Grundfos PHT-D250, PHT-D125, PHT-D150, PHT-F125, PHT-F150 Installation And Operating Instructions Manual
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GRUNDFOS INSTRUCTIONS
PHT Pressurisation unit
Installation and Operating Instructions
Models: PHT-N/D/F/T/V
Residential and Commercial
ORIGINAL INSTRUCTIONS
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GRUNDFOS INSTRUCTIONS
EC/EU Declaration of Conformity
Name of manufacturer: Grundfos Manufacturing Limited.
Address: Ferryboat Lane,
Castletown,
Sunderland.
SR5 3JL.
United Kingdom
We, Grundfos, declare under sole responsibility that the product PHT-*, to which the
declaration below relates, are in conformity with the Council Directives listed below on the
approximation of the laws if the EC/EU member states.
Machinery Directive (2006/42/EC).
Standards used: EN ISO 12100:2010
Low Voltage Directive (2014/35/EU).
Standard used: EN 60335-1:2012 +A11:2014
EMC Directive (2014/30/EU)
Standard used: EN 61000-6-1:2007 and EN 61000-6-3:2007+A1:2011
Standard used: EN 60730-1:2016
This EC/EU declaration of conformity is only valid when published as part of the Grundfos
Installation and Operating instructions (publication number 99354499).
Authorised signature:
John Austin – Engineering Manager
(Name) (Position)
Date of issue: 11/12/2017
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GRUNDFOS INSTRUCTIONS
Table of Contents
1.0 About this manual.
2.0 Symbols used in this document.
3.0 Scope of these instructions.
4.0 Product identification.
5.0 Operating Principles.
5.1 Standard Pressurisation Unit.
5.2 Twin System Pressurisation Unit.
5.3 Glycol Pressurisation Unit.
6.0 General information.
6.1 Delivery and handling.
6.2 Delivery inspection upon receipt.
6.3 Warranty.
6.4 Site storage on receipt.
6.5 Weather, Temperature and long term storage.
6.6 Operating Environment.
6.7 Installation Location.
6.8 General requirements.
6.9 Operating Conditions.
6.10 Wall Fixings.
7.0 System Controller Overview.
7.1 Programming the Controller.
7.2 Start-Up Sequence.
7.3 Main Operating Screen.
7.4 Menu Entry.
7.5 Menu System.
7.6 Fault Indication.
7.7 Fault Log.
7.8 Uploading the Fault Log.
7.9 Programable outputs.
7.10 Digital Outputs.
7.11 System 1 Interlock Output (D01).
7.12 General Fault Output (D02).
8.0 Installation and commissioning – General.
8.1 PHT-N/D/V unit – Float valve.
adjustment requirements.
8.2 PHT-F/T unit – Float valve adjustment.
8.3 Priming the Pumps.
8.4 Installation Checklist.
8.5 Commissioning Checklist.
8.6 Commissioning Record.
8.7 Settings Record.
9.0 User Maintenance
9.1 Planned Preventative Maintenance.
9.2 Annual Service
10.0 Technical drawings.
10.1 Product Drawings – PHT-N.
10.2 Product Drawings – PHT-D (Single pump).
10.3 Product Drawings – PHT-D (Dual pump).
10.4 Product Drawings – PHT-F.
10.5 Product Drawings – PHT-T.
10.6 Technical Drawings – PHT-V.
10.7 Connection Drawing.
10.8 Wiring Diagram.
10.9 Pump set Fill Pressures.
10.10 PTH-V Glycol settings.
11.0 Spare parts list.
12.0 De-commissioning, dismantling and
disposal.
12.1 De-commissioning.
12.2 Dismantling.
12.3 Disposal.
13.0 CIM Modules.
14.0 Fault finding checklists.
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GRUNDFOS INSTRUCTIONS
1.0 About this manual.
This manual contains all the necessary information to install, commission, operate, maintain and
fault find on the Grundfos PHT range of pressurization products. It is strongly recommended
that this manual should be fully read before undertaking any work on this equipment.
It is highly recommended that this equipment is commissioned by a Grundfos engineer.
Contact details for Grundfos Service can be found below.
Grundfos Pumps Ltd.,
Telephone: +44 (0) 1525 850 000
** It is advisable that the Installation and Operating manual remains with
the product for the duration of the product lifecycle.
2.0 Symbols used in this document
WARNING(S)
If these safety instructions are not observed, it may result in personal injury or damage
to property.
If these instructions are not observed, it may lead to electric shock with consequent
risk of serious personal injury or death.
CAUTION
NOTE
If these safety instructions are not observed, it may result in malfunction or
damage to the equipment.
Notes or instructions that make the job easier and ensure safe operation.
3.0 Scope of these Instructions.
These Installation and Operating instructions apply to the:
Grundfos PHT range of Pressurisation products
For all other Technical Information consult the PHT Datasheet and sales brochure.
All the above documents can also be found on the Grundfos Product Center website at:
www.grundfos.co.uk
CAUTION
NOTE
NOTE
Static sensitive components, observe static sensitive handling procedures.
Product damage may occur
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GRUNDFOS INSTRUCTIONS
4.0 Product Identification.
The PHT unit has a silver label attached to the cabinet.
This label gives the following key information.
Fig. 1 – Product Nameplate
5.0 Operating Principles.
The function of the PHT pressurization equipment is to continuously monitor the pressure within
hydronic pressurized heating and chilled water systems, maintaining the optimum operating
pressure through providing automatic pressurised water top when required to compensate for
system losses. (e.g. slow leaks, air venting, etc.).
The PHT equipment will also provide signals and alarms for connection to building management
systems.
The PHT equipment will not fill systems
The PHT equipment will not cope with major water loss.
(e.g. System drain down, burst pipe)
The PHT equipment is not intended to be used for water boosting applications
Please consult the appropriate datasheets for product selection
Three distinct types of unit are described in this document:
1. Standard Pressurisation Unit – Single and twin pump configurations
- Delivers water into a single system
2. Twin System Pressurisation Unit – Twin pump only
- Delivers water into two different systems
3. Glycol Pressurisation Unit - Twin pump only
- Delivers a mix of water and glycol into a single system
Part no.
Serial no.
Electrical data
Hydraulic data
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GRUNDFOS INSTRUCTIONS
5.1 Standard Pressurisation Unit (PHT-N/D/F models).
The following schematic shows the arrangement of the PHT-N/D/F pressurisation models:
Fig. 2 – PHT-N/D/F Schematic
The pressurisation unit is connected into the sealed system (System 1) through the System 1
Connection(6.
The System 1 Isolation Valve(7) provides a point to isolate the unit from the system.
The System 1 Drain Valve(8) provides a point to drain down the unit and/or system and for
commissioning purposes.
The System 1 Pressure Transmitter(AI1) measures the pressure in System 1.
The PHT unit can be configured with one or two pumps (P01 and P02) which when energised, will
transfer water from the Break Tank into System 1 to increase the pressure as required.
The pumps run in a duty/standby configuration where only one pump runs at a time (the duty
pump). The duty pump will always be the pump with the least accumulated total run time. This is a
measure to spread the wear evenly between the two pumps.
In single pump units Pump 1(P01) permanently acts as the duty pump.
A Current Sensor(AI5) (not shown on schematic), measures the electrical current consumption of
Pump 1(P01) and Pump 2(P02) to detect faults in the pumps.
A System 1 Fault Output(DO1) (not shown on schematic) is used to interlock the boiler or chiller on
System 1 to disable it if the system pressure falls outside of safe operating limits.
A General Fault Output(DO2) is provided to signal any fault presented by the unit.
Three additional outputs are provided which can be customised to signal a range of specific faults
or functions, Programmable Output 1(DO6), Programmable Output 2(DO7) and Programmable
Output 3(D08).
The pressurisation unit is fitted
with a Break Tank(1) which is filled
from the Water Supply(2), via a
Float Valve(3). The break tank is
fitted with a Drain Overflow(4) in
case the Break Tank overfills, and a
Weir Overflow(5) in case the Drain
Overflow becomes blocked.
A Low Water Float Switch(DI1) is
fitted to detect a low water
condition.
A High Water Float Switch(DI2)
(optional extra) is fitted to detect
overfilling of the tank.
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GRUNDFOS INSTRUCTIONS
5.2 Twin System Pressurisation Unit (PHT-T models).
A variation of the design allows a single pressurisation unit to provide top-up for two systems,
referred to as a Twin System Pressurisation Unit.
The following schematic shows the arrangement of a twin system pressurisation unit:
Fig. 3 – PHT-T Schematic
This design allows the pressurisation unit to provide top up to two systems independently, with
different parameters, using the same two pumps.
In addition to the features described for a standard pressurisation unit, the following additional
features are provided:
The pressurisation unit is connected into the second system (System 2) through the System 2
Connection(9) via the System 2 Isolation Valve(10), a manual valve provided for isolating the unit
from the system. The System 2 Drain Valve(11) is provided for draining down the unit and/or
system and for commissioning purposes.
The System 2 Pressure Transmitter(AI2) measures the pressure in System 2.
The System 1 Valve(DO3) directs flow from the pumps into System 1.
The System 2 Valve(DO4) directs flow from the pumps into System 2.
When used in twin system mode the Programmable Output 3(DO8) is set to function as a
critical fault output for system 2 by default and cannot be changed.
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GRUNDFOS INSTRUCTIONS
5.3 Glycol Pressurisation Unit (PHT-V model).
Another variation of the design allows the unit to deliver a predetermined mix of water and glycol
into a single system.
The following schematic shows the arrangement of a glycol pressurisation unit:
Fig. 4 – PHT-V Schematic
In addition to the features described for a standard pressurisation unit, the following additional
features are provided:
Glycol is held in the Glycol Tank(12). The Low Glycol Switch(DI3) detects when the glycol has run
out and requires refilling.
When the pumps run, they draw a predetermined mix of water and glycol out of the two break
tanks.
The ratio of water to glycol is set by manually adjusting the Glycol Flow Regulator(13) with respect
to the Water Flow Regulator(14).
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GRUNDFOS INSTRUCTIONS
6.0 General information.
6.1 Delivery and handling.
The PHT unit is supplied from the factory in either a cardboard box (PHT-N) or a
plastic bag (All other models) which will be strapped to a wooden pallet suitable
for handling by forklift equipment or similar.
The weight and size of the PHT unit may require the use of proprietary lifting equipment to be
handled safely. Please observe the weight indicated on the box label before selecting lifting
method.
Do not stack items on top of the box.
Do not drop the pallet/unit
6.2 Delivery inspection upon receipt.
The PHT should be immediately unpacked and inspected.
Any damage must be reported to the supplier within seven days in writing or sooner.
It is important that this Installation and Operating manual is studied carefully before any
installation takes place. The installation and operation should also be in accordance with local
regulations and accepted codes of practice.
Under no circumstances should the unit be operated until correctly installed in the
system pipework and ensure that the controller cover and product cover are secured
in their appropriate positions.
6.3 Warranty.
1. The Grundfos warranty covers all defects within the PHT originating from faulty
workmanship and/or materials for a period of two years from the date of installation or
thirty months from the date of dispatch from the factory, whichever is the shorter.
2. The warranty covers the replacement of any faulty parts and our labour cost to replace the
faulty parts. It does not cover the cost of removing, returning and refitting the PHT unit or any
secondary losses arising from the failure.
3. Under no circumstances should faulty equipment be dismantled. Failure to comply with this
instruction could invalidate the warranty.
4. Defects arising from incorrect installation, water containing debris, or harmful chemicals,
inadequate electrical protection, faulty ancillary equipment, lightning or other circumstances
beyond our control, are not covered by the warranty.
6.4 Site storage on receipt.
It is strongly recommended once the PHT unit has been delivered to site, that it is placed
immediately into a dust, moisture and frost-free area which has been secured to prevent
unauthorised interference. If this is not possible then the unit should be stored in an area which
is as near as possible to the ideal storage conditions as described above.
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GRUNDFOS INSTRUCTIONS
6.5 Weather, Temperature and long term storage.
The PHT unit needs to be protected against the weather and extremes of temperature during
summer and winter. Provision to maintain the PHT’s operating conditions needs to be made
within the overall system design and location setting.
The PHT unit must be protected from freezing conditions. Should the unit be placed outside then
the unit needs to be protected against the weather and consideration must be made for trace
heating and/or lagging.
The PHT unit must be protected from heat. Should the unit be placed in an environment that could
potentially become hotter than the operational recommendations then air venting and circulation
must be considered.
If the PHT unit is being stored during periods of frost the whole unit should be drained to
avoid damage. Remove all drain and vent plugs and allow the unit to drain.
Do not replace the plugs until the PHT unit is to be used again.
6.6 Operating Environment.
The PHT unit must not be used in an environment which has been classified as
hazardous where it could provide a source of ignition and therefore cause an explosion by
flame path.
Grundfos do not accept any responsibility for the use of the PHT unit to pump liquids which
could be construed as being hazardous to health either by touch, ingestion or inhalation of
fumes or gases given off by the liquid.
6.7 Installation Location.
Careful consideration must be given to the location of the PHT unit.
The following are minimum requirements:
The PHT unit should ideally be placed in a location where the control panel and status LED can
readily be seen and the internal buzzer heard without obstruction.
These are primary warning and alarm events and should be available to be observed and heard.
The pump must be vented/primed before it is started again.
Refer to the commissioning section.
The PHT may be located outdoors in a weather, frost and rodent proof enclosure with
adequate ventilation especially during hot weather. All pipe work subject to freezing
conditions must be adequately protected. Alternative system provision must be
made for alerting the inhabitants to the PHT warnings and alarms.
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GRUNDFOS INSTRUCTIONS
To enable maintenance and service of the PHT unit to be carried out satisfactorily,
the area should have adequate lighting for this work to be carried out safely.
Ensure that the PHT is positioned to allow access for examination and service.
Allow the following:
A minimum of 50 cm should be left above all units.
A minimum of 50 cm should be left to the system connection side of all units.
A minimum of 100 cm should be left at the front of the unit.
Adequate drainage facilities and protection from water damage in the immediate
vicinity of the PHT unit must be provided.
If the PHT unit is installed into a roof spaces, then provisions should be made for the
small level of vibration associated with any rotating equipment in case it causes
disturbance. Provision should also be made for drainage of the unit, leakage and any loss of water
during commissioning and service.
The PHT unit should not be installed in an unventilated small space, ensure
adequate ventilation for the motor.
6.8 General requirements.
The installation pipework may need to be properly supported
before being connected to the PHT unit so that the PHT unit is not stressed.
The pipework installation to and from the PHT unit should be in accordance with local
water authority regulations, best industry practice and according to any design
recommendation
The electrical installation of the PHT unit should be in accordance with the latest issue of
the I.E.E. regulations and performed by a competent installer.
The equipment must be Earthed
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GRUNDFOS INSTRUCTIONS
6.9 Operating Conditions.
Electrical supply: 230 V +10 /-6%, 50 Hz
Electrical load:
Model
Power (Watts)
Full Load current (Amps)
PHT-N130/PHT-N230
28 W
0.12 A
PHT-D125/PHT-D225
410 W
1.83 A
PHT-D150/PHT-D250
900 W
3.94 A
PHT-F125/PHT-F225
410 W
1.83 A
PHT-F150/PHT-F250
900 W
3.94 A
PHT-F180/PHT-F280
1150 W
5.2 A
PHT-T225/PHT-V225
410 W
1.83 A
PHT-T250/PHT-V250
900 W
3.94 A
Quiescent All models
15 W
0.07 A
Pollution Degree: 3 Noise level: <70 dB(A) at full speed
Liquid temperature range: +1°C to +60°C Ambient temperature: From +1°C to 40°C
Relative humidity: 95% (non-condensing)
Usage: Indoor (Outdoor, subject to restrictions found)
Type of protection: Class 1 (earthed) equipment
Equipment type: Stationary, fixed equipment
Construction type: Fixed construction, no moveable parts
EMC Environment: B (light industrial, commercial and residential)
Inlet pressure max: 3 bar
6.10 Wall Fixings.
All units must be mounted/stood in the vertical position.
The PHT-N and PHT-D units are suitable for wall fixing.
The wall fixing dimensions are given below.
Fig 5. – Wall fixing dimensions
Refer to the Product weight table also.
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GRUNDFOS INSTRUCTIONS
7.0 System Controller overview.
The front face of the PHT controller has the following items.
Fig 6. - Controller front screen
The ON/OFF Switch is an illuminated switch indicating that the unit is powered ON/OFF.
The Display panel gives the Status of the unit, the current pressure, the Date and time when
operating without a fault. When operating with a fault the Status will indicate the fault detected.
The Display panel will auto-dim to save energy after a predefined period without operation.
The Keypad has:
UP/DOWN arrow keys used to move between pages and increase/decrease values.
Home Key to return to the Home page
OK key to confirm a value entered/Access the password protected menu’s
Return key to step back in the program
The Status LED gives a quick and easy Status for the unit.
Green – Status Healthy
Red – Status Fault
The system status is also supported by an audible buzzer.
The buzzer activates with Critical faults and can be silenced by pressing and holding the OK key.
7.1 Programming the PHT Controller.
The PHT controller has a simple, intuitive and ergonomic design that is easy to pick up.
Fixed combination volt free outputs that allow critical and general fault monitoring.
Programmable outputs provide complete flexibility.
The controller can communicate with the Grundfos range of CIM modules providing protocol
support for BACnet, Modbus and others.
ON/OFF Switch
(Illuminated when ON)
Display panel
Keypad
Status LED
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GRUNDFOS INSTRUCTIONS
7.2 Start-Up Sequence.
Upon powering up the unit, the controller shall display the below for 3 seconds:
PHT-*
Grundfos
14.25
The screen will then show the software version of the unit for a further 3 seconds:
Software Version
V1.0.0
7.3 Main Operating Screen.
When the unit is operating normally and the status is healthy the display will include:
Status: OK / System 1 Pressure and value / Current Date and Current Time:
Status: OK
System 1 Pressure 1.5 Bar
23/08/2017
14.25
With the PHT-T configuration, the display will also show System 2 Pressure and value:
Status: OK
System 1 Pressure 1.5 Bar
System 2 Pressure 2.0 Bar
23/08/2017
14.25
If a fault condition is active, then the Status will show FAULT and the line below will carry a
message indicating the fault. If more than one fault exists then the first detected fault is shown
until cleared. The next fault is then displayed:
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GRUNDFOS INSTRUCTIONS
Status: FAULT
Low Water
System 1 Pressure 1.5 Bar
23/08/2017
14.25
If a pressure sensor fault has been registered, then no pressure reading will be shown:
Status: FAULT
Sensor
System 1 Pressure Bar
23/08/2017
14.25
If the unit requires servicing, then the Status will show SERVICE:
Status: SERVICE
System 1 Pressure 1.5 Bar
23/08/2017
14.25
If a fault is present and a service is required, then the Status will show FAULT - SERVICE:
Status: FAULT - SERVICE
Sensor
System 1 Pressure Bar
23/08/2017
14.25
7.4 Menu Entry.
To enter the password protected menus press and hold down the OK button for three seconds
The screen will prompt for a 4-digit numeric password:
Enter Password
_ _ _ _
User Password: 4321
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