
13
1.1
1
12
1.2
1
1.1
13
1.1
3
4
5
1.2
2
1
1.2
2
3
4
3
4
6.3
5
11
6.3
5
6.1
2
out-of-line
6
6.1
8
11
out-of-line
out-of-line
6
6.1
6
24
Fig. 3.4 · Type 2494/5825, PN 25
(flow and differential pressure or
pressure regulator
22
Fig. 3.3 · Type 2491/5825, PN 25,
set point range up to 1 bar
(flow and differential pressure or
pressure regulator)
11
21
22
25
23
20
Fig. 3.5 · Type 2489/5825, PN 25
(flow regulator with thermostat)
Fig. 3 · Various versions of the regulators
2
T 3135 EN
Principle of operation
The regulators consist of a standard instrument for flow and differential pressure control. Their principle of operation is described in the Data Sheets listed in the Selection Guide.
The electric actuator is mounted to the control valve assembly
over the adapter. Depending on the nominal size, the flow rate
set point (without actuator) is set at the adjustment screw (13) or
at the set point adjuster (12) which can be lead-sealed.
The Type 5824, Type 5757 1) and Type 5857 1) Actuator do not
have a fail-safe action. The Type 5825 Actuator, however, has
fail-safe action, i.e. the valve is closed when the power supply is
interrupted.
These actuators are operated by control signals from an electric
control device. As a result, the orifice (1.2) is adjusted, thus controlling the flow rate across the valve.
The Type 2489/582.. instrument combination is equipped with
an additional Type 2430 K Control Thermostat.
This thermostat operates without auxiliary energy and allows
the additional control of a temperature variable.
An internal excess pressure limiter functions as an overload
protection (16) in the actuator of Type 2487/582.. and
Type 2495/582.. Regulators to protect the seat and plug from
overload during exceptional conditions that could lead to damaging the valve or plant.
1) Type 2488/5857 or Type 2488/5757: DN 15 to 25 only
Selection guide for Type 24../5824, Type 24../5825, Type 2488/5857 or Type 2488/5757 instrument combinations
This table shows the various versions of the combined regulators and their possible scope of application. Refer to the data sheets
listed for a detailed description of the standard regulator.
Regulator
Type
Standard device
Type
See Data Sheet
2488/5824
2488/5825
2488/5857
2488/5757
2489/5824
2489/5825
2491/5824
2491/5825
46-7
45-9
2469/2430 K
47-1
T 3131 EN
T 3128 EN
T 3132 EN
•
•
2487/5824
2487/5825
2494/5824
2494/5825
2495/5824
2495/5825
47-4
47-5
T 3131 EN
Application for
Diff. pressure control Δp
Flow control V&
•
•
•
•
•
•
•
•
•
•
•
Temperature control
Installation Flow pipe
in
Return pipe
•
•
•
•
•
•
•
•
0.11)/0.2 2)
0.2
0.2
2.0
0.5
0.5
•
•
•
Fixed
Set point
Δp
•
•
Min.
0.11)/0.2 2)
Max.
2.0
Adjustable
Δp (bar)
.
V
Adjustable
•
•
Type 5824 Electric Actuator
•
•
•
•
•
•
Type 5825 Electric Actuator with
fail-safe action
•
•
•
•
•
•
•
Type 2430 K Control Thermostat
Type 5857
Actuator
1)
or Type 5757
1)
Electric
•
•
1) DN 15 to 32
2) DN 40 to 50
3
T 3135 EN
Typical applications
Indirectly connected district heating system with
Type 2488/5825 Flow Regulator
Directly connected district heating system with
Type 2495/5825 Differential Pressure and Flow Regulator
Fig. 4 · Typical applications
Table 1 · Technical data · Valves · All pressures in bar (gauge)
Nominal size
KVS
z value
DN
Valve with screwed ends
0.4 1)
15/20/25
15
20
25
1 1)
4 1)
6.3
8
2.5
32 2)
−
Flanged valve body
Valve with screwed ends
0.6
12.5
16
20
20
25
0.45
0.40
0.5
0.45
PN 16 3)/25
Nominal pressure
Max. perm. diff. pressure Δp at valve
0.45
PN 25
10 4)/20 bar
Max. perm. temperature
50 2)
12.5
0.55
−
Flanged valve body
40 2)
16 bar
For liquids 130 °C (PN 16)/150 °C (PN 25) · For air and non-flammable gases 80 °C
Flow rate set point ranges for water in m³/h
Flow rate set point range/limitation for water with an upper
differential pressure of 0.2 bar
1)
m³/h
0.03 to
0.2
0.12 to
0.64
0.2 to
1.2
0.8 to
0.6 to
2.3 5)
1.3 5)
0.6 to 2.5 0.8 to 3.6
0.8 to
3.5 5)
0.8 to 5
2 to
5.8 5)
2 to 10
3 to
9.1 5)
3 to 12.5
4 to
14.1 5)
4 to 15
Special version
Additional version: Valve with flanged body made of spheroidal graphite iron (EN-JS1049)
Not for Types 2489/... and 2491/...
For version with PN 16
When the indicated flow rates are exceeded, it must be expected that the noise level also increases, even if cavitation does not occur in the flow
2)
3)
4)
5)
Table 2 · Differential pressure set points
Type
2487/....
2491/....
2494/....
2495/....
–
–
0.2/0.3 bar
0.4/0.5 bar
0.2/0.3 bar
0.4/0.5 bar
DN 15 to 32
0.1 to 0.5 bar
0.1 to 1.0 bar
0.5 to 2.0 bar
0.1 to 0.5 bar
0.1 to 1.0 bar
0.5 to 2.0 bar
–
–
DN 40 to 50
0.2 to 0.5 bar
0.2 to 1.0 bar
0.5 to 2.0 bar
0.2 to 0.5 bar
0.2 to 1.0 bar
0.5 to 2.0 bar
–
–
Differential pressure set points Δp
fixed
continuously
adjustable
4
T 3135 EN
Table 3 · Technical data · Electric actuators
Electric actuator
Rated travel
Type 5824-...
Type 5825-...
- without fail-safe action -
- with fail-safe action -
10
11
Valve DN 15 to 25
7.5 mm
Valve DN 32 to 50
−
45 s
Transit time for rated travel
Transit time in case of fail-safe action
Nominal thrust
Nominal thrust of return spring
Power supply
- without fail-safe action −
7.5 mm
−
6 mm
−
12 mm
−
45 s
90 s
70 s
20 s
4s
5s
8s
−
10
11
7.5 mm
−
7.5 mm
−
12 mm
−
90 s
70 s
700 N
−
300 N
−
500 N
−
230 V/24 V (±10%),
50 Hz
230 V, 50 Hz (on request 24 V, 50 Hz)
Power consumption
Override
Type 5857
20
20
−
Type 5757
Approx. 3 VA
Approx. 3 VA + 1 VA
Approx. 3 VA
With
Possible 1)
With
Perm. ambient temperature
0 to +50 °C
Perm. temperature at connecting
stem
0 to +110 °C
Degree of protection (upright
position acc. to DIN IEC 529)
IP 54
IP 42
IP 42
Further details in Data Sheet
T 5824 EN
T 5757 EN
T 5857 EN
1) Override with 4 mm hexagonal wrench with housing cover removed. Valve always returns to fail-safe position after fail-safe action has been activated.
Table 4 · Technical data · Type 2430 K Control Thermostat
Type 2430 K Control Thermostat
Set point range
Continuously adjustable: 0 to 35 °C, 25 to 70 °C, 40 to 100 °C,
50 to 120 °C, 70 to 150 °C
Ambient temperature
–20 to +80 °C
Temperature at sensor
Max. 50 K above adjusted set point
Pressure at sensor
Max. 40 bar
Capillary tube
2 m (5 m special version)
Table 5 · Materials · Material number acc. to DIN EN
Body
Red brass CC491K (G-CuSn5ZnPb, Rg 5) · Spheroidal graphite iron EN-JS1049 (GGG-40.3) 1)
Seat
Stainless steel 1.4305
Plug
Upper section
PN 25
Brass, free of dezincification, with EPDM soft sealing 2)
PN 16
Brass, free of dezincification and plastic with EPDM soft sealing
PN 25
Red brass CC491K (G-CuSn5ZnPb, Rg 5) · Spheroidal graphite iron EN-JS1049 (GGG-40.3) 1)
PN 16
Stainless steel 1.4301
Valve spring
Restriction
Operating diaphragm
Stainless steel 1.4310
Brass, free of dezincification
EPDM with fabric reinforcement 2)
EPDM 2)
Seals
Type 5824, Type 5825, Type 5857 and Type 5757 Electric Actuators
Housing
Plastic (PPO glass fiber reinforced)
Coupling nut
Brass
Type 2430 K Control Thermostat
Sensor and capillary tube
Thermowell
Copper
Copper or stainless steel 1.4571
1) Additional version for DN 32, 40 and 50: Valve with flanged body made of spheroidal graphite iron
2) Special version for oils (ASTM I, II, III): FPM (FKM)
5
T 3135 EN
Dimensions and weights
Dimensions in mm and weights in kg
15
20
25
321)
401)
501)
Pipe diameter d
21.3
26.8
32.7
42
48
60
Thread size R
G¾
G1
G 1¼ G 1¾
G2
G 2½
Nominal size
DN
Width ac. flats SW
30
36
46
59
65
82
Length L
65
70
75
100
110
130
155
216
Height H3
122
163
Height H1( H2)
Height H
Weight, approx. in kg3)
6
H
SW
d R
Type 2488/...
85
105
140
Type 2494/...
122
140
192
Type 2495/...
108
125
175
Type 2487/...
248 (185)
265
(205)
415
Type 2491/...
265 (200)
285
(220)
425
Type 2489/...
245
265
295
Length L1
with welding ends
L
H1
G18
Ø 116(Ø 160)
L1
Type 2494/5824(5825)
Type 2495/5824(5825)
- Dimensions in parentheses apply to DN 40 and DN 50! -
210
234
244
268
294
330
Type 2488/...
3.0
3.1
3.2
4.4
6.9
7.4
Type 2494/...
Typ 2495/...
3.6
3.7
3.8
4.9
7.6
8.1
Type 2489/...
3.9
4.0
4.1
5.2
7.9
8.4
Type 2487/...
Type 2491/...
4.0
4.1
4.2
5.4
13.4
13.9
Special versions
6
H
SW
dR
L
H2
129
144
159
Male thread A
G½
G¾
G1
Weight
180
196
G 1¼ G 1½
min. 30 mm
146
G18
with threaded ends
Length L2
min. 30 mm
146
228
G2
Ø 116
L1
See version with welding ends
with flanges2) (PN 16/25) or with flanged body (DN 32 to 50)
–
Height H5
–
196
105
140
Length L3
130
150
160
180
200
230
Weight, approx. in kg3)
Height H4
Type 2488/...
4.4
5.1
5.7
7.6
10.9
12.4
Type 2494/...
Type 2495/...
5.0
5.7
6.3
8.1
11.6
13.1
Type 2489/...
5.3
6.0
6.6
8.4
11.9
13.4
Type 2487/...
Type 2491/...
5.4
6.1
6.7
8.6
17.4
18.9
1)
Additional version: Valve with flanged body
2)
Flanges are already mounted on valves in DN 40 and 50
3)
Type 2489/582...: Weights for version with bulb sensor and thermowell.
Type 2487/5824(5825)
Type 2491/5824(5825)
0.1 to 0.5 bar or
0.1 to 1.0 bar
Minus 0.2 kg for version with thermowell
Fig. 5 · Regulator dimensions
6
T 3135 EN
146
min. 30 mm
6
min. 30 mm
146
min. 30 mm
114
6
H4
H
H3
SW
SW
d R
L
H1
d R
L
H1
G18
Ø 116(Ø 160)
L1
G 18
H5
Ø 116(Ø 160)
L1
Type 2488/5824(5825)
with welding ends
G18
L3
Type 2488/5857 or 5757
with welding ends
Type 2488/5824(5825)
with flanged body
(DN 32 to 50 only)
146
min. 30 mm
146
min. 30 mm
6
6
H
SW
H
SW
d R
d R
L
L
min. 30 mm
Ø 116(Ø 160)
L1
185(220)
Ø 116(Ø 160)
L1
185(220)
H1
G18
H1
G 1 8 G½
(G¾)
Ø 12(Ø 19) Ø 9.5(Ø 16)
Type 2487/5824(5825)
Type 2491/5824(5825)
- Dimensions in parentheses apply to DN 40 and DN 50! -
Bulb sensor
with
thermowelll
Bulb sensor
with
screw gland
Type 2489/5824(5825)
with welding ends
L3
A
L2
SW
with threaded ends
7
SW
with flanges
T 3135 EN
Installation
– Install a SAMSON strainer (e.g. Type 1N or 2N) upstream of
the regulator.
DN 15 to 25: 0.5 mm mesh width
DN 32 to 50: 0.75 mm mesh width
– The regulators are only suitable for installation in horizontally
running pipelines. Regulators in nominal sizes DN 15 to 25
may also be installed in vertically running pipelines.
– The medium must flow through the valve in the direction indicated by the arrow on the valve body.
– Prior to assembling the actuator and valve:
Retract the actuator stem!
– The electric actuator must always be located above the valve
body.
– When the valve is insulated, use an intermediate insulating
piece. The insulating limit is in this case approx. 25 mm
above the top of the valve body.
Do not insulate the actuator and the coupling nut as well!
– Observe the maximum permissible ambient temperature
range!
Ordering text
Flow Regulator
Type 2488/5824(5825); Type 2488/5857;
Type 2488/5757; Type 2489/5824(5825)
Flow and Differential Pressure or Pressure Regulator
Type 2491/5824(5825); Type 2494/5824(5825);
Type 2487/5824(5825);
Flow and Differential Pressure Regulator
Type 2495/5824(5825)
With valve DN …, PN …,
perm. temperature … °C, KVS …
With welding ends/threaded ends/flanges
with flanged valve body
Differential pressure set point … bar
Upper differential pressure at the restriction … bar
With Electric Actuator Type 5824-.../Type 5825-.../
Type 5857/Type 5757
With Control Thermostat Type 2430 K
Set point range… °C
On option, accessories …/special version …
Version with control thermostat
– The temperature sensor may be installed in any desired position. Its entire length must be immersed in the medium.
– It should be installed in a location where overheating or considerable idling times cannot occur.
– The capillary tube should be run in such a way that the ambient temperature range cannot be exceeded, any deviations in
temperature cannot occur and that the tube cannot be damaged. The smallest permissible bending radius is 50 mm.
Specifications subject to change without notice.
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 069 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
T 3135 EN
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix v |
Temperature Regulator 43-2N
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Temperature Regulator Series 43
Type 43-2 N
Fig. 1 ⋅ Type 43-2 N
Mounting and
operating instructions
EB 2186 EN
Edition July 2001
Design and principle of operation
1. Design and principle of operation
1.1 Temperature regulator
The temperature regulator consists of the
valve and the Type 2430 K Thermostat
which are screwed together.
The valve comprises the valve body, seat
and plug, the thermostat comprises operating bellows, set point spring, capillary tube
and temperature sensor.
1.2 Version with double adapter
and/or manual adjuster
For measurement of an additional process
variable, the temperature regulator can be
equipped with a double adapter plus an addi-
tional thermostat, or with a manual adjuster.
For further details, refer to EB 2176 EN.
Principle of operation:
The temperature regulator works according
to the adsorption principle. The temperature
of the process medium produces a pressure
in the sensor, which is proportional to the
actual value. This pressure is transmitted via
the capillary tube (10) to the operating element (13) and converted into a positioning
force.
This force acts upon the operating bellows
(9) and the operating element pin (12) and
is passed on to the plug stem and plug (3).
Turning the set point adjuster (8) changes
the regulator’s point of response via the
spring (7). As a result, the valve plug passes
through its travel range within a higher or
The device may only be assembled, started up and operated by trained and
experienced personnel familiar with this product.
According to these mounting and operating instructions, trained personnel is
referred to as individuals who are able to judge the work they are assigned to
and recognize possible dangers due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards.
Any hazards which could be caused by the process medium, the signal press-
2
EB 2186 EN
ure and moving parts of the control valve are to be prevented by means of appropriate measures.
In addition, it is necessary to make sure that the control valve is only used in
areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order.
Proper shipping and appropriate storage are assumed.
Design and principle of operation
lower temperature range sensed by the sensor.
Note: For thermostats working according to
the vapor pressure principle, refer to
EB 2430-3 EN.
1.1
1
2
3
4
5
15
(20Nm)
7
10
7
8
9
12
13
1 Valve body
1.1 Coupling nut with gasket and
accessory weld-on fittings
(must be ordered separately)
2 Seat
3 Plug
4 Plug stem
5 Valve spring
7 Set point spring
8 Set point adjuster
9 Operating bellows
10 Capillary tube
12 Pin of operating element
13 Operating element
14 Lead bore
15 Coupling nut
Fig. 2 ⋅ Sectional drawing
EB 2186 EN
3
Installation
2. Installation
On installing the regulator, make sure that
the permissible ambient temperature does
not exceed 80 °C.
2.1 Installing the valve
The valve may be installed in any desired
position, however, we recommend that the
valve be installed in a horizontal pipeline
with the thermostat vertically suspended.
The medium must flow through the valve in
direction indicated by the arrow on the
valve body.
2.1.1 Strainer
A strainer (SAMSON Type 1 NI) must be installed upstream of the relevant valve, since
sealing particles, globules or other impurities carried along by the process medium could impair the proper functioning of
the valve, especially tight shut-off.
The filter element must be vertically suspended.
1
2
3
1
Ensure that ample space is available to
remove the filter.
2.1.2 Additional installation instructions
Ideally, hand-operated shut-off valves
should be installed both upstream of the
strainer and downstream of the regulator.
This allows the plant to be shut down for
cleaning and maintenance routines, or
when the plant is not operated for extended
periods.
To check the adjusted set point, we recommed that a thermometer be installed
near the sensor immersed in the medium to
be controlled.
2.2 Installing the temperature sensor
The temperature sensor may be installed in
any desired position. Its entire length must
be immersed in the medium to be controlled.
When choosing the point of installation,
make sure that the sensor is installed in a lo-
4
5
1
2
3
4
5
Fig. 3 ⋅ Installation example in a water-heated boiler
4
EB 2186 EN
Shut-off valves
Strainer
Regulator
Thermometer
Temperature sensor
Adjusting the set point
cation where overheating and considerable
idling times do not occur.
A welding socket with a G 1/2 female
thread connection should be welded where
the sensor is to be installed.
Seal the screw gland or thermowell into
the welding socket.
Insert the sensor and tighten it with the
clamping screw.
CAUTION!
To prevent damage caused by corrosion, it
is important to make sure on installing the
sensor or thermowell that only the same
kind of materials are used together. For example, do not use a sensor or thermowell
made of non-ferrous metal in a stainless
steel heat exchanger. In this case, the sensor should be used together with a stainless
steel thermowell.
2.2.1 Capillary tube
The capillary tube should be routed without
bends or twists. The smallest bending radius
is 50 mm. Roll up any extra length to form
a ring. Do not bend or shorten.
The ambient temperature around the tube
should be kept as even as possible.
3. Operation
3.1 Adjusting the set point
To adjust the set point value, use the black
plastic ring (set point adjuster 8) while watching the reference thermometer.
The adjustment diagrams below can be used
as a guide to find the first approximate value.
The adjustment is infinitely variable. Turning
the ring clockwise reduces the temperature
and counterclockwise turning increases it.
The temperature can be fixed at an adjusted
value by lead-sealing the bore (14) in the set
point adjuster.
Set point
range °C
Set point change
per turn
Sensor
diameter
0 to 35
2.5
9.5
25 to 70
3
9.5
40 to 100
4
9.5
˚C
100
40...100
80
25...70
60
40
0...35
20
0
0
1
2
3
4
Turns of adjuster (scale marking)
Fig. 4 ⋅ Set point adjustment
EB 2186 EN
5
Adjusting the set point
4. Troubleshooting
5. Customer inquiries
Should the temperature exceed the set point
adjusted, the cause could be either contamination of seat and plug or wear and tear of
the seat and plug no longer ensuring tight
shut-off.
For remedy, the valve can be disassembled
after shutting down the plant.
Should you have any inquiries regarding
the temperature regulator, please submit the
following details:
(see also nameplate)
Type and nominal size
Order no. and product no.
Upstream and downstream pressure
Type of process medium and temperature
6
EB 2186 EN
Max. and min. flow rate
Has a strainer been installed?
Installation drawing
Dimensions in mm
6. Dimensions in mm
ISO 228/1 - G¾B
65
Bulb sensor
with thermowell or
with screw gland
65
Ø12
185
185
150
G½
Ø9.5
Soldered ends
107 for ∅di =15, 103 for ∅di =18
Version with threaded ends
G½
Ø21.3
di
129
SW30
SW30
Version with weld-on fittings
Ø21.3
210
SW30
EB 2186 EN
7
EB 2186 EN
S/C 2001-07
SAMSON AG ⋅ MESS- UND REGELTECHNIK
Weismüllerstraße 3 ⋅ D-60314 Frankfurt am Main
Telefon (0 69) 4 00 90 ⋅ Telefax (0 69) 4 00 95 07
Internet: http://www.samson.de
Self-operated Temperature Regulator
Series 43
Type 43-2 N
Application
Temperature regulators for plants which require heating · Especially suitable for local heat supply and large heating networks ·
Valve closes when temperature increases · Temperature set
points from 0 to 100 °C · Nominal size DN 15 · Nominal pressure PN 16 · For treated water up to 120 °C
Special features
• Self-operated P regulators which require little maintenance
• Process medium: water
• Especially suitable for local heat supply and large heating
networks
• Single-seated valve, soft-sealed without balanced plug
• Typetested according to DIN 3440
Versions
The regulator consists of a valve and a control thermostat with
set point adjuster, a capillary tube and a temperature sensor
working according to the adsorption principle.
Type 43-2N × Temperature Regulator with Type 2432 N Valve ·
Nominal size DN 15 with connecting thread according to ISO
228/1- G ¾ B on both sides for attachment of threaded ends G ½,
weld-on fittings or soldering ends · Type 2430 K Control Thermostat
Special version
With fast-responding thermostat according to the vapor pressure principle · Set point range +45 to 65 °C
Accessories
– Threaded ends G ½, weld-on fittings, soldering ends
– Thermowells
Copper or CrNiMo steel (1.4571), PN 40, G ½
Fig. 1 · Type 43-2 N Temperature Regulator,
version with weld-on fittings
Versions according to ANSI on request
Associated Information Sheet
T 2010 EN
Edition September 2006
Data Sheet
T 2186 EN
Principle of operation
The medium temperature creates a pressure according to the
actual value in the measuring sensor (thermostat). This pressure
is transmitted onto the operating element (8) through the connection line (10) and converted into a positioning force. Depending on the set point adjustment, the positioning force acts
on the valve plug (3) via the operating element pin (9) and the
plug stem (4).
1.1
1
2
3
4
By turning the set point adjuster (7), the point of response is
changed in a way that allows the valve plug to pass through its
travel in a temperature range measured by the sensor.
5
11
Special version
Vapor pressure thermostat with short time constant of approx. 3 s.
The temperature sensor is filled with a liquid which evaporates
depending on the temperature. As a result, a pressure in proportion to the temperature is created in the sensor. This pressure
is transmitted onto the operating bellows through the connection
line and converted into a positioning force. This force moves the
valve plug according to the set point adjustment.
10
6
7
Table 1 × Technical data × All pressures as gauge pressure in bar
8
Type 2432 N Valve
Nominal size
Connection
Type of connection
ISO 228/1- G ¾ B
Threaded ends G ½ ×
Weld-on fittings × Soldering ends
KVS value
2.0
Nominal pressure
PN 16
Max. perm. diff. pressure Dp
6 bar
120 °C
Max. perm. temperature
Type 2430 K Control Thermostat
Set point range
Continuously adjustable 0 to 35 °C,
25 to 70 °C and 40 to 100 °C
Capillary tube
2 m (special version: 5 m)
Sensor connection
Max. permissible ambient
temperature range
9
DN 15
1 Valve body
1.1 Screw joints on both sides
with flat gasket (accessories)
2 Seat
3 Plug
4 Plug stem
5 Valve spring
Stuffing box G ½
-20 to +80 °C
Table 2 · Materials · Material no. according to DIN EN
Plug
Plug stem
Flow diagram for water
1.4301 and CW617N
with EPDM sealing ring
Valve spring
1.4310 K
Thermostat
10
2.5
2
0.5
0.2
S235JR (St 37-2)
Brass
Soldering ends
Red casting brass
2
20
PETP, glass-fiber reinforced
Threaded ends
Thermowell
50
1
Copper
Accessories
Weld-on fittings
Kvs
1.4305
CW602N
Set point adjuster
m3
h
CW602N
Seat
Sensor, capillary tube
Positioning spring(s)
Set point adjuster
Operating element
Operating element pin
Connection line
Coupling nut (connection
valve - control thermostat)
Fig. 2 · Principle of operation
.
V
100
Valve body
6
7
8
9
10
11
Copper or stainless steel
1.4571
0.1
0.01
p
0.05 0.1
0.5
1
5
bar
Values apply to a fully opened valve.
Fig. 3 · Flow diagram for water
T 2186 EN
Dimensions
ISO 228/1 - G¾B
65
Ø68
Ø12
Ø9.5
Type 43-2N with Type 2430 K Control Thermostat and temperature sensor with/without thermowell
Ø21.3
Ø21.3
Weight: approx. 1.5 kg
185
185
150
G½
129
SW30
Valve with weld-on fittings
L
di
G½
210
SW30
SW30
Valve with soldering ends
Valve with threaded ends
Soldering ends × Dimensions
Fig. 4 · Dimensions in mm
Installation
Valves
– Any mounting position, preferably with the thermostat vertically suspended,
– Flow direction according to the arrow on the body.
Connection pipe
– Make sure the permissible ambient temperature range is not
exceeded in the section near the connection pipe,
– Avoid mechanical damage,
– The smallest possible bending radius is 50 mm.
Temperature sensor
– Any mounting position. Note special mounting instructions
for vapor pressure thermostats,
– Choose appropriate point of installation to avoid overheating and noticeable dead time,
– The sensor must immerse in the process medium with its full
length.
3
Inside Æ di
15
18
Length L
107
103
Application with a thermowell:
– Only use SAMSON thermowells,
– Only combine materials of the same kind, e. g. heat
exchangers of stainless steel in combination with
thermowells of stainless steel 1.4571.
Ordering text
Type 43-2 N Temperature Regulator
Standard version without accessories
Accessories:
Screw joints on both sides with threaded ends G ½ /
weld-on fittings / soldering ends (di = 15 or 18 mm)
Thermowells of copper/CrNiMo steel
T 2186 EN
Specifications subject to change without notice.
SAMSON AG · MESS- UND REGELTECHNIK
Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de
T 2186 EN
Notes on Type 2430 Thermostat
(vapor pressure principle)
Mounting
Observe the correct mounting position as indicated
by the following marking when installing the temperature sensor:
Vertical mounting position
Sensor tip pointing up
Sensor tip pointing down
Horizontal mounting position
Rotate the sensor such that the nodge at the end of
the sensor faces up.
Edition May 1999
EB 2430-3 EN
Type 2430
Thermostat
Product no.
Sensor
material
Mounting position of the
sensor
2750-05003
2750-05053
Cu
CrNiMo
Horizontal to vertical
with the sensor tip
pointing up
2750-05004
2750-05054
Cu
CrNiMo
Horizontal to vertical
with the sensor tip
pointing down
Sensor dimensions
Packing
Ø 10x170
G 1⁄2
The thermostat is designed for use on tested heat exchangers.
Type designation and temperature range (45 to
65 °C) are labeled onto the scaled cap.
Mounting instructions
With plate heat exchanger:
Product no.
2750-05107
2750-05137
1)
Sensor
material
CrNiMo
Sensor dimensions,
packing
Ø 12x190, without1)
Ø 12x190, G 1⁄2
With Type 43-8
Make sure to insert the sensor horizontally into the
hot water duct. Observe the mounting position with
the nodge facing up.
Screw the sensor thread into the adapter. Align the
sensor and tighten it by hand using the clamping
screw.
Observe the face-to-face dimensions specified in the
drawing to the right.
1)
2)
_125
>
5 1)
2)
Plate heat exchanger <130 mm
Plate heat exchanger >130 mm
_140
>
Hot water
outlet
A
Adapter with
temperature sensor
View A
Connection nut
(max. 20 Nm)
Clamping screw
2.5 mm hex socket screw
Nodge
Set point
With Type 43-8
70
65
60
50
45
40
0
0
1
2
3
3.5 4
Scale value
Set point adjustment
Turn the black plastic ring to adjust the desired temperature set point, observing the adjustment diagram.
Note! Do not remove these mounting and operating
instructions from the thermostat.
SAMSON AG ⋅ MESS- UND REGELTECHNIK
Weismüllerstraße 3 ⋅ 60314 Frankfurt am Main ⋅ Germany
Phone: +49 69 4009-0 ⋅ Fax: +49 69 4009-1507
Internet: http://www.samson.de
Rev.10 2013-Aug-22
Installation, Operation & Maintenance Instructions
Appendix vi |
Junction Board U22-2
www.ormandyltd.com
Ormandy Rycroft, Duncombe Road, Bradford, BD8 9TB. England.
Tel: +44 (0)1274 490 911
Fax: +44 (0)1274 498 580
Junction Unit U22-2
for Type 5757-7 and 5757
– Installation Guide –
TV-SK 6394-1 EN
Junction Unit U22-2-x • Variants of the Printed Circuit Board (PCB) with different equipment
This Junction Unit U22-2 (equipped printed circuit board; PCB) is an accessory for the device Controller with
Electric Actuator Type 5757-7 and Type 5757. The PCB’s provide all connections by spring-type terminals.
U22-2-1 1402-0059 (Fig. 1) [int. Poti ON=S1 (right)] .......... without relay; 10-pin sensor terminal; old variant
U22-2-2 1400-9969 (Fig. 2) [int. Poti OFF=S1 (left)] .......... .....with relay; 10-pin sensor terminal; old variant
U22-2-3 1402-0059 (Fig. 3) [int. Poti ON=S1 (right)] .......... without relay; 8-pin sensor term.; substitutes U22-2-1
U22-2-4 1400-9969 (Fig. 4) [Int. Poti OFF=S1, S2=OPEN] . .....with relay, 8-pin sensor term.; substitutes U22-2-2
Circuit Diagrams and Connections U22-2-1 and U22-2-2
The circuit diagrams present the interconnections between 5757-7, sensors,
supply, pump and the additional Room
Thermostat; equipped without/with relay.
Fig. 1 • Junction Unit U22-2-1
Fig. 2 • Junction Unit U22-2-2
The equipped 1000 ohms Potentiometer (tolerance 10%) is connected in series with a 1000 ohms resistor.
Switch position “OFF” (S1) – as shown in Fig. 2 and Fig. 3 – disconnects the internal Potentiometer from
“BI1/ P”; switch position “ON” connects the Potentiometer to these terminals.
Attention: Switch “S1” is in position “ON” or “OFF” depending on the specific variant factory setting!
SAMSON AG • MESS- UND REGELTECHNIK
V43 / Sn / 14.07.2010
1/4
Junction Unit U22-2
for Type 5757-7 and 5757
– Installation Guide –
TV-SK 6394-1 EN
Junction Unit U22-2-4 • New design of the PCB with different equipment
This Junction Unit U22-2-4 was introduced to be able to choose the binary status when using a Room Thermostat (Switch S2). Position “OPEN” (factory setting) uses the opening contact; position “CLOSE” uses the
closing contact of the relay – more about this see under “Circuit Diagrams and Connections ...“.
Circuit Diagrams and Connections U22-2-3 and U22-2-4
The circuit diagrams present the interconnections between 5757-7, sensors,
supply, pump and the additional Room
Thermostat; equipped without/with relay.
Fig. 3 • Junction Unit U2-2-3
Fig. 4 • Junction Unit U2-2-4
Switch S1 in position “ON” connects the internal Potentiometer with the input “BI1/ P” (1...2 k ohms). Switch
S2 inverts the binary signal of the Room Thermostat. Switch position “OPEN” (factory setting) – as shown in
fig.4 – selects the “opening”-contact of the relay which is connected to the input “BI 2/RFS”. In practice this
means; if configured F11=0 and F12=0 (function of BI 2 at Type 5757-7 without Return Flow Sensor), then
the controller’s control mode is “OFF” if the Room Thermostat’s contact is open.
Attention: If an external Potentiometer is to be connected (BI1/ P), make sure that “S1” is “OFF”!
Attention: If a Return Flow Sensor is to be connected (BI2/RFS), position of “S2” must be “CLOSE”!
SAMSON AG • MESS- UND REGELTECHNIK
V43 / Sn / 14.07.2010
2/4
Junction Unit U22-2
for Type 5757-7 and 5757
– Installation Guide –
TV-SK 6394-1 EN
Installation
To install a wire into a spring-type terminal, simply push the bright wire (wire end) into the terminal
(see fig. 5). To uninstall the wire, press down the spring (white array) and pull out the wire (see fig. 6).
Twisted wires are to be connected generally by using a tool, pressing down the spring while connecting
or disconnecting (see fig. 6).
Fig. 5 • How to install a wire
Fig. 6 • How to uninstall a wire
This Junction Unit U22-2 has been developed to ease the wiring for type 5757-7 heating application basically. The identical PCB may also be used for type 5757 tap water application.
Please note that the printed sensor terminal labelling primarily provides heating application!
Heating application – standard labelling (in connection with type 5757-7)
FS
Flow Temperature Sensor
BI 2/RFS
Binary Input 2 or Return Flow Sensor (alternatively)
OS
Outdoor Sensor
BI 1/P
Binary Input 1 or (internal/external) Potentiometer
5257-7
123
Connection for terminals 1, 2 and 3 of corresponding room sensor
type 5257-7.
Fig. 7 • Sensor Terminal
– Standard labelling Heating –
(8-pin spring-type terminal)
Tap water application – (differing labelling necessary in connection with type 5757)
(FS)
FS
Flow Temperature Sensor
(BI 2/RFS)
BI
Binary Input
(5257-7)
FRS
Flow Rate Sensor
(BI 1/P)
FSW
Flow SWitch (alternatively to FRS)
(+ mA –)
+ mA –
mA DC signal / 0...20 mA / 4...20 mA may be used as an external
set point or as a process value; has to be configured accordingly.
Fig. 8 • Sensor Terminals
– Differing labelling necessary –
(8-pin spring-type terminal)
Attention: If tap water application is used (5757), turn “S1” to position “OFF” and “S2” to “CLOSE”!
“S1”=”OFF”=Potentiometer off. If the relay is equipped, but not in use: “S2”=”CLOSE”=open terminal contacts.
SAMSON AG • MESS- UND REGELTECHNIK
V43 / Sn / 14.07.2010
3/4
Junction Unit U22-2
for Type 5757-7 and 5757
– Installation Guide –
TV-SK 6394-1 EN
Determine the Installation Box
To install the Junction Unit U22-2 into an installation box it is necessary to know all dimensions. Maximum
height of the equipped PCB is approximately 18 mm.
Please note that the installed wires need to have a minimum radius and must fit into the box!
Fig. 9 • Dimensional drawing of the Junction Unit U22-2-x scale 1:1
SAMSON AG • MESS- UND REGELTECHNIK
V43 / Sn / 14.07.2010
4/4