SG150D - HONEYWELL - Free user manual and instructions

USER MANUAL SG150D HONEYWELL

1. Follow the installation instructions. 2. Use the appliance • according to its intended use • in good condition • with due regard to safety and risk of danger. 3. Note that the appliance is exclusively for use in the applications detailed in these installation instructions. Any other use will not be considered to comply with requirements and would invalidate the warranty. 4. Please take note that any assembly, commissioning, servicing and adjustment work may only be carried out by authorized persons. 5. Immediately rectify any malfunctions which may influence safety.

Installation position

Horizontal and vertical

Set by manufacturer at 6.0, 8.0 or 10.0 bar Subsequent alteration of the setting is not permitted and is impossible without destroying the security cap

Operating temperature Max. 40 °C Minimum pressure drop 1 bar Connection size

5. Scope of delivery The safety group comprises: • Housing with test socket G 1/4" • Connections (versions AA, AB and AC) • Shutoff valve • Complete pressure reducer (only with SG150D) with fine screen (mesh opening 0.16 mm) and clear sighted strainer cup • Check valve cartridge • Approved safety valve exchange insert • Drain connector • Insulation shells • Pressure gauge optional

2. Functional description Safety groups of this type combine pressure reducing valve (only SG150D), check valve, shutoff valve, test point and diaphragm type safety valves in one appliance. Flow first passes through the pressure reducing valve which operates on a force equalising system whereby the force of a diaphragm operates against the force of an adjustment spring. The inlet pressure has no influence on either opening or closing of the valve and therefore inlet pressure fluctuations have no influence on the outlet pressure. The check valve has a movable valve disc which pushes against a spring when flow occurs. The downstream safety valve is a direct operating safety valve. That is, the opening force operates against the force of a spring. The shutoff valve enable the check valve to be checked and serviced.

6. Options SG150- ... AA = With threaded male connections, 6.0 bar SG150- ... AB = With threaded male connections, 8.0 bar SG150- ... AC = With threaded male connections, 10.0 bar SG150- ... EA = Without fittings, set pressure 6.0 bar SG150- ... EB = Without fittings, set pressure 8.0 bar SG150- ... EC = Without fittings, set pressure 10.0 bar SG150D- ... AA =With threaded male connections, 6.0 bar SG150D- ... AB =With threaded male connections, 8.0 bar SG150D- ... AC =With threaded male connections, 10.0 bar SG150D- ... EA =Without fittings, set pressure 6.0 bar SG150D- ... EB =Without fittings, set pressure 8.0 bar SG150D- ... EC =Without fittings, set pressure 10.0 bar

3. Application For closed hot water storage units up to 200 litres according to DIN 4753 Part 1 and DIN 1988. Tested to TRD 721 for 1.0 to 10.0 bar pressure range. Medium Inlet pressure Outlet pressure Operating pressure

Water Max. 16 bar (SG150D only) 1.5 - 6 bar Maximum at least below 20 % opening pressure of safety

Honeywell GmbH GB 7. Assembly

7.1 Installations Guidelines • Safety group must be fitted in the cold water supply to the hot water storage unit • Installation in horizontal or vertical pipeline possible • The installation must be carried out so that: o There are no shutoff valves or fittings, narrowing of the pipework or strainers between the water heater and the safety valve o Good access is provided for service and maintenance o The safety valve is fitted above the top of the water heater to avoid the need for draining down when exchanging the safety valve insert • If there is no drainage facility in the room where the heater is installed, then the safety valve may be fitted in an adjacent area. DIN 1988, part 2 is to be observed • Distance to the water heater approx. 1m • While heating, water must escape in the discharge line for safety reasons. Do not close off! • The drain line of the membrane safety valve must be viewable! • If the drain guide is not connected directly with the safety group, a discharge line must be installed between the safety group and the drain guide! • The discharge line must be performed to the size of the safety valve discharge cross-section and may not have more than 2 elbows and or be longer than 2m! • If, for compelling reasons, more elbows or a greater length becomes necessary, then the entire discharge line must be designed to a larger nominal width. More than 3 elbows, as well as lengths over 4m are not permitted! • The discharge line must be installed with an incline! 7.2 Assembly instructions 1. Blow out or rinse pipe line out well 2. Install safety group in the cold water line o Note flow direction o Install without tension or bending stresses

8.1 Setting outlet pressure Set outlet pressure min. 1 bar under inlet pressure. 1. Close shutoff valve on inlet 2. Release pressure on outlet side (e.g. through water tap) 3. Close shutoff valve on outlet 4. Loosen slotted screw o Do not remove slotted screw 5. Slacken tension in compression spring o Turn control handle to the left (-) until it does not move any more 6. Slowly open shutoff valve on inlet 7. Turn control handle until the setting scale shows the desired value 8. Retighten slotted screw 9. Slowly open shutoff valve on outlet

9. Maintenance DIN 1988, Part 8 specifies that the following operations be carried out regularly. A scheduled maintenance scheme is recommended. 9.1 Inspection 9.1.1 Pressure reducing valve Interval: once a year 1. Close shut off valve on outlet 2. Check back pressure using a pressure meter when there is zero through-flow o If the pressure is increasing slowly, the valve may be dirty or defective. In this instance, carry out servicing and cleaning 3. Slowly open shutoff valve on outlet 9.1.2 Check valve Interval: once a year 1. Close shut off valve on outlet 2. Open check valve o Until the pressure is released, some water will flow out of the check valve. After a short period of time the water flow should stop. If the water continues to drip or run, then the backflow preventer must be replaced - see servicing of backflow preventer 3. Close check valve again 4. Open shut-off valve again

GB 9.1.3 Safety valve Frequency: every 6 month

9.2.2 Check valve To be carried out by an installation company

1. Actuate lifting device 2. Release lifting device • Shut-off valve closes • available water flows completely off Malfunction: 1. Actuate lifting device multiple times, if necessary initiate repairs 9.2 Maintenance 9.2.1 Pressure reducing valve Frequency: every 1-3 years (depending on local operating conditions) To be carried out by an installation company 1. Close shutoff valve on inlet 2. Release pressure on outlet side (e.g. through water tap) 3. Close shutoff valve on outlet 4. Loosen slotted screw o Do not remove slotted screw Caution ! There is a spring in the spring bonnet. It may cause injuries if the spring is derailing. • Make sure tension in compression spring is slakkened! 5. Slacken tension in compression spring o Turn control handle to the left (-) until it does not move any more 6. Unscrew spring bonnet o Use double ring wrench ZR06K 7. Remove slip ring 8. Remove valve insert with a pair of pliers 9. Unscrew filter bowl o Use double ring wrench ZR06K 10.Remove slotted ring 11.Check that sealing ring, edge of nozzle and slotted ring are in good condition, and if necessary replace the entire valve insert 12.Remove filter, clean and reinsert 13.Place O-ring onto filter bowl 14.Reassemble in reverse order Press in diaphragm with finger before inserting slip ring Screw in filter cup hand-tight (without tools) 15.Adjust setting scale and set outlet pressure

1. Close shutoff valve on inlet 2. Release pressure on outlet side (e.g. through water tap) 3. Close shutoff valve on outlet 4. Replace check valve 9.3 Adjusting the setting scale If the adjustment knob is removed, this setting is lost. A new setting can be achieved using a pressure gauge. 1. Close shutoff valve on inlet 2. Release pressure on outlet side (e.g. through water tap) 3. Close shutoff valve on outlet 4. Fit manometer 5. Loosen slotted screw o Do not remove slotted screw 6. Slowly open shutoff valve on inlet 7. Set desired outlet pressure (e.g. 4 bar) 8. Align scale (e.g. 4) in middle of viewing window 9. Retighten slotted screw 10.Slowly open shutoff valve on outlet 9.4 Cleaning Caution ! Do not use any cleaning agents containing solvents and/or alcohol to clean the plastic parts! If necessary, the filter bowl and the filter can be cleaned. To be carried out by an installation company or the operator. Detergents must not be allowed to enter the environment or the sewerage system! 1. Close shutoff valve on inlet 2. Release pressure on outlet side (e.g. through water tap) 3. Close shutoff valve on outlet 4. Unscrew filter bowl o Use double ring wrench ZR06K 5. Remove filter, clean and reinsert 6. Place O-ring onto filter bowl 7. Screw in filter cup hand-tight (without tools) 8. Slowly open shutoff valve on inlet 9. Slowly open shutoff valve on outlet

GB 10. Disposal • Dezincification resistant brass housing • Brass threaded connections • Stainless steel filter mesh on pressure reducing valve • Transparent synthetic material filter bowl on pressure reducing valve • High grade synthetic material pressure reducing valve insert, spring bonnet with adjuster knob,

shutoff valves, test socket, check valve, safety valve insert and drain connector • Fibre-reinforced NBR diaphragm • NBR seals • EPP insulation shells Observe the local requirements regarding correct waste recycling/disposal!

11. Troubleshooting Problem SG150 and SG150D Drips

During the heating up of the water heater Continually drips from soiling

no error, normal function

Actuate lifting grip multiple times so that dirt particles are flushed out, or replace as necessary Backflow stopper does not close Pressure increase in the front pres- Replace backflow stopper off tightly in the front pressure sure area area. Seal surfaces dirty or worn Replace backflow stopper Too little or no water pressure Cut-off fixtures before or after the Open the shutoff valves fully safety group not opened entirely Safety group not installed in the flow Install safety group in flow direction direction (observe arrow direction on housing) only SG150D Water is escaping from the Diaphragm in valve insert is faulty Replace valve insert spring bonnet Too little or no water pressure Pressure reducing valve is not set to Set outlet pressure the desired outlet pressure Filter in pressure reducing valve is Clean or replace filter contaminated The outlet pressure set does not Filter in pressure reducing valve is Clean or replace filter remain constant contaminated or worn Valve insert, sealing ring or edge of Replace valve insert nozzle is contaminated or worn Rising pressure on outlet (e.g. in Check check valve, safety group etc. boiler) Expansion water from the hot water Inspect backflow stopper before the hot purifier water purifier and single-lever mixing valve if necessary. Close shut-off valves to the hot water purifier supply line. Open hot water tap connection. Does pressure remain constant? Expansion water of the hot water purifier. Does pressure increase? Pressure reducer defect. MU1H-1355GE23 R0907

..* valid approval No.

Blanking plug with O-ring R1/4" (5 pcs.)

Spring bonnet complete with setting scale

1/2" + 3/4" Valve insert complete (without filter)

Replacement filter 1/2" + 3/4"

M07M M08M D150/D160S VST06-A M08M ZR06K VST06-B Pressure gauge

FN09S Housing ∅ 50 mm, connecting pin above G1/4" Partition: 0-16 bar D150

FN09S VST06-A VST06-B HABEDO ® Retrofit filter Reverse-rinsing filter for retro-conversion to a filter combination unit of pressure reducing valves

Pressure reducing valve Pressure reducer D150-1/2 for completion of the safety group SG 150 with connection size 1/2”

D160S M08M M07M Pressure gauge Housing diameter 63 mm, rear connection thread G1/4". Ranges: 0 - 4, 0 - 10, 0 - 16 or 0 - 25 bar. Please indicate upper value of pressure range when ordering

Pressure reducing valve Pressure reducer D160S-3/4 for completion of the safety group SG 150 with connection size 3/4“

M08M VST06-A Connection set

Pressure gauge Housing ∅ 50 mm, connecting pin above G1/4" Partition: 0-16 bar

Threaded connections VST06-B Connection set Solder connections

ZR06K Double ring wrench For removal of spring bonnet and filter bowl

VST06-A Connection set Threaded connections

VST06-B Connection set Solder connections

Manufactured for and on behalf of the Environmental and Combustion Controls Division of Honeywell Technologies Sàrl, Ecublens, Route du Bois 37, Switzerland by its Authorised Representative Honeywell GmbH MU1H-1355GE23 R0907 Subject to change © 2007 Honeywell GmbH