WATTS Isomix-HC Control Station Instruction Manual

: June 5, 2024
: WATTS

WATTS Isomix-HC Control Station

General information

Important information about this manual

The plant operator is responsible for ensuring compliance with the local laws and regulations (e.g. accident prevention regulations, etc.).
Incorrect operation or operating the Isomix-HC outside the specifications invalidates all warranty claims.

This installation and operating manual

is an integral part of the Isomix-HC
contains instructions and information about safe and correct installation and commissioning of the Isomix
must be available to all users throughout the entire service life of the Isomix
is intended for trained personnel who are familiar with the applicable standards and regulations and, in particular, with the relevant safety concepts, operation and maintenance of the Isomix-HC
is protected by copyright and may not be altered without the manufacturer’s permission

Product conformity

A Declaration of Conformity according to Machinery Directive
2006/42/EC has been issued for the Isomix-HC product.

Product features

All connections to the system have 1″ male thread and flat sealing
Very convenient controls, compact, space-saving design

Safety

Presentation of safety information

DANGER indicates an imminent danger that may cause serious physical injury or death if the appropriate safety precautions are not in place.
WARNING indicates a danger arising through incorrect behavior (e.g. misuse, disregarding notices, etc.) that may cause serious physical injury or death.

CAUTION indicates a potentially dangerous situation that may cause minor or slight injuries if the appropriate safety precautions are not in place.
NOTE indicates a situation that may
cause material damage if the corresponding precautions are not taken.

Important safety information

Before using the Isomix-HC, read this operating manual through carefully.
Connect the Isomix-HC only to a power source that corresponds to the mains voltage specified on the rating plate of the Isomix-HC.
The power supply to the Isomix-HC must be disconnected prior to maintenance, cleaning and repair work.
Maintenance, cleaning and repair work may be carried out by trained specialist personnel only.
The Isomix-HC must not be used if it is damaged or is no longer operating correctly. In this case, contact your specialist dealer immediately.
Observe the maintenance instructions and intervals.
Protect the Isomix-HC from the weather.
Never use the Isomix-HC outdoors.
The unit may be used only in accordance with its intended use.

Intended use

The control station Isomix-HC is used for constant maintenance of the flow temperature in surface heating systems. The control station is intended for use in dry rooms in residential or commercial areas. It is usually installed in the heating room or in a distribution cabinet.
The Isomix-HC is not intended to be operated by people (including children) with limited physical, sensory or mental capacities, or by people with insufficient experience or previous knowledge.

Foreseeable misuse

The following is considered to be foreseeable misuse:

Operating the Isomix-HC beyond its specifications.
Improper use of the Isomix-HC.
Modifications to the Isomix-HC that have not been agreed with the manufacturer.
Use of replacement or wear parts that have not been approved by the manufacturer.
Operating the Isomix-HC outdoors.

Responsibilities of the plant operator

The plant operator must ensure that:

the Isomix-HC is used only for its intended purpose
the Isomix-HC is installed, operated and maintained according to the specifications of the installation and operating manual
the Isomix-HC is operated only in accordance with local regulations and occupational health and safety regulations
all precautionary measures have been taken to avoid dangers originating from the Isomix-HC
all precautions for first aid and firefighting have been taken
only authorized and trained users have access to the Isomix-HC and operate it
users have access to this installation and operating manual at all times

Personnel groups

Only qualified persons may install and operate the Isomix-HC and carry out maintenance work.

Operators
Operators are deemed to be qualified if they have read these operating instructions and understood the potential hazards associated with improper behavior.

Fitters/commissioning engineers
Fitters/commissioning engineers are in a position to carry out work on the Isomix-HC, taking into consideration the applicable standards, provisions, regulations and laws and their technical training and technical knowledge, and can detect and prevent potential hazards.

Information on the operating environment

Corrosion and chemical and physical reactions can damage the control station.

The system planner is responsible for evaluating these parameters and developing remedies.

Structure

Circulation pump
3-point actuator
3-way mixer valve
Connection for flow sensor 11 1)
Eccentric screw connection with Thermometer
Insert check valve
Return temperature sensor connection 1/8″ (option)
Temperature limiter (optional)
Climatic controller CC-HC
External temperature sensor
Flow temperature sensor 1/8″
A Primary supply (1″ male thread)
B Primary return (1″ male thread)
C Surface heating/cooling supply (1″ union nut)
D Surface heating/cooling return (1″ union nut)

Function

The set value for the flow temperature, determined by the climatic controller CC-HC (9) using the current external temperature and the heating curve, is monitored continuously by the flow sensor (11). If there are temperature fluctuations, the controller causes the 3-point actuator (2) to open or close the 3-way mixer (3), or to maintain the valve position when the set value is reached. The hot water fed in from the primary circuit (A) via the 3-way mixer (3) is mixed directly with the water from the underfloor heating return (D). The mixed medium is distributed by the pump (1) to the heating circuit manifold and from there to the connected heating circuits.
The underfloor heating flow temperature can be seen on the climatic controller (9).
There is a non-return valve (6) between the primary feed and the return connection on the mixer valve, which prevents a short-circuit in the primary circuit.

Technical Data

Overall dimensions

Pressure loss diagram

Installation and commissioning

Electrical energy! Risk of death from electric shock.

Work on parts carrying live voltage must be carried out by qualified electricians only.
Disconnect the power supply of the system and secure it to prevent it from being switched on again before carrying out any installation, maintenance, cleaning or repair work.

The installation and commissioning of
the Isomix-HC must be carried out only by trained personnel who have been authorized by the manufacturer.

When repairing the unit or replacing parts, be sure to observe the specified installation positions and flow directions of the parts being replaced!
Material damage!
Pressure shocks may occur if the stop valve is opened or closed quickly

Always open and close the stop valves slowly and in a controlled way

Examples of applications

Installation

All screw fittings must be checked and tightened if necessary prior to installation and commissioning! For the torques of the fitting see „5 Technical Data“ on page 4.

Hot water!
Risk of severe scalding.
Do not reach into the hot water when emptying the
Isomix-HC. Ensure that the Isomix-HC has cooled down before carrying out maintenance, cleaning and repair work.

During installation it must be ensured that:

the cables from the pump and temperature limiter are not damaged or kinked
the sensor capillary tube is not damaged or kinked
The cables must not be under tension.

Fit the control station to the manifold with the 1″ nuts and associated seals.
The control station can be fitted on the right or left of the manifold by turning the eccentric screw fitting (5, Fig. 8-1), also upside down.
Fit the temperature limiter to the supply collector pipe on the manifold. Set the temperature on the (optional) temperature limiter to approx. 55 °C.
Connect the control station to the power supply.
Further information about electrical connection of the control station can be found in the separate documentation for the assemblies.
Set the temperature on the (optional) temperature limiter to approx. 55 °C.

Temperature limiter

In the event of a fault, the temperature limiter switches off the circulation pump and so avoids overheating of the surface heating system.

The temperature limiter must be fitted to the supply of the heating circuit manifold.
Set the temperature on the (optional) temperature limiter toapprox. 55 °C.

Mounting in combination with Heat Interface Unit HIU 2

For use in combination with the Watts HIU 2 Heat Interface Unit, the Isomix-HC must be converted (overhead) and the eccentric rotated.

Release nut (A, Fig. 8-1)
Rotate eccentric (5, Fig. 8-2)
Position the temperature limiter (8, Fig. 8-2)

To ensure that the pump runs only when heat is required, the manufacturer recommends connecting the pump to a pump relay (e.g. the pump logic of an electrical control distributor that also controls the actuators). Alternatively, the pump can be operated with a timer switch.

Inbetriebnahme

Connect the control station to the pipe network.
Shut off the ball valves (15).
Switch off the pump and close all of the heating circuits on the distributor.
It is sufficient to close the valves in the return of the heating circuit manifold with the protection caps.
Fill the manifold and control station with hot water (in accordance with VDI 2035):
connect the filling hose to the fill and drain valve on the return (9b, Fig. 8-3) and the draining hose to the fill and drain valve on the supply (9a, Fig. 8-3).
Heating circuits are closed.
Open both fill and drain valves and fill the manifold and control station until water comes out of the fill and drain valve on the supply. Close both fill and drain valves.
To fill and flush the heating circuits, connect the filling hose to the supply fill and drain valve (9a, Fig. 8-4) and the emptying hose to the return fill and drain valve (9, Fig. 8-4).
Open the heating circuit to be flushed.
Open fill and drain valve and flush out the heating circuit in the direction of flow until the air and any contaminationhas been removed from the circuit completely.
The non-return valve (14) in the mixer bypass prevents any short circuit when flushing.
Repeat the process for all the heating circuits.

Flushing is permitted only in the direction of flow of the heating circuits, i.e. the water must enter through the flow manifold and come out of the return!
The drain must always be open, as otherwise the high water pressure could damage the heating system.
The instructions on flushing in the operating manual for the heating circuit manifold must also be observed.

Wartung

Electrical energy!
Perform maintenance work on the Isomix-HC only when the power supply has been disconnected.

Hot water!
Risk of severe scalding.
Do not reach into the hot water when emptying the
Isomix-HC. Ensure that the Isomix-HC has cooled down before carrying out maintenance, cleaning and repair work.

Hot surfaces!
Risk of serious burns.
Do not touch the pipes or components during operation. Ensure that the Isomix-HC has cooled down before carrying out maintenance, cleaning and repair work.
Wear heat-resistant safety gloves if it is necessary to carry out work on hot components.

Maintenance of the Isomix-HC must be
carried out only by trained personnel who have been authorized by the manufacturer.

Annual maintenance

General visual inspection
• Check the control station for leaks and retighten sealing connections or replace seals, as required.
Functional check
• Check that settings and operating and performance parameters are set correctly.
• Check flow noise during operation.
• Ask users if there are any noticeable problems.
Action to be taken following maintenance work
• Check that all screw fittings that were unscrewed have been retightened and retighten if necessary.
• Remove all tools, materials and other equipment used from the working area.
• Restore the power supply.
• Slowly pressurize the Isomix-HC and vent it.
• Readjust the system settings if required.

Replacement of wear parts

Please note that the Isomix-HC contains parts that, for technical reasons, are subject to wear depending on the intensity of use, even if the specified care and maintenance has been provided.
This applies especially to mechanical parts and parts that come into contact with water and steam, such as seals, valves, etc.
By their nature, defects caused by wear do not constitute a fault and are therefore not covered by the warranty or any guarantee. Nevertheless, these defects and malfunctions must be remedied by trained specialist personnel only. Contact your specialist dealer for this.

Troubleshooting

Fault

Possible cause| Remedy
1 Underfloor heating circuits do not heat up; pump not running
1.1 Temperature limiter (TL) is switching the control station pump off. Reason: TL setting is too low.| Set TL to approx. 10 K higher than the underfloor heating flow temperature. Note the maximum permitted temperature for the underfloor heating! The switching difference of the TL is approx. 5 K. The control station is ready to operate more quickly if the TL is removed briefly to cool down to its switching temperature.
1.2 TL is switching the control station pump off. Reason: The pump remains switched on despite closed underfloor heating circuits. The water inside the control station is being heated by waste heat from the pump. The TL switches the pump off when the maximum temperature is reached!| Remove TL from the control station and fit to supply heating circuit manifold. Use electrical control distributor with pump logic (relay). The pump logic ensures that the pump runs only if at least one underfloor heating circuit is open.
1.3 The pump is connected to a room thermostat or electrical control distributor. If all actuators are closed, the pump switches off. During a lengthy shutdown, the underfloor heating flow cools down. The controller therefore causes the 3-way mixer valve to open. Hot water is injected from the primary heating circuit. As a result, the control station heats up. When the maximum temperature of the TL is reached, the contact opens. The pump does not switch on again.| Remove TL from the control station and fit to supply heating circuit manifold. See 1.1
2 Underfloor heating flow temperature cannot be set to the required value or the feed temperature fluctuates significantly
2.1 Supply and return on the control station have been mixed up| Check that all connections on the control station are correct (see Section “Structure” on page 5)
2.2 The head / pumping level of the pump is set too low| Change the pump setting (see separate pump instruction manual).
2.3 The differential pressure of the primary pump is too high (>500mbar)| Change the pump setting (see separate pump instruction manual) or fit differential pressure controller.
2.4 The heating load is too high for the control station, i.e. heat consumption exceeds the nominal output of the control station. This condition can come about temporarily, for example, when heating up a “cold” floor.| Establish maximum heat requirement and compare with nominal output. The heating circuits may have to be shared with a second control station with a corresponding heating circuit distributor. If this is caused by heating up the underfloor heating for the first time, it may start working normally after the heating up phase (2 – 3 days). This is particularly likely in the case of operation at the upper nominal output limit.

Disposal

Potential for contamination of the environment and groundwater from improper disposal!
The legal regulations and guidelines in the country of operation must be observed when disposing of components and operating materials.

Ensure that all assemblies and components are de-energized.
Disassemble the Isomix-HC properly or commission a specialist company to do so.
Sort the assemblies and component parts into recyclable materials, hazardous substances and operating materials.
Dispose of the assemblies and components in accordance with local laws and regulations or take them to be recycled.

Return to the manufacturer

Get in contact with the manufacturer if you would like to return the Isomix-HC or parts of it.

Notification of administrative bodies and the manufacturer

Inform the manufacturer of decommissioning and disposal of the Isomix-HC for statistical purposes.

Warranty

WATTS products are tested extensively. WATTS therefore guarantees only to replace or repair components of the products supplied free of charge – at the sole discretion of
WATTS – if, in the opinion of WATTS, they exhibit verifiable manufacturing faults. Warranty claims due to defects or defects of title may be asserted within one (1) year of delivery/transfer of risk. Excluded from the warranty is damage attributable to normal product use or friction and to damage resulting from modifications or unauthorized repairs to the products, for which WATTS rejects all claims for compensation (direct or indirect). (For more detailed information, please refer to our website.) In all cases, supply is subject to the General Terms and Conditions, which can be found on www.wattswater.eu/gtc/.

The descriptions and photographs contained in this product specification sheet are supplied by way of information only and are not binding.
Watts Industries reserves the right to carry out any technical and design improvements to its products without prior notice. Warranty: All sales and contracts for sale are expressly conditioned on the buyer’s assent to Watts terms and conditions found on its website atwww.wattswater.de/agb.
Watts hereby objects to any term, different from or additional to Watts terms, contained in any buyer communication in any form, unless agreed to in a writing signed by an officer of Watts.

Watts Industries Deutschland GmbH
Godramsteiner Hauptstr. 167 • 76829 Landau • Deutschland
Tel. +49 6341 9656 0 • Fax +49 6341 9656 560
WIDE@wattswater.com • www.wattswater.eu