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Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALIATel: +39 02 97249134 - +39 02 97249135www.icmaspa.it - [email protected]

Pag.1

MIXING AND CIRCULATION GROUPR001 - R002 - R003

TECHNICAL DATA SHEET 03/2019 - ENG

The mixing and circulation groups are used to adjust the distribution and temperature of the heat carrying fluid in multi-storey and/or multi-zone systems.They are usually installed in the thermal plant, downstream the hydraulic separator.The groups R001 – R002 – R003 can be installed on a special “inlet-outlet” distribution manifold, article 785.The groups are supplied with insulation shells. The fastening brackets and coupling manifolds, with the relevant insulation shells, are supplied on request.

Art. R001“Variable point” mixing and circula-tion group, provided with:- 3-Speed circulating unit or variable speed electronic circulating unit class“A”- Shut-off ball valves with thermometer (check valve incorporated in the return valve)- 3-Way mixing valve with 3-point electric servomotor- Insulation shell version 93 and 94.

Art. R002“Fixed point” mixing and circulation group, provided with:- 3-Speed circulating unit or variable speed electronic circulating unit class“A”- Shut-off ball valves with thermometer (check valve incorporated in the return valve)- 3-Way mixing valve with fixed point thermostatic regulator with remote sensor.- Insulation shell version 93 and 94.

Description

Products

Version 93

Version 93

Version 94

Version 94


Pag.2



Art. R003Mixing and circulation group for “direct high/low temperature” provided with:- 3-Speed circulating unit or variable speed electronic circulating unit class“A”- Shut-off ball valves with thermometer (check valve incorporated in the return valve)- Shut-off ball valve on delivery pipes- Insulation shell version 93 and 94.

Components List1. Ball valve G3/4” with blue hand-wheel for connection to the return pipes, with thermometer 0-160°C and incorporated check valve.2. Ball valve G3/4” with red hand-wheel for connection to the deli-very pipes, with thermometer 0-160°C.3. Steel stub with ends threaded G1”1/2M.4. 3-Speed circulating unit or variable speed electronic circulating unit, class “A”, with union connection G1”1/2 and distance betwe-en centers 130mm.6y5. 3-Way mixing valve with connections G1”1/2.6. Electric modulating 24 Volt or 230 Volt servomotor, for mixing valve regulation.7. Thermostatic head, with remote sensor, regulation range 20-50°C (to be combined with the pit our art. 87189AD06).8. Ball valve with coupling G1”1/2 for connection to the incoming pipe from the boiler.(Optional for groups R001 and R002: contact control thermostat with two-metal sensor ns. art. 9061009053)

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Version 93

Version 94


Pag.3



ARTICLE A B C D Ø 1 Ø 293 94 93 94

R001 360 270 200 180 125 3/4”F G 1”M G 1”1/2 MR002 360 270 200 180 125 3/4”F G 1”M G 1”1/2 MR003 360 270 200 180 125 3/4”F G 1”M G 1”1/2 M

Dimensions

Technical SpecificationsTECHNICAL DATA:

Fluids used: Water and glycol based solutionsMaximum percentage of glicole: 50%Maximum operating pressure: 10 barMaximum temperature: 95 °CThermometers scale: 0÷160 °CCircolators: See specifications below

MATERIALS:

Bodies: Brass CW617N - EN 12165Caps and unions: Brass CW617N - EN 12165Stub: Galvanized steelThermometer: Steel/AluminiumLocking brackets: Galvanized steelFlat gaskets: EPDM PeroxSealing gaskets: PTFESealing components: EPDM PeroxInsulation shell: EPPDensity Ver. 93: 40 kg/m3

Density Ver. 94: 60 kg/m3

Conducibility of shell λ (ΔT) Ver. 93: 0,036 W/(m·k) a 10°CConducibility of shell λ (ΔT) Ver. 94: 0,039 W/(m·k) a 10°C

CONNECTIONS:

Upper connections: G 3/4” FLower connections: G 1”1/2 M

SHELL 94 SHELL 93

* For the 1 “1/2 M connection use Art.797. See page 19.


Pag.4



Hydraulical Features

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K V 2K V 2

G ruppo di r ila nc io/c irc olation unit A rt.R 001G ruppo di r ila nc io/c irc olation unit A rt.R 001

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P R E S S U R E DR O P DIA G R A MDIA G R A MMA DE L L E P E R DIT E DI C A R IC O P R E S S U R E DR O P DIA G R A MDIA G R A MMA DE L L E P E R DIT E DI C A R IC O

WA T E R F L OWP OR T A T A D'A C Q UAWA T E R F L OWP OR T A T A D'A C Q UA

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K V 1K V 1

5,25,2(A ngled w ay ) K v1 [m/h](A ngled w ay ) K v1 [m/h]

(s tra ight wa y) K v 2 [m/h](s tra ight wa y) K v 2 [m/h] 5,855,85

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K V 2K V 2

G ruppo di r ilanc io/c irc olation unit A rt.R 002G ruppo di r ilanc io/c irc olation unit A rt.R 002

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P R E S S UR E DR O P DIA G R A MDIA G R A MMA DE L L E P E R DIT E DI C A R IC O P R E S S UR E DR O P DIA G R A MDIA G R A MMA DE L L E P E R DIT E DI C A R IC O


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K V 1K V 1

4,84,8(A ngled wa y ) K v1 [m/h](A ngled wa y ) K v1 [m/h]


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G ruppo di rilanc io/c irc olation unit A rt.R 003G ruppo di rilanc io/c irc olation unit A rt.R 003

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WA T E R F L O WP OR T A T A D'A C QU AWA T E R F L O WP OR T A T A D'A C QU A

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6,86,8(S tr aight wa y) K v [m/h](S tr aight wa y) K v [m/h]33

**

CirculatorsArt. P321 - Synchronous circulation pump with 3 speeds:

Technical specifications

Brand: GrundfosModel: UPSO 25 – 65 130 mmCentre to centre distance: 130 mmConnections: G 1”1/2 MElectrical power supply: 230V – 50HzOperating temperature: +2°C ÷ +110°C.Max operating pressure: 10 barProtection level: IP44

Hydraulical Specifications:


Pag.6



Art. P326 - Circulation pump with 3 speeds:

Technical specifications

Brand: GrundfosModel: UMP3 PWM 25 70 130Centre to centre distance: 130 mmConnections: G 1”1/2 MElectrical power supply: 230V – 50HzOperating temperature: +2° / +95°C.Max operating pressure: 10 barProtection level: IP44Energy class (EEI): ≤0.23


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Portata-Flow rate [m³/h]

Prevalenza residua-Remaining head Art.R004- Grundfos UMP3 Hybrid 25-70

Grundfos UMP3 Hybrid 25-70 Constant curve 4 (usable) Constant curve 3 (usable) Constant curve 2 (usable) Constant curve 1 (usable)


Pag.7



Art. P328 - Circolator with PP (proportional pressure), CP (con-stant pressure) CC (constant curves), PWM (profile A o C), AA (auto adapt):

Technical specifications Brand: GrundfosModel: UPSO 25 – 65 130 mmCentre to centre distance: 130 mmConnections: G 1”1/2 MElectrical power supply: 230V – 50HzOperating temperature: +2°C / 110°C.Max operating pressure: 10 barProtection level: IP44Energy class (EEI): ≤0.20 Part 3PWM signal cable code: C64P3280153 (NOT INCLUDED)

Hydraulical specifications:

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Art. P327 - Circulator with ΔP constant and ΔP variable:

Technical specifications :

Brand: WiloModel: CIRCULATOR PARA 25/8 130Centre to centre distance: 130 mmConnections: G 1”1/2 MElectrical power supply: 230V – 50/60HzOperating temperature: 0°C / 100°C.Max operating pressure: 10 barProtection level: IPx4DEnergy class (EEI): ≤0.21


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Prevalenza residua-Remaining head Art.R001 - WILO PARA 25/8 130

WILO PARA 25/8 130 Constant curve III (usable) Constant curve II (usable) Constant curve I (usable)

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Pag.10



Art. P330 - Circulator with fixed ΔP , variable ΔP and 3 costant speed:

Technical Specifications:

Brand: WiloModel: CIRCULATOR PARA 25/8 130Wheelbase: 130 mmConnections: G 1 “1/2 MVoltage Power: 230V - 50 / 60HzWorking temperature: 0 ° C / 100 ° C.Maximum working pressure: 10 barDegree of protection: IPx4DEnergy Class (EEI): ≤0.21


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Pag.12



The unit is supplied in two versions:- with right side delivery and flow upwards (equivalent, if reversed, to a left side delivery and flow downwards)- with left side delivery and flow upwards (equivalent, if reversed, to a right side delivery and flow downwards).The position of the flow direction can be reversed, if needed.Following are the operations to be carried out, referred to a unit with right side delivery and flow upwards,in order to turn it in a left side unit with flow upwards.

(AVAILABLE FOR R001-R002 GROUPS) ONLY

1) Remove the insulations shells that are slightly stuck each other.

5) The layout of the mixing valve is to be reversed. For this operation, please refer to the specific sections on page 6, regarding the fixed point mixing valve and the variable point mixing valve, respecti-vely.

2) Unscrew the caps which allow knocking down the unit, as shown in the picture. The special wrenches must be used; avoid damaging the gaskets.

6) Assemble the unit accor-ding to the new layout, with pump located at the left side, as shown in the picture.Tighten all the caps using suitable wrenches; carefully check the correct positioning of the gaskets.

3) Reverse the position of both on/off valves RED/BLUE of the steel stub con-nected to the BLUE valve.

7) Finally replace the insula-tion shells by slotting them in.

4) Move the pump to the unit left side; the impeller must be rotated. To perform this ope-ration, unscrew the 4 screws marked with the arrows on the picture, remove the impeller, rotate it by 180° and reassemble it on the pump body.

8) The unit is now arranged according to the version with left side delivery and flow upwards (equivalent, if reversed upside down, to a right side delivery and flow downwards).

RIGHT-LEFT SWITCHING


Pag.13



R002 - MIXED VALVE FIXING POINT

Following are the instructions to change the layout of a “Fixed Point” mixing valve; please refer to the diagram shown.1) Unscrew the 4 screws “A”.2) Withdraw the plug “B” and the regulation unit “F”.3) Withdraw the two elements of the by-pass “C” and “E”.4) Reinstall the elements “C” and “E”, reverse their position; care must be taken in preventing damages to the sealing O-Rings in peroxide EPDM.5) Install the plug “B” and the regulation unit “F”; rever-se the position of this unit, as well. Both elements are provided with a small reference slot on the outer edge, which must always match the relevant reference notch on the valve body “D”. Care must be taken in avoiding damages to the sealing O-Rings in peroxide EPDM.6) Fasten the whole assembly with the 4 screws “A”.

R001 -MIXING VALVE VARIABLE POINT

To change the layout of a “Variable Point” mixing valve, the instruction described above for the “Fixed Point” valves apply. The regulation unit “F” of the two models slightly differs, but the operating procedures are the same.Following is the only additional operation to be perfor-med:7) Reverse the position of the Dowel Pin “R”, which acts as a lock for the servomotor.

BY-PASS AdjustmentThe mixing valve is provided with an adjustable by-pass duct. This prevents overwork of the pump, and avoids its operation at extreme head values, should the mixing valve be in fully closed position.The by-pass is regulated by the brass screw shown on the drawing below (use a flat screwdriver).As far as the positions OPEN/CLOSED are concerned, please refer to the diagram shown.When the plant is being started, it is advisable to keep the by-pass fully open (regulate it afterwards).

(AVAILABLE FOR R001-R002 GROUPS ONLY)Conversion of Mixing Valves

Adjustment screwBY-PASS BY-PASS OPEN

BY-PASS CLOSED


Pag.14



The servomotor can be arranged according to the two layouts shown below and according to the target type of group.

To change the layout of a servomotor, the equipment must be knocked down as shown in the diagram below. Then it must be reassembled. Attention must be paid to the position of the RED/BLUE disk “S”. Please refer to the two layouts shown above.

WARNING: In both configurations the “S” disk must be installed with the RED part upwards.The handle “M” on the motor body “O” can be coupled in one single position, resulting from the coupling of a toothed spindle of the motor body and the relevant seat on the handle.

The servomotor has two type of functioning: AUTOMATIC and MANUAL.The servomotor “AUTOMATIC” working position is set by pressing with a flat screwdriver the pushbutton “P” and rotating it to lead the reference mark towards the letter “A”; the handle is then linked to the servomotor internal mechanism and will move automatically. The servomotor “MANUAL” working position is set by pressing with a flat screwdriver the pushbutton “P” and rotating it to lead the reference mark towards the symbol of the “hand”; the handle is then free and it is possible to rotate it manually in the desired position.

Valid only for variable point mixing and circulation groups R001 - with servomotor.LAYOUTS OF SERVOMOTOR

MANUAL /AUTOMATIC FUNCTIONING

O S M N


Pag.15



SERVOMOTOR ASSEMBLY INSTRUCTIONSON THE VARIABLE POINT MIXING VALVE

When the required arrangement for the mixing and circulation group has been selected and once the operations described in the paragraphs above have been carried out, the servomotor can be installed on the mixing valve.The servomotor must be assembled according to a specific position; following are the operations to be carried out for its correct installation on a mixing valve with layout “LEFT” and “RIGHT”.WARNING: the wrong installation of the servomotor on the mixing valve could heavily jeopardize the correct ope-ration of the whole mixing and circulation group.

Mixing valve setting: position the black hand-wheel “V” with the reference arrow turned upward or downward, according to the selected arrangement of the unit (refer to the diagrams below).Remove the screw that secures the hand-wheel to the valve being careful not to twist (should stand in the position just set).Install the reference pin “R” on the same side of the valve body where the hand-wheel is installed.

(Valid only for variable point mixing and circulation groups R001 - with servomotor)

V R R V

Left side delivery and upward flow direction Right side delivery and upward flow direction

Servomotor setting: take the pushbutton “P” to the automatic operation position “A” (using a flat screwdriver, press the pushbutton, rotate it to the “A” position and release it). Keep the pushbutton “P” pressed, take the hand-le “M” to one of the two positions shown below (only the RED colour of the disk must remain visible). Release the pushbutton: the handle must remain locked in the correct position.

Servomotor installation on the mixing valve: position the servomotor on the valve checking the coupling with the black hand-wheel “V” and the dowel pin “R” (the pin must be inserted in the horizontal slot).Then lock the servomotor to the valve by the screw M5x70 provided, element “N” (page 8).The unit layout must be as shown in one of the two pictures below, ready to be installed in the groups.


MM

P P



Pag.16



OPERATION OF THE MIXING VALVE

MODULATING SERVOMOTOR

Valid only for variable point mixing and circulation groups R001 - with servomotor.(Please find to follow a group with delivery pump to the right-hand)

ACTUATOR HAND REGULATION:

The valve can be hand operated with the servomotor installed: to carry out this operation, press the pushbutton “P” and turn the handle “M” to the required position (please refer to the diagrams shown above). When the pu-shbutton is released, the servomotor gets back to automatic operation.

Electrical connection

MP

FULLY OPEN POSITION:

With the handle “M” of the servomotor in this position, the mixing valve is fully open.The heat carrying fluid coming from the boiler is con-veyed directly to the plant.

REGULATION POSITION:

With the handle “M” of the servomotor in this position, the mixing valve is under regulation.The heat carrying fluid coming from the boiler is mixed with the return fluid from the plant.

FULLY CLOSED POSITION:

With the handle “M” of the servomotor in this position, the delivery is completely excluded.The heat carrying fluid coming from the return circuit is recirculated in the plant.

Technical features:

Electric power supply: 230V - 50Hz Max current absorption: 3,5 VA Execution time on 90°: 135 s Nominal load torque: 10 Nm Operating temperature: -10 / +50 °C Protection degree: IP 40 External shell material: Polycarbonate


Pag.17



Accessories for circulation groups

Art. 789:Threaded fitting G 1” F X G 1” 1/2 F is needed in order to reduce G 1” 1/2 F thread to G 1” F thread.

CODE SIZE

82789AF05 1” F X 1” 1/2 F


Pag.18



Installation Diagram

The above diagram shows the installation example of the three mixing and circulation groups R001 – R002 – R003.The connections to the mixing and circulation groups conveying the heat carrying fluid to the zones to be heated start from the manifold located downstream the hydraulic separator.

“Variable point” mixing and circulation group art.R001, it is the first unit starting from left; in the diagram shown, it controls a low temperature plant.According to the data collected by an ambient thermostat and by an external probe, the electronic control station directly controls the recirculating pump, the 3-point servo-control and so the mixing valve, modulating the tempe-rature of the heat conveying fluid circulating in the plant and maintaining the set environmental conditions.

“Fixed Point” mixing and circulation group art.R002, it is in the middle, and it controls a low temperature plant.An ambient thermostat operates the system when the ambient temperature drops below the set values, and di-rectly controls the recirculating pump. In addition, a thermostatic regulator with remote probe directly controls the mixing valve and keeps at the set value the temperature of the heat conveying fluid sent to the user’s point. The remote probe detects the temperature of the heat conveying fluid, coming out of the mixing unit. For this reason it is installed in a pit, on the delivery duct.

Mixing and circulation group for “High Temperature” art.R003, its is the last unit, on the right. It controls a high temperature plant (radiators or fan coils system).Unlike the other units, this unit is not equipped with a mixing valve and with the relevant control.An ambient thermostat directly controls the operation of the recirculating pump, that sends the heat conveying fluid to the user’s points at the outlet temperature from the boiler.


Pag.19



SAFETY:

Before starting the equipment, carefully read the assembly and start-up instructions, to prevent any accidents or failures of the system resulting from improper use of the product. It must be pointed out that non authorized modifications or tampering with during the assembly and construction stages may lead to the forfeiture of the right to the guarantee. In addition to the directives stated above, the following rules must be followed:

DIN 4751 Water heating systemsDIN 4757Solar heating systemsDIN 18380Heating systems and sanitary water heating systemsDIN 18382Electric and running systems in buildingsDIN 12975Thermal solar systems and relevant construction

WORKING CONDITIONS:The limit values shown MUST IN NO WAY be exceeded. The operation safety conditions are therefore assured by respecting the general conditions and the operation limit values described in this sheet.

SAFETY RULES FOR ASSEMBLY AND INSPECTION:The assembly and inspection operations shall be carried out by qualified personnel, duly authorized and well aware of the instructions described herein. Before starting any works on the devices and equipment, it is impor-tant to check that they are switched off.

ELECTRICAL CONTACT:The electric connections shall be carried out by qualified personnel.Before powering the mixing and circulation group, check that the voltage type and values supplied by the electric grid meet the data on the manufacturer’s plate. All connections shall be made as prescribed by law.

MAINTENANCE:The maintenance operations shall be carried out by qualified personnel, duly authorized and well aware of the instructions described herein. Before starting any works on the equipment, it is important to check that they are switched off. Should the pump be replaced, rotate the on/off valve to closed position. Warning! The surface temperature could reach very high values, according to the operation conditions of the pumps and to the features of the system. Therefore, DO NOT touch the pump directly. Danger of burns!

CONFORMITY STATEMENT (CE):The circulating units provided with the ICMA mixing and circulation groups comply with the following harmonizing directives:

CEE Machine Directives89/392/CEE, 91/368/CEE, 93/44/CEE, 93/68/CEE.Electromagnetic compatibility89/336/CEE, 92/31/CEE, 93/68/CEEGeneral harmonized standardsEN 809, EN 50081-1, EN 50081-2, EN 50082-1, EN 50082-2.

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