Mini-HYDRO TM Installation Manual

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1 Mini-HYDRO TM Installation Manual Zone Pump Version Zone Valve Version

2 NOTICE: READ THESE INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW INSTRUCTIONS VOIDS WARRANTY. Introduction: The Mini-HYDRO (patent pending) is an economical small hydraulic separator system that allows fast completion of primary/ secondary piping for many different heat sources and zoning options. The Mini-HY- DRO may be piped from either side and the primary and secondary components may be oriented to accommodate installation layouts. The Mini-HYDRO utilizes PHP s Pro-Modular zoning modules to provide a fast and compact multiple zone installation. The Mini-HYDRO improves installation efficiency since the majority of system piping requirements are included within the compact design. Components are positioned properly for optimal performance. The expansion tank is located at the Point of No Pressure Change. The Mini-HYDRO connects to the Pro-Modular secondary zoning modules by using a pump adapter or zone valve adapter kit. When zone pumps are used, zone mixing is available using either a 3-way manual mixing valve, a 3-way Taco ivalve, or a 2- way Taco ivalve Pro-Modular assembly to achieve multiple temperature delivery. Built into the Mini-HYDRO is a highquality air vent, a pressure-reducing fill valve, purge/sediment drain, expansion tank, primary loop kit, zoning modules with proper components for either zone valve or zone pump options, and taps for an indirect water tank kit. The installing contractor saves installation time and space requirements in the mechanical room while being assured of proper system performance. The Mini- HYDRO eliminates piping errors that may occur in field-assembled installations, especially when those installations include primary/secondary piping, zone pumping and mixing requirements, or zone valve configurations. The Mini-HYDRO is factory pressuretested and PHP provides a 3-year leak-free warranty. Hydraulic Separation: The internal hydraulic separation chamber hydraulically uncouples the primary and secondary loops to prevent ghost flows similarly to closely-spaced Tees. Mixing patterns are dependent on flow rates in the primary and seconday loops as shown. Secondary side Zone supply Zone return A Primary side Boiler supply Boiler return A: When primary-loop flow is GREATER than secondary-loop flow - the secondary zones will always be the temperature of the primary loop. B: When primary-loop flow EQUALS secondary-loop flow - there is no mixing in the chamber. The secondary loops are the temperature of the primary loops and the boiler return is the temperature of the secondary return. C: When primary-loop flow is LESS than secondary-loop flow - secondary loops will be lower temperature than primary loop. Zone supply Zone return Zone supply Zone return B C Boiler supply Boiler return Boiler supply Boiler return

3 Mini-HYDRO TM Details (USA Patent Pending) Air vents Differential Pressure By-Pass Kit Zone valve component module (shown with 2-zone module/additional zones can be added) Zone Valve Version Zone Valve Starter and Purge Kit Spriotop Primary Loop Kit J-Bend Kit Fast-fill pressurereducing valve Expansion tank with mounting bracket Zone pump component module (shown with 2-zone module/additional zones can be added) End caps with plugs Zone Pump Version Zone Pump Starter and Purge Kit

4 Component Details: Air elimination: The Mini-HYDRO uses a Spriotop to eliminate air. Air-entrained water entering the hydraulic separation chamber undergoes a volume and velocity change allowing air to percolate to the top of the chamber where it is eliminated via the air vent. While not as effective as and in-line air eliminator, the air vent will remove air over time. If desired, an additional in-line air eliminator may be added to the system piping. Sediment removal: The Mini-Hydro separator has a drain port at the bottom to aid in flushing the system and removing accumulated sediment. As with air removal, sediment will settle out of solution due to the volume and velocity change in the separator chamber. Mini-HYDRO TM Separation Chamber 3) When a secondary-loop zone turns on, water travels through the chamber to the secondary-loop supply pipe and is circulated to the zone. 1) Primary-loop water circulates from the boiler to the separation chamber. The Mini-HYDRO separation chamber works as a hydraulic separator due to the large size of the chamber and the use of closely-spaced Tees. This ensures that there is minimal pressure drop between the primary-loop inlet and outlet that would induce or influence flow in the secondary loop. Secondary-loop supply Primary-loop supply Secondary-loop return Primary-loop return 4) Water from the secondaryloop zones returns through the return pipe to the chamber body and back to the boiler. 2) Hydraulic separation occurs in the space between the closely-spaced Tees. Installing the Mini-HYDRO : READ THESE INSTRUCTIONS CARE- FULLY. FAILURE TO FOLLOW INSTRUC- TIONS VOIDS WARRANTY. Installing the Mini-HYDRO requires that you are a qualified installer with knowledge of local, national and other applicable building and mechanical codes, as well as an understanding of good hydronic practice, heat transfer, building heat requirements, friction losses, flow and controls. If you do not have these skills you should not install the Mini-HYDRO. It is the installer s sole responsibility to verify the suitability of the Mini-HYDRO for the project in which it is to be installed. 1) Unpack the Mini-HYDRO and make sure you have received all the parts in good condition. Verify that you have received the correct model for your job. The Mini-HY- DRO is available in zone valve or zone pump models.

5 2) Evaluate your mechanical room space and decide where you will place the Mini- HYDRO with consideration to where other components will be placed, and the components that will be connected to the Mini-HYDRO. Also check required clearances to electrical panels and other components in a mechanical area. Remember the Mini-HYDRO may be installed with the primary loop facing left or right and up or down. 3) It is recommended that 3/4 plywood be attached to the wall behind where you want to install the Mini-HYDRO with the 3/4 plywood securely attached to framing. 4) Mount the Mini-HYDRO to the plywood with two (2) 1 lag screws on all of the support bracket struts. Use washers to prevent the lag screws from working through the strut. Remember the top of the Mini-HYDRO has the air vent. Do not install sideways or upside down. 5) If your Spirotop Jr. is shipped separately, use teflon thread tape and attach it to the top of Mini-HYDRO. 6) Pipe the primary-loop supply and return pipes to the Mini-HYDRO. The Mini-HY- DRO may be piped with the primary/secondary loops on the right or left. The supply and return from the primary/seconday loops must be on the on the same side; i.e. primary supply/return on the right, secondary supply/return on the left. The supply line is the top pipe on each side; the return line is the bottom pipe on each side. Do not cross-connect the pipes or the separation chamber will not work properly. 7) When connecting zoning modules to the Mini-HYDRO, the zoning modules attach to the left or right side. Install the appropriate adapter kit then the zoning module. If using zone valves, install the differential pressure bypass valve(dpbv) assembly between the zone valve module and the end caps. If installing the zoning modules vertically, install air vents in place of the plugs in the end caps. 8) Pressure test the system as required by good practice and code. Wire pumps, valves and controls. Fill with fluids. If necessary, protect system from freezing with propylene glycol or other methods. 9) Purge primary and secondary loops prior to operation of boiler or other heated water producing appliance. Purge secondary-loop zones one at a time sequentially with the secondary-loop return port ball valve closed and purge valve open and connected to a hose terminated out of doors or in a drain. Once all zones have been purged, close purge valve, open secondary-loop return port ball valves and run secondary-loop pump(s) sequentially to further purge system. Then operate primary loop to purge primary loop. Only after system is well purged should boiler or other heated water producing appliance be operated.

6 Optional Mixing Modules Mixing modules, available in up to 3-zone assemblies, may replace zoning modules or be added if multiple system supply temperatures are required. This feature allows for high- and low-temperture zones to be installed on the secondary side of the Mini- HYDRO system. Mixing modules include a manual 3-way mixing valve, Taco 3-way i-valve, or Taco 2-Way I-Valve, zone pump, temperature gauge, isolation valves and check valve. Flow Rate Ft. Head Press. Drop Ft. Head Press. Drop Ft. Head Press. Drop way Manual Mix Module 3/4 3-way manual valve Cv = /4 3-way Taco i-valve Cv = way Taco i-valve Mix Module 3/4 2-way Taco i-valve Cv = way Taco i-valve Mix Module WARNINGS! Never operate boiler with expansion tank disconnected or isolated from the system. Failure to do so can result in explosive condition, injury or death. Purge air from system before operating pumps. Water lubricated pumps will fail if air-locked or run dry for extensive periods of time. Many boilers require a specific flow for correct operation and can differ significantly in resistance to flow. It is the installer s responsibility to verify the correct pump. Failure to do so may cause premature failure of boiler or a dangerous condition. Make sure boiler or heat source has a properly operating 30 PSI pressure relief valve connected to the system and is in good working condition. Never isolate it. Failure to do so may result in explosive condition, injury or death. It is the installer s responsibility to install a code compliant backflow preventor on the fill line. The expansion tank supplied with the Mini-Sep Plus may not be the correct or adequately sized tank under certain conditions. It is the installer s responsibility to verify that it is adequate, and if not, replace it with a larger tank or add another so that the acceptance capacity is adequate for the system. Read and follow all instructions of components supplied as part of the Mini- Sep /Mini-Sep Plus. Always disconnect power from any component connected to the Mini- Sep /Mini-Sep Plus before servicing the unit. Failure to do so could result in burns, electrocution, injury or death. For indoor hydronic use only. Do not use with steam or in steam heating applications.

7 Mini-HYDRO TM Zoning Options Combination zone pump/zone valve configuration with heat source connection on left. J-bend kit may be eliminated if horizontal installation is desired. Zone valve confituration with heat source connection on right. Pressure differential bypass valve used with zone valves. Zone pump configuration with heat source connection on right. Horizontal layout shown. Add J-bend kit to change orientation of zoning module. Note: Mixing modules may be added to zoning modules. Mixing options include 3-way manual valve, Taco 3-way i-valve or Taco 2-way i-valve.

8 Submittal Data Information Mini-HYDRO tm System Job: Engineer: Contractor: Rep: ITEM NUMBER MODEL NUMBER Application: The Mini-HYDRO System is very versatile since it can be configured to accommodate various system requirements. Using the 1-1/4 Mini-Sep Plus as the base component, the boiler connection, zone transition, and zone packages can be added. Use just the Mini-Sep Plus, or any of the other components. Adding 2-zone and 3-zone modules allows for multiple zone configurations simply by combining additional modules. Available in zone pump or zone valve assemblies. Capacity: 1-1/4 inch models: up to Btuh All Products U.S. Patent Pending Mini-HYDRO TM zone valve system shown Common Components: PHP-MSEPPLUS-1250 PHP-MSEP-BCG PHP-MSEP-BCT 1-1/4 inch supply/return pipe size Primary loop kit with Grundfos UPS FC, included taps for indirect water tank connection Primary loop kit with Taco 00R-MSF1-IFC, included taps for indirect water tank connection Zone Pump Components: PHP-MSEP-1250SW KIT PHP-PMPCM-1GSW PHP-PMPCM-2GSW PHP-PMPCM-3GSW PHP-PMPCM-1TSW PHP-PMPCM-2TSW PHP-PMPCM-3TSW Pump module adapter kit; includes end caps with plugs, shutoff with purge valve 1-zone pump component module with Grundfos UPS FC 2-zone pump component module with Grundfos UPS FC 3-zone pump component module with Grundfos UPS FC 1-zone pump component module with Taco 00R-MSF1-IFC 2-zone pump component module with Taco 00R-MSF1-IFC 3-zone pump component module with Taco 00R-MSF1-IFC Zone Valve Components: PHP-MSEP-1250SW KIT GF Zone valve starter and purge kit; includes end caps with plugs, purge valve, Grundfos UPS FC PHP-MSEP-1250SW KIT TACO Zone valve starter and purge kit; includes end caps with plugs, purge valve, Taco 00R-MSF1-IFC PHP-MSEP-1250SW KIT TDT Zone valve starter and purge kit; includes end caps with plugs, purge valve, Taco delta-t pump PHP-MSEP-1250SW KIT WDP Zone valve starter and purge kit; includes end caps with plugs, purge valve, Wilo delta-p pump PHP-PMZVCM-1SW 1-zone valve component module PHP-PMZVCM-2SW 2-zone valve component module PHP-PMZVCM-3SW 3-zone valve component module PHP-PMDPV750SW KIT Differential pressure bypass valve kit for use with conventional secondary pump; not needed with delta-t or delta-p pumps. Accessory Components: PHP-AVA 1250 PHP-PMJBENDSW PHP-SWC PHP-SWC Air vent; used when headers are installed upwards (2 required) J -bend kit, 1 short, 1 long bend; used with installing zone modules up or down 1-1/4 stainless steel flex connector with sweat adapters; 18 long 1-1/4 stainless steel flex connector with sweat adapters; 24 long Precision Hydronic Products - Division of JL industries, inc NE 79th Court - Portland, OR Phone: ; Fax:

9 Submittal Data Information Mini-HYDRO tm System Job: Engineer: Contractor: Rep: ITEM NUMBER MODEL NUMBER Configuration Examples Zone pump module Zone Pump Assembly Air vents Zone Valve Assembly DPBV kit Pump module adapter kit Zone valve module End caps with plugs 1-1/4 Mini-Sep Plus Primary loop kit Zone valve starter and purge kit J -bend kit Zone pump module 1-1/4 Mini-Sep Plus Primary loop kit Primary loop kit J -bend kit 1-1/4 Mini-Sep Plus Zone valve starter and purge kit Combination Zone Pump/ Zone Valve Assembly Zone valve module End caps with plugs DPBV kit Precision Hydronic Products - Division of JL industries, inc NE 79th Court - Portland, OR Phone: ; Fax:

10 Precision Hydronic Products Airport Business Center 6730 NE 79th Court - Portland, OR Phone: ; Fax:

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