REMKO EFS Series, EFS 50, EFS 35, EFS 25 Assembly And Operating Instructions Manual

Assembly and operating instructions
REMKO fresh water station Controller EFS
Instructions for user and specialist
0066-2013-10 Edition 1, en_GB
Read the instructions prior to performing any task!
Read these operating instructions carefully before commis­sioning / using this device!
These instructions are an integral part of the system and must always be kept near or on the device.
Subject to modifications; No liability accepted for errors or mis­prints!
Installation and operating instructions (translation of the orig­inal)

Table of contents

1 Safety and usage instructions............................................................................................................. 4
1.1 General safety notes....................................................................................................................... 4
1.2 Identification of notes...................................................................................................................... 4
1.3 Personnel qualifications.................................................................................................................. 4
1.4 Dangers of failure to observe the safety notes................................................................................ 4
1.5 Safety-conscious working............................................................................................................... 4
1.6 Safety instructions for the operator................................................................................................. 5
1.7 Safety notes for installation and inspection tasks........................................................................... 5
1.8 Unauthorised modification and changes......................................................................................... 5
1.9 Intended use................................................................................................................................... 6
1.10 Safety-conscious working............................................................................................................. 6
1.11 Warranty........................................................................................................................................ 6
1.12 Transportation and packaging....................................................................................................... 6
1.13 Environmental protection and recycling........................................................................................ 6
2 Technical data....................................................................................................................................... 7
2.1 Unit data.......................................................................................................................................... 7
2.2 Cable specification.......................................................................................................................... 8
3 Unit construction.................................................................................................................................. 9
3.1 Housing........................................................................................................................................... 9
3.2 Display............................................................................................................................................ 9
4 Operation............................................................................................................................................. 12
4.1 Buttons and Display...................................................................................................................... 12
4.2 Operating modes........................................................................................................................... 12
4.3 Setting menu................................................................................................................................. 15
4.4 Functions....................................................................................................................................... 16
4.5 Information messages................................................................................................................... 23
5 Assembly and dismantling................................................................................................................. 23
6
Electrical wiring................................................................................................................................... 25
7 Commissioning................................................................................................................................... 29
8 Troubleshooting and customer service............................................................................................ 30
9 Index..................................................................................................................................................... 34
3
REMKO fresh water station Controller
1 Safety and
usage instructions

1.1 General safety notes

Carefully read the operating manual before com­missioning the units for the first time. It contains useful tips and notes such as hazard warnings to prevent personal injury and material damage. Failure to follow the directions in this manual not only presents a danger to people, the environment and the system itself, but will void any claims for liability.
Keep this operating manual and the refrigerant data sheet near to the units.

Identification of notes

1.2
This section provides an overview of all important safety aspects for proper protection of people and safe and fault-free operation.The instructions and safety notes contained within this manual must be observed in order to prevent accidents, personal injury and material damage.
Notes attached directly to the units must be observed in their entirety and be kept in a fully legible condition.
Safety notes in this manual are indicated by sym­bols. Safety notes are introduced with signal words which help to highlight the magnitude of the danger in question.
DANGER!
CAUTION!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may cause injury or mate­rial and environmental damage.
NOTICE!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may cause material and environmental damage.
This symbol highlights useful tips and recom­mendations as well as information for efficient and fault-free operation.

1.3 Personnel qualifications

Personnel responsible for commissioning, opera­tion, maintenance, inspection and installation must be able to demonstrate that they hold a qualifica­tion which proves their ability to undertake the work.
Contact with live parts poses an immediate danger of death due to electric shock. Damage to the insulation or individual components may pose a danger of death.
DANGER!
This combination of symbol and signal word warns of a situation in which there is immediate danger, which if not avoided may be fatal or cause serious injury.
WARNING!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may be fatal or cause serious injury.
Dangers of failure to observe
1.4 the safety notes
Failure to observe the safety notes may pose a risk to people, the environment and the units. Failure to observe the safety notes may void any claims for damages.
In particular, failure to observe the safety notes may pose the following risks:
n The failure of important unit functions. n The failure of prescribed methods of mainte-
nance and repair.
n Danger to people on account of electrical and
mechanical effects.

1.5 Safety-conscious working

The safety notes contained in this manual, the existing national regulations concerning accident prevention as well as any internal company working, operating and safety regulations must be observed.
4
1.6 Safety instructions for the oper­ator
The operational safety of the units and compo­nents is only assured providing they are used as intended and in a fully assembled state.
n The units and components may only be set up,
installed and maintained by qualified per­sonnel.
n The existing regulations concerning accident
prevention must be adhered to.
n Do not operate units or components with
obvious defects or signs of damage.
n Contact with equipment parts or components
can lead to burns or injury.
n Ensure that electrical energy does not pose a
risk.
n Regulations of the VDE and the local energy
supply company must be adhered to.
NOTICE!
Material damage due to mineral oils!
Mineral oil products permanently damage EPDM seal elements; the sealing properties may therefore be lost. We do not take respon­sibility or provide warranty replacements for damage caused by seals that are damaged in this way.
It is essential that you prevent EPDM from
coming into contact with mineral oil sub­stances.
Use a lubricant that is free of mineral oil
and has a silicone or polyalkylene basis, such as Unisilkon L250L and Syntheso Glep 1 made by Klüber, or a silicon spray.

1.7 Safety notes for installation and inspection tasks

n The operator must ensure that all inspection
and installation work is carried out by author­ised and qualified personnel who have thor­oughly read the operating manual.
n Works on the pump/system may only be car-
ried out whilst at a standstill as a matter of prin­ciple.
n Appropriate hazard prevention measures must
be taken to prevent risks to people when per­forming installation, repair, maintenance or cleaning work on the units.
n The setup, connection and operation of the
units and its components must be undertaken in accordance with the usage and operating conditions stipulated in this manual and comply with all applicable regional regulations.
n Regional regulations and laws as well as the
Water Ecology Act must be observed.
n The power supply should be adapted to the
requirements of the units.
n The units and components must be kept at an
adequate distance from flammable, explosive, combustible, abrasive and dirty areas or atmospheres.
n Safety devices may not be modified or
bypassed.
NOTICE!
Malfunction!
The fresh water module must be integrated into the equipotential bonding system of the elec­trical installation. If this is not ensured by the pipe network, set up an approved potential equalisation connection to the main potential connection.

1.8 Unauthorised modification and changes

The operational safety of the fresh water module that was delivered is guaranteed only with intended use in accordance with section 1.8 of the operating instructions. Under no circumstances should the threshold values specified in the data­sheet be exceeded.
Modifications or changes to units and components are not permitted and may cause malfunctions. Safety devices may not be modified or bypassed. Original replacement parts and accessories authorised by the manufacturer ensure safety. The use of other parts may invalidate liability for resulting consequences.
5
REMKO fresh water station Controller

1.9 Intended use

The fresh water controller, subsequently referred to as the controller, is an independent, mounted electronic temperature controller for assembly and installation. Integration in a pump group is possible if the technical data of the controller is complied with. The maintenance-free controller is provided exclusively for controlling and monitoring a REMKO fresh water station. Use only REMKO accessories in conjunction with the controller.
Any different or additional use is a non-intended use. The manufacturer/supplier assumes no lia­bility for damages arising from a non-intended use. The user bears the sole risk in such cases. Intended use also includes working in accordance with the operating and installation instructions and complying with the maintenance requirements.
The threshold values specified in the technical data must not be exceeded.
1.10

Safety-conscious working

WARNING!
Plastic films and bags etc. are dangerous toys for children!
Why:
- Leave packaging material are not around.
- Packaging material may not be accessible to children!

1.13 Environmental protection and recycling

Disposing of packaging
All products are packed for transport in environ­mentally friendly materials. Make a valuable contri­bution to reducing waste and sustaining raw mate­rials. Only dispose of packaging at approved collection points.
The safety notes contained in this manual, the existing national regulations concerning accident prevention as well as any internal company working, operating and safety regulations must be observed.

1.11 Warranty

For warranty claims to be considered, it is essential that the ordering party or its representative com­plete and return the "certificate of warranty" to REMKO GmbH & Co. KG at the time when the units are purchased and commissioned.
The warranty conditions are detailed in the "Gen­eral business and delivery conditions". Further­more, only the parties to a contract can conclude special agreements beyond these conditions. In this case, contact your contractual partner in the first instance.
1.12 Transportation and pack­aging
The units are shipped in sturdy transport pack­aging or within the heat pump housing. Immedi­ately check the units on delivery and make a note of any damage or missing parts on the delivery note. Inform the forwarding agent and contractual partner. Claims under guarantee made at a later date will not be accepted.
Disposing of the units and their components
For the manufacture of the units and components, only recyclable materials have been used. Help protect the environment by ensuring that the units or components (for example batteries) are not dis­posed of in household waste, but only in accord­ance with local regulations and in an environmen­tally safe manner, e.g. using authorised disposal and recycling specialists or council collection points.
6

2 Technical data

2.1 Unit data

Series EFS
Inputs/outputs
Rated voltage (system voltage) V / Hz 115... 230V / 50/60 Hz
Energy consumption W
Outputs R1, R2 - number Type Switching current Voltage
L
- Switching current
const
Voltage
Total - Switching current Voltage
Signal inputs/outputs
Signal inputs 1 ... 5 - Number Type of signal inputs 1 ... 4 Type of signal input 5
Signal output RS type
Maximum contact rating
Signal outputs PWM R1, PWM R2 - type
Maximum load capacity
0.8 W, two Pt1000 temperature probes connected
2
Triac
2.0 (2.0) A
115... 230V / 50/60 Hz
2.0 (2.0) A
115... 230V / 50/60 Hz
4.2 (4.2) A
115... 230V / 50/60 Hz
5
Pt1000 (temperature detection) Bus communication for cascading
Potential-free NO contacts 1 (0) A, 24 V
PWM, 250 Hz, 11 V; Characteristics: 0 % PWM = Pump off 100 % PWM = Maximum speed 10 mA
Hydraulic variants
Number 5
Display
Type LCD with background illumination
Operating conditions
Enclosure class IP 22, DIN 40050 [without front panel: IP 20]
Protection class I
Ambient temperature °C 0 ... +50 °C for free wall mounting
7
REMKO fresh water station Controller
Unit data (continued)
Series EFS
Physical values
Dimensions L x W x H mm 110 x 160 x 51
Weight g 350
Software class A
Mode of operation Type 1.Y
Fastening method for permanently-con­nected lines
Degree of contamination 2
Temperature of the ball pressure check
Overvoltage category Class II (2500 V)
Type X
Housing walls: 125 °C Remaining housing parts: 75 °C

2.2 Cable specification

Mains cable
Mains power supply type Outer diameter of jacket Single wire cross section (rigid) finely-stranded (with wire end sleeves)
Diameter of the internal strain relief mm 6.5 to 10
Signal cable
Length of probe cable m ≤ 100 m, including extension
Extension cable for probe configuration
H05 VV-... (NYM…)
6.5 mm to 10 mm ≤ 2.5 mm ≤ 1.5 mm
Wires twisted in pairs for length > 10 m
2
2
Cross-section per conductor
0.75 mm2 for length < 50m
1.5 mm2 for length > 50 m
8
2
1
4
3
5
6
error
v
1
2
3
4
1
2
4
3
V

3 Unit construction

3.1 Housing

3.2 Display

Overview
Fig. 2: Overview over the areas of the display (all elements visible)
1 System diagram
2 Setting menu
3 Pictograms for functions
4 Operating and setting values
The areas of the display are described below.
Fig. 1: Front view of the controller
No. Element See
1 Operating mode button
(below the front panel)
2 Buttons
r, SET, ESC, s
3 Display
4 Front panel
5 Terminal cover
6 Fastening screw for the
terminal cover
1)
You can find the description of the connection
terminals under the terminal cover here.
Ä
on page 9
1)
Symbols of the system diagram
The table below describes the symbols in the system diagram (no. 1 in
Symbol Description
Pipe
External heat exchanger
Domestic hot water extraction point
Storage tank
3-way valve with flow direction specified
Pump, switched on
Pump, switched off
Temperature sensor
Medium flow rate probe
Fig. 2).
9
2
1
4
3
5
Legio
REMKO fresh water station Controller
Setting menu
The setting menu (no. 2 in Fig. 2) contains the fol­lowing entries:
Fig. 3: Setting menu
1: Time 2: Functions 3: Thermal disinfection 4: Domestic hot water target temperature 5: Reset to factory setting
Pictograms for functions
The table below describes the pictograms for func­tions (no. 3 in Fig. 2).
Symbol Description
Manual mode
Pump is controlled with speed regulation
Alarm output
Thermal disinfection
1)
The symbol is visible as long as the function/the
1)
1)
1)
parameter is being edited in the setting menu.
10
Operating and setting values
2
1
4
3
5
6
The display of the operating and setting values (no. 4 in Fig. 2) consists of the following elements:
Fig. 4: Display of operating and setting values
1 This symbol is displayed if an error occurs
2 Symbol for time control of functions. This symbol is displayed if:
• a time limit/time control is set
• the status of the time limit/time control is displayed
• the time limit blocks a temperature control (symbol flashes)
3 Number of the time window that is currently set/displayed in the setting menu or that actually
includes the current time. The time control of a functions consists of 1 or 3 time windows that can be set.
Example: Time window 1: 06:00 - 08:00 Time window 2: 11:00 - 12:30 Time window 3: 17:00 - 19:00
4 Additional information:
On, off: Switching status/switching condition on, off max, min: maximum value, minimum value Σ: cumulative operating value since initial commissioning, cannot be reset Δ: cumulative operating value since the last reset to 0
5 Display of:
• Measured values
• Set values
• Error codes
• Additional information, e.g. software version
6 Physical unit of the value displayed in no. 5: °C, l/min, %‚ h, kWh, MWh
11
2
1
3
REMKO fresh water station Controller

4 Operation

4.1 Buttons and Display

This section contains general information about operating the controller.
Buttons
Operation takes place using the r, s, SET, ESC and
r
s
SET • Selects a set value to be changed
ESC • Discards a setting
buttons as follows:
• Scrolls up in the menu
• Increases the setting value by 1 level)
• Scrolls down in the menu
• Reduces the set value by 1 level
(setting value flashes)
• Confirms a set value or moves down one menu level
• Calls the set menu (not in manual mode
• Moves up one operating level
Sets the operating mode
Display during operation
n A component flashing in the system diagram
means the following: The operating value or setting value that is displayed applies to the flashing components. Exception: It always flashes in manual mode.
n Displays that are automatically alternating are
shown overlapping in the figures. Example: Fig. 6.

4.2 Operating modes

Change operating mode
NOTICE!
Danger of damage to the pump due to dry run­ning. Switch on the manual and automatic operating modes only if the system is filled.
1. Remove the front panel.
2. Press the button for 2 seconds to
change the operating mode.
3. Repeat step 2 if required.
4. Attach the front cover.
We recommend noting changed settings in writing.
Fig. 5: Change operating mode
1: Off 2: Manual mode
3: Automatic
12
Operating mode off
Method of operation
n All outputs are switched off (outputs/control
outputs switched off, relay open)
DANGER!
The pump lines are still powered because these are constantly supplied with 230 V
n "OFF" and the software version are displayed
alternating. Example in St 1.3
n The background lighting is red n The variant display can be called (see Fig. 6)
Operation
1. Press "SET" to call the display of the pre-set
Friwa variant.
Fig. 6: Operating mode off - operation
2.
Press the "r" and " s" buttons at the same time for 2 seconds, in order to access variant selection. The pre-set REMKO factory setting is for the EFS 25 variant 02, for the EFS 35 variant 04 and for the EFS 50 variant 10.
Fig. 6: Software version
Manual operating mode
Method of operation
n The background lighting is red, the open-end
wrench symbol flashes.
n The outputs of the controller (pumps, valves)
can be switched manually. Possible switching statuses: 0: Off 1: On 0% ... 100%: Control the HE pump via PWM
(only H1, H2) A: Automatic operation in accordance with the
settings in the settings menu
n The current temperatures and operating hours
can be displayed (status display).
n The Display of the hot water temperature
shows a value that is not smoothed.
n When switching to manual operation, all out-
puts are set to A, R1 is displayed.
n Typical use: Function test (maintenance), trou-
bleshooting.
Operation
You can switch the outputs on and off as fol­lows:
1.
If necessary, press "r s" to select a dif­ferent output.
2. Press "SET". The switching status flashes.
3.
Press "r s" to change the switching status.
4. Press "SET" to apply the change.
Also see (2) in the next figure.
NOTICE!
The variant may only be changed by a spe­cialist. Otherwise, we cannot guarantee that the Controller will function correctly after changing the variant.
13
3
2
3
4
5
6
7
REMKO fresh water station Controller
You can display the current temperature and operating hours as follows:
1. Press "ESC". The temperature/operating
hours value is displayed, the corresponding component flashes ( shown).
2.
Press "r s" to select a different component.
3. Press "SET" to exit the display of the temper-
ature/operating hours value.
), the display is not
Automatic operating mode
Method of operation
Automatic operating mode is pre-set in the deliv­ered state. Automatic is the normal operating mode, the system is controlled automatically. The following actions are possible:
n Display status (status display): Display status
of external components (temperatures, switch statuses, running times)
n Display the saved minimum and maximum
values (temperature probe) or the cumulative/ difference values (operating hours1) of the pumps and valves)
Cumulative values (Σ symbol): Operating hours since initial commissioning. Cumulative values cannot be reset.
Difference values ( since the last reset to 0
n Reset the saved minimum/maximum/difference
values
n Call the setting menu
1)
Cumulative switch on times for the outputs
Δ symbol): Operating hours
Fig. 7: Manual operating mode - operation
14
5
6
7
7
7
7
6
6
6
6
Domestic hot water
target temp.

Time
SET
the time
Setting
Functions
SET
Heat content
F:01

Thermal
disinfection

Factory setting

Circulation
F:02

SET
5 Sek.
Reset to factory
setting
Distrib. valve in
return flow- F:03

Comfort
function F:04

Bypass
F:05

Follow-up
F:06

Sliding hot water
temp.
.- F:07


Thermal
disinfection F
:08
Cascade
F:09

Operation
√ The controller is in the status display.
You can display and reset the saved minimum/ maximum/difference values as follows:
1.
If necessary, press "r s" to display a dif­ferent component 4, component flashes).
2. Press "SET". The minimum/maximum/differ­ence values are displayed alternately
.
3. If necessary, press "SET" for 2 seconds to reset the value that is currently (!)
displayed
.
4. Press "ESC". The status display is displayed.
5. Repeat steps 1 to 4 if required.
You can display the status of external compo­nents as follows:
Press "r s" to display the status of a different component (4).
You can call the setting menu as follows:
Press "SET" for 2 seconds 7. The setting menu is displayed.

4.3 Setting menu

Overview
The diagram below provides an overview of the structure of the setting menu.
Fig. 8: Automatic operating mode - operation
Call the setting menu and select the menu entry
√ "Automatic" or "Off" operating mode is selected.
15
1. Press "SET" for two seconds. The setting menu is displayed, the menu entry flashes.
2.
Press "r s" to select a different menu entry.
3. Change the settings as described in the fol­lowing sections.
Func
Para
Legio
Legio
Legio
REMKO fresh water station Controller
Setting the time
√ flashes.
1. Press "SET". The hour flashes.
2.
Press "rs" to set the hour.
3. Press "SET". The minute flashes.
4.
Press "rs" to set the minute.
5. Press "SET".
6. Repeat steps 4 and 5 to set the year, month
and date.
Set functions
√ Proceed as described in
on page 16.
Set the domestic hot water target temperature
Method of operation
The controller attempts to regulate the hot water temperature to the set value. The hot water tem­perature can be changed within the following limits:
Minimum: 20 °C Maximum: 90 °C Factory setting: 50 °C
Operation
1. Press "SET". The domestic hot water target
2. Press "SET". The temperature value flashes.
3.
4. Press "SET", the change is applied.
flashes.
Ä
Chapter 4.4 ‘Functions’
flashes.
temperature is displayed, the corresponding component in the system diagram flashes (Fig. 9).
Press "r s" to change the value.
Switch on thermal disinfection
Method of operation
If required, the fresh water module provides higher domestic hot water temperatures, in order to kill dangerous germs. At the same time, the circulation pump is activated, as long as the circulation func­tion was activated. If the circulation function was not activated, only the domestic hot water target temperature is increased to the disinfection tem­perature. Thermal disinfection is started via the setting menu. After a manual start, thermal disin­fection must be stopped again manually. For safety reasons, thermal disinfection is deactivated after one hour of running time if it was started manually.
Detailed settings for thermal disinfection must be made in the corresponding
Ä
‘Thermal disinfection’ on page 22.
In cascade operation, the master controller releases both modules during the disinfection period.
Operation
√ The "Thermal disinfection (F:08)" function was activated, see the "Thermal disinfection" section. Otherwise, "---" is displayed.
1. "StArt" is displayed.
2. Press "SET". "oFF" is displayed.
3. Press "SET". "oFF" flashes.
4.
Press "rs". "on" and
5. Press "SET". The changes are applied. flashes. The controller remains in the
Legio menu until thermal disinfection is deac­tivated manually.
function (F:08), see
flashes.
flash.
Fig. 9: Set the domestic hot water target tempera­ture
Reset to factory setting
flashes, "RESEt" is displayed.
1. Press "SET" for 5 seconds.
2. After a short running display, the controller
switches to "Automatic" operating mode.

Functions

4.4
General information for operating the functions
Display functions
When displaying the functions, the following infor­mation is visible:
16
Func
n Function number, e.g. F:01 (Fig. 10) n Switching status:
- "on": Function is activated
- "off": Function is deactivated (Fig. 10)
If the function is not displayed or if neither on nor off are displayed, the function cannot be used.
Possible reasons:
The system set does not allow the function All outputs are occupied
You can display the functions as follows:
1. Press "SET". F:01 flashes.
2.
flashes.
Press "rs" to display the next function.
1. Press "SET". The function is selected and flashes.
2. Press "SET". "oFF" is displayed.
3. Press "SET". "oFF" flashes.
4.
Press "rs". "on" flashes.
5. Press "SET". The function is activated.
6. Set the key variables as described below.
Fig. 11: Activate function
Fig. 10: Display functions
Activate function
In order to be able to use a function, it must be activated (activation = "on") and its key variables must be fully set. If the function is activated and exited before all required key variables are set, "oFF" flashes for a short time (Fig. 11). The func­tion is then displayed with the switching status "oFF" (function is deactivated).
You can activate a function as follows:
√ Function number flashes.
Set key variable
The functions have a different number of key varia­bles. The value of a key variable is always set with the same operating steps.
You can set the value of a key variable as fol­lows:
√ The function was activated as described above.
1.
Press "r s" to select the key variable.
2. Press "SET". The value of the key variable and the corresponding component flash in the system diagram.
3.
Press "r s" to change the value.
4. Press "SET" to apply the change.
5. Repeat steps 1 to 4 for further key variables.
6. Press "ESC" when all key variables of the
function are set. The function number flashes.
Key variables
The following describes important key variables of the functions. The figures show examples.
17
REMKO fresh water station Controller
Temperature control
If a function is to be controlled by temperature, the temperature control must be switched on (tc = tem­perature control). In the Fig. 12, the temperature control is activated ("on").
Fig. 12: Key variable for temperature control
Clock control
If a function is to be controlled by time, the clock control must be switched on and the time window set (cc = clock control). In the Fig. 13, the clock control is activated ("on").
Fig. 14: Key variable of time window start
End time of a time window
When setting the end time of a time window, the following is displayed to the left of the end time (see Fig. 15):
n n Number of time window 1 ... 3, its end time was
set (here: 1)
n "off"
Fig. 15: Key variable of time window end
Fig. 13: Key variable of clock control
Start time of a time window
When setting the start time of a time window, the following is displayed to the left of the start time (see Fig. 14):
n n Number of time window 1 ... 3, its start time
was set (here: 1)
n "on"
The start time is always before the end time! If you attempt to set the start time to later than the end time, the end time is automatically pushed back.
18
Flow control
If a function is to be controlled by flow, the flow control must be switched on (Fc = flow control). In the Fig. 16, the flow control is activated ("on").
Fig. 16: Key variable of flow control
Function descriptions
The tables in this section describe the key variables of the functions as follows:
n The rows contain the key variables in the same sequence as they appear on the display. n The columns contain the following information from left to right:
Column Description
Display Example for the display when setting the key variables.
Speed control for the circulation pump
If a function is to be controlled by speed, the speed of the circulation pump must be set.
Fig. 17: Key variable for speed control of pump
Key variable Descriptions of the key variables and their dependencies to each other. Dependent key
variables can only be selected and set of the higher-level key variable has the value "on". This is displayed as follows:
n Higher-level key variable: Bold font n Dependent key variables: Below the higher-level key variable and indented to the
right
Example: In the table of the circulation function, the probe input, switch-on temperature and switch-off temperature key variables are only displayed if the temperature control has the value "on".
minimum, max­imum, factory setting
Heat content
Calculates the heat content determined using the following key variables:
n Hot water temperature, secondary n Cold water temperature, secondary n Medium flow rate, secondary
No further settings are required. The function can only be activated or deactivated.
The lower (minimum) and upper (maximum) limits of the value range of a key variable, as well as the factory setting. If a value range only contains a few values, these are specified individually. Example: "on", "oFF".
Fig. 18: Calculating heat content
Measured value display: The measured values are displayed in the status menu. The current per­formance and the daily heat content are displayed after the fresh water values.
19
REMKO fresh water station Controller
Current thermal performance: The corresponding maximum value is displayed when "SET" is pressed.
Fig. 19: Current thermal performance, maximum value
Daily heat content: When "SET" is pressed, the total heat content and the daily heat content are displayed alternately.
n Permanently switched on if the temperature
control is deactivated ("oFF")
n Controlled by temperature if the temperature
control is activated ("on")
Flow control: Flowing for a short time (<5s) switches the circulation pump on for the duration of activation. After the duration of activation expires, the circulation pump remains switched off at least for the duration of the waiting time. The flow con­trol works independent of the clock control.
Key variable min. max.
Activation on, oFF oFF
Speed regulation
Temperature control (tc)
Activation temperature T
Deactivation temperature T
0% 100% 40%
on, oFF oFF
T
on
off
0 °C
Ton+2 K
-2 K
off
95 °C 35 °C
Factory
setting
30 °C
Fig. 20: Display of total heat content and daily heat content
In cascade operation, each controller displays its "own" calculated heat content.
Key variable min. max. Factory setting
Activation on, oFF on
Circulation
Switches a circulation pump that is controlled by temperature, clock and/or flow on and off. The three control modes can be combined in any way.
Temperature control: If the temperature on the circulation return falls below the Ton value, the cir-
culation pump is switched on until the temperature reaches the T
time-limited if the clock control is activated. Clock control: If the current time is within one of 3
time windows that can be set, the circulation pump is:
value. The temperature control is
off
Clock control
(cc)
Day day: 1 to day: 7 -
Time window 1 start/end
Time window 2 start/end
Time window 3 start/end
Flow control
(fc)
Duration of acti­vation
Waiting time 0 min 60 min 10 min
Distribution valve in return flow
Switches the distribution valve in the return flow on. The cold water probe is pre-defined at output R2.
No further settings are required. The function can only be activated or deactivated. R2 on if TKW ≥ R2 off if TKW ≤ 23 °C
28 °C
on, oFF oFF
0:00 23:59 6:00/8:00
0:00 23:59 12:00/13:30
0:00 23:59 18:00/20:00
on, oFF oFF
1 min 10 min 2 min
20
Fig. 21: Distribution valve in return flow
In cascade operation, this function may only be activated for the master controller. This func­tion is blocked in the slave controller. The slave controller sends its cold water temperature to the master controller. If both stations are active, the higher cold water temperature is used as the switching value.
Key variable min. max. Factory setting
Measured value display: The measured values are displayed in the status menu. The temperature of the cold water probe and the operating hours of the distribution valve are displayed after the fresh water values.
Temperature of the cold water probe: The corre­sponding minimum/maximum value is displayed when "SET" is pressed.
Fig. 22: Display of minimum/maximum value
Operating hours of the distribution valve: When "SET" is pressed, the delta value and the cumula­tive value of the operating hours are displayed alternately.
Activation on, oFF oFF
Sliding hot water temperature
Adjusts the domestic hot water target temperature to the temperature level of the buffer tank for pre­heating systems that are discharged from the Buffer tank without re-heating (Tww target = TVL - 5 K).
This function works according to fixed parameters. No further settings are required. If this function is active in operation, this is symbolised by a flashing temperature.
The function can only be activated or deactivated.
Fig. 24: Sliding hot water temperature
In cascading operation, this function is recom­mended only in exceptional cases because high temperature fluctuations occur at the dis­pensing connection when switching the mod­ules. If the function is selected despite this, it must be activated in the master and slave con­trollers. The function works independently in each of the controllers.
Fig. 23: Display of the delta value and the cumula­tive value of the operating hours
21
Key variable min. max. Factory setting
Activation on, oFF on
REMKO fresh water station Controller
Thermal disinfection
The fresh water station provides higher domestic hot water temperatures, in order to kill dangerous germs. At the same time, the circulation pump is activated, as long as the circulation function was activated. If the circulation function was not acti­vated, only the domestic hot water target tempera­ture in the defined time window is increased to the disinfection temperature.
Fig. 26: Cascade
The cascade function must be activated in both controllers; one controller must be configured as the master (MA) and the other as the slave (SL).
The master controller forwards the following infor­mation to the slave:
n "Switch on" command n "Switch off" command
Fig. 25: Thermal disinfection
Only one time window per day is available for thermal disinfection.
Key variable min. max.
Activation on, oFF oFF
Disinfection temperature
Clock control on, oFF on
Day day: 1 to day: 7 -
Time window 0:00 23:59 01:00/02:00
Cascade
Controls cascade operation of two fresh water sta­tions.
Both controllers are connected to each other via a communications bus. The connecting line is con­nected to both controllers at connections 5, ^. If the minimum cross-section is 0.25 mm2, the length of the bus connection must not exceed 3 m. 2-way valves must be integrated into the cold water pipe and connected to R1. The circulation pump must be plugged into a combined circulation phase pro­vided by the customer ahead of the two modules. Use only original REMKO accessories.
60 °C 80 °C 73 °C
Factory
setting
n Domestic hot water target temperature n Date and time
Key variable min. max. Factory setting
Activation on, oFF oFF
Master / Slave
Alarm output
Controls the set output for the following errors:
n Probe errors due to a short circuit or an inter-
ruption
n Medium flow rate errors: Er:1 n Electronic overload check/fuse has been trig-
gered: Er:2 ... Er:5
1)
more information in
shooting and customer service’ on page 30
The alarm output is always active
NOTICE!
The signal output RS may only be operated with low voltage up to 24 V and limited power.
MA, SL MA
1)
1)
Ä
Chapter 8 ‘Trouble-
22
1
22
1
3
5
4

4.5 Information messages

Display Description
The sliding domestic hot water tem-
Flashes
perature is active.
5 Assembly and
dismantling
NOTICE!
The following section only describes the instal­lation of the controller. When installing external components (valves etc.), follow the instruc­tions provided by the relevant manufacturer.
Opening/closing the housing
Remove the front panel
n Grasp the front panel
the side 2 and pull it forwards 3 (Fig. 27).
by the grip grooves on
Fig. 27: Remove the front panel
1: Front panel 2: Grip grooves 3: Pull front panel forwards 4: Screw 5: Terminal cover
Attach the front cover
n Position the front panel 1 carefully and press it
onto the housing so that it clicks into place.
23
5
1
2
2
1
2
REMKO fresh water station Controller
Remove the terminal cover
DANGER!
Danger of death due to electric shock!
Disconnect the controller from the power
supply before removing the terminal cover.
Ensure that the power supply to the open
unit cannot be switched on inadvertently.
n Loosen the screw 4 (Fig. 27). n Remove the terminal cover
.
Attach the terminal cover
n Position the cover 5. n Tighten the screw 4 with a torque of 0.5 Nm.
Mount the housing
The controller is firmly fitted. This section should be consulted only in service situations (changing the controller).
√ The mounting location fulfils the required usage conditions; for more information, see .
√ The mounting surface is vertical and enables free mounting in an easily-accessible position.
1. If required, remove the terminal cover.
2. Screw in the screw for the top mounting
opening
(Fig. 28) so that the screw head has a distance of 5 ... 7 mm to the mounting surface.
3. Hook the controller on to the screw at the top mounting opening and align it vertically.
4.
Mark the bottom mounting opening through the controller housing.
5. Remove the controller and prepare the mounting hole for the bottom screw.
6. Hook the controller to the top mounting opening 1 and fix it through the bottom mounting opening 2 with the screw.
7. Attach the terminal cover.
DANGER!
Danger of death due to electric shock!
Before opening the housing, disconnect the
controller from the power supply.
Ensure that the power supply cannot be
switched on inadvertently when the housing is open.
Do not use the housing as a drilling tem-
plate.
Fig. 28: Rear of the controller with the mounting openings at the top 1 and bottom
24
Dismantling
DANGER!
Danger of death due to electric shock!
Before opening the housing, disconnect the
unit from the power supply.
All work on the open unit may only be car-
ried out by a specialist.
1. Dismantle the controller in the opposite sequence to that used for installation; for more information, see 5 ‘Assembly and dismantling’ on page 23.
2. Dispose of the electrical and electronic com­ponents of the system in accordance with the guidelines for old electrical and electronic equipment. If you have any queries, contact the local authorities responsible.
Ä
Chapter

6 Electrical wiring

Set up electrical wiring
DANGER!
Danger of death due to electric shock!
Ensure that the following conditions are met when carrying out the works described in this section:
During installation, all cables to the con-
troller must be disconnected from the mains and cannot be inadvertently con­nected to the mains!
The earth conductors (PE) from the power
supply, pump cables and valve cables are connected to the terminal block earth con­ductors.
All cables are located so that people
cannot step on them or trip over them.
The cables fulfil the requirements specified
in .
The local power supply matches the data
on the name plate of the controller.
The power supply cable is to be connected
to the mains as follows:
- with a plug to a wall socket or
- via an isolating device for full isolation in fixed locations
The power supply cable is located
according to the legal and local regulations of the responsible electricity supply com­pany.
NOTICE!
Danger of damage and malfunction.
Only connect components that do not over-
load the inputs and outputs of the con­troller; for more information, see the name plate and .
NOTICE!
The polarity of signal inputs/outputs 1-4
and RS is not fixed during connection.
Only temperature probes of the type
Pt1000 are permitted.
Probe cables must be located at least 100
mm away from power supply cables.
Use shielded probe cables if inductive
sources are present, e.g. high-voltage cables, radio transmitters, microwave units.
25
R3
E1
E2
1
2
3
4
5
6
7
8
REMKO fresh water station Controller
Position of the connection terminals
Fig. 29: Connection terminals in the lower part of the controller (terminal cover removed)
Terminal block power supplies:
L 1x phase conductor (power input)
R1, Output (TRIAC, for pumps or valves)
R2 Switch contact REMKO RES valve (black)
R3 Output (relay, for pumps or valves)
L
const.
N 4x neutral (combined neutral, REMKO RES valve (blue)
NOTE: Outputs R1 and R2 are protected by an electronic fuse.
Terminal block earth conductor:
PE 4x safety earth (combined safety earth for terminal block power supplies)
Terminal block signals:
1-4 4x probe input (temperature probe Pt1000)
5 1x communication connection for cascading
R
S
PWM R1 2x control outputs (control for high-efficiency pumps)
PWM R2 Connection: PWM = brown, ^ = blue
^
2x phase conductors, live phase REMKO RES valve (brown)
1x signal output (potential-free relay contact for protective low voltages)
7x ground (combined ground for probe inputs and communication connections, as well as control outputs)
Multi-pin connector, only for internal use, 2 x input for REMKO FlowSonic (white)
Cable openings on the back of the housing
Top strain reliefs (2 identical plastic bridges, each with 2 strain reliefs; included in the delivery)
Bottom strain reliefs
Cable openings on the underside of the housing
26
5
1
1
4
Preparing the cable openings
The cables can be fed through openings on the back of the housing or the underside of the housing. The openings are pre-cut and must be prepared as required before mounting.
You can prepare the cable openings on the back of the housing as follows:
1.
Break the cable openings
(Fig. 29)
through using a suitable tool.
2. Deburr the edges
You can prepare the cable openings on the underside of the housing as follows:
1.
Cut the required cable openings 8 (Fig. 29) out left and right with a suitable knife and break them through.
2. Deburr the edges.
Connect the electric cables
√ All cables are de-energised. √ The cable openings are prepared. Connect the cables whilst observing the following
points:
n Assign cables to the connection terminals as
Ä
described in the following section
‘Terminal
assignment’ on page 28.
n Power input and outputs: First connect PE and
then N and L.
n Strain reliefs:
- First insert the strain reliefs at the bottom and then the strain reliefs at the top.
- When using a strain relief at the top, use the plastic bridge as described below.
- If the opening of a strain relief is too large, e.g. for thin cables, turn the strain relief frame (bend it downwards).
- Only use strain reliefs with cabling through the underside of the housing. For cabling through the back of the housing, use external strain reliefs.
Insert or remove plastic bridges
You can insert the plastic bridges as follows:
1. Insert the right plastic bridge first using the
locking catch
(Fig. 30).
2. Press the other side of the plastic bridge down 2 until the clip clicks into place.
3. Insert the left plastic bridge in the opposite manner (locking catch left, clip right).
Fig. 30: Inserting the right plastic bridge
You can remove the plastic bridges as follows:
1.
Insert a screwdriver 2 on the right plastic bridge between the housing and the clip (Fig. 31).
2.
Carefully push the screwdriver to the left 3. In this way, raise the clip 1 to the right until the plastic bridge
is free.
3. Pull the plastic bridge upwards using your free hand 5.
4. Remove the left plastic bridge in the same way.
Fig. 31: Removing the right plastic bridge
27
E.1
E.11
4
R2 R1
L
const.
PWM (R)2
L
const.
PWM (R)1
REMKO fresh water station Controller
Terminal assignment
The following tables and circuit diagrams describe assignment of the external components (pumps, probes) to the controller terminals of the corre­sponding Friwa variant.
Inputs
Ter­minal
Individual operation / cascade oper­ation
1, ^ Inlet temperature, primary (TVL)
2, ^ ---
3, ^ ---
4, ^ Cold water temperature, secondary
(TKW)
E.1, T Hot water temperature, secondary
E.1, V Medium flow rate, secondary
Outputs
Fig. 32: The active R1 valve is not displayed in the controller display.
Ter­minal
Individual opera­tion
Cascade opera­tion
R1, N --- Switching valve
Return valve (optional, on master controller)
R2, N
Return valve (optional)
R3, N --- ---
Primary pump, secondary pump (circulation, on master controller)
Secondary pump (circulation, on master controller)
L
const
PWM R1, ^
PWM R2, ^
Primary pump,
, N
secondary pump (circulation)
Primary pump Primary pump
Secondary pump (circulation)
Rs, Rs Alarm Alarm
28
T

7 Commissioning

DANGER!
Danger of death due to electric shock!
Before initial commissioning, carry out all of the tasks described in
dismantling’ on page 23 and 6 ‘Electrical wiring’ on page 25 completely.
After the unit has been disconnected from
the mains for a long time, the date and time must be set again when switching on (see steps 1-5 below).
Saved functions that are not connected to
a time setting remain set even after an extended power failure (> 15 minutes).
The controller is pre-set when it is manufac­tured. You only have to set the date and time (Fig. 33
).
Ä
Chapter 5 ‘Assembly and
Ä
Chapter
You can bring the controller into operation as follows:
1. Set up the power supply to the controller.
- The time 12:00 is displayed.
- 12 flashes (Fig. 34
2.
Press "sr" to set the hour.
3. Press "SET". The minute flashes.
4.
Press "sr" to set the minutes.
5. Press "SET".
6. Repeat steps 4 and 5 to set the year, month
and date.
Fig. 34: Setting the time
)
Fig. 33: Setting the time
T: Time
For information about operation, refer to Values can be changed retroactively within con-
trolled operation. The following applies:
n "s/ESC/r" navigates forwards and backwards
block by block (Fig. 33: "s" = forwards; "ESC/r" = backwards).
n Navigating (with "s/ESC/r") is always pos-
sible after completing a block.
n Retroactive changes to a block are initiated
using "SET".
29
REMKO fresh water station Controller
8 Troubleshooting and
customer service
Error elimination
DANGER!
Danger of death due to electric shock!
Disconnect the unit from the power supply
immediately if safe operation can no longer be guaranteed, e.g. if there is visible damage.
Disconnect the unit from the power supply
before opening the housing.
All works on the open unit may only be car-
ried out by a specialist.
The controller is a quality product and was designed for many years of continuous use. Therefore, note the following points:
The cause of an error is often not the con-
troller but one of the connected compo­nents.
The following notes for identifying errors
refer to the most common causes of errors.
Do not send the controller in until you are
sure that none of the causes of errors described here apply.
General errors
The unit and components are manufactured using state-of-the-art production methods and tested several times to verify their correct function. How­ever, if alarms should occur, please check the functions as detailed in the list below. For systems with an indoor unit and outdoor unit, refer to the chapter "Troubleshooting and customer service" in both operating manuals. Please inform your dealer if the unit is still not working correctly after all func­tion checks have been performed!
30
Error description Cause Remedial measures
The controller does not function
The display is blank or dark The power supply to the controller
is interrupted
The controller continually displays 12:00
"12" flashes The power supply to the controller
was interrupted for more than 15 minutes
The primary pump does not run even though domestic water is being dispensed
The pump symbol rotates The power supply or control signal
to the pump is interrupted
The pump is stuck Unblock the pump, replace it if nec-
The pump symbol does not rotate
n The pump symbol does not
rotate
n The display is red n Flashes
The domestic hot water maximum temperature is temporarily exceeded
Manual operation is switched on, output R1 is set to 0 (off)
n Check the power supply to the
controller
n Check the power supply's fuse
Set the time; saved functions that are not connected to a time setting remain set even after an extended power failure. The circulation (if the time window "cc" was activated") and thermal disinfection functions are inactive
Check the mains power and control line to the pump
essary
This is not an error
Switch on automatic operating mode
n The pump symbol does not
rotate
n The display is red
The primary pump runs even though no domestic water is being dispensed
The pump symbol rotates
n The pump symbol rotates n The display is red n is displayed
The primary pump is running, domestic water is being dispensed, heat is not transported to the heat exchanger
The pump symbol rotates There is air in the primary circuit Check the primary circuit for air
A short circuit or an interruption for the temperature probe
n The comfort function is active n Thermal disinfection is active n Circulation is active n The probe identifies dispensing n The pump runs due to blocking
protection
Manual operation is switched on, output H1 is set to > 10%
Shut-off valve closed Check the shut-off valve
The heat exchanger is dirty or scaled
n Query the current value of the
connected temperature probe on the controller
n Check the probes and cables
n This is not necessarily an error n Deactivate the functions if nec-
essary
n Probe error E.1 (continual dis-
play of a flow)
Switch on automatic operating mode
Flush/clean the heat exchanger according to the manufacturer's instructions.
31
REMKO fresh water station Controller
Error messages
Errors are displayed as shown below, the background lighting is red. The figures in this section show system examples.
Display (example) Description Solution
An interruption was detected on the probe input displayed (here: probe input 4).
A short circuit was detected on the probe input displayed (here: probe input 4).
The domestic hot water target tempera­ture was not reached. Possible causes:
n The storage tank not heated n The shut-off valve in the primary cir-
cuit is closed.
n There is air in the pipes n The primary pump is defective n The heat exchanger is scaled
A short circuit occurred at output R1. Pos­sible causes:
n The valve is defective n There is a wiring fault
Check the cables and probes connected to the probe input.
Check the cables and probes connected to the probe input.
n Heat up the storage tank n Check the shut-off valve n Bleed the system n Check the pump n De-scale the heat exchanger
n Check the valve n Check the wiring of R1
Output R1 was overloaded. Cause: The values permitted for R1
according to the name plate were exceeded continuously, the output was switched off.
A short circuit occurred at output R2. Possible causes:
n The valve is defective n There is a wiring fault
Output R2 was overloaded. Cause: The values permitted for R1 according to the name plate were exceeded continuously, the output was switched off.
In cascade operation, no communication between master and slave controller took place for a minimum of 1 min.
Possible causes:
n - Cascade functions inadvertently
activated
n - Master (MA) or Slave (SL) is set at
both controllers
Check the electrical data of the valve, replace the valve if necessary. R1 is switched back on automatically.
n Check the valve n Check the wiring of R2
Check the electrical data of the valve, replace the valve if necessary. R2 is switched back on automatically.
n Automatic fault correction after suc-
cessful communication
n Deactivate cascade function n Check the master/slave settings
32
Error on the probe
An error on a probe only affects the functions that use the probe. The controller can no longer execute the affected function correctly and stops controlling this function. All other functions of the controller continue to work properly.
Error on the probe Terminal Effect on control
Inlet temperature, primary (TVL) 1, ^ The controller takes 75 °C as the preliminary
value so that regulation can continue to be carried out.
Hot water temperature, secondary (TWW) 2, ^ The controller uses the temperature value of
the E.1 and T probes for regulation.
Source temperature, primary (TQ) 3, ^ The source temperature has no effect on reg-
ulation.
Cold water temperature, secondary (TKW) 4, ^ The cold water temperature has no effect on
regulation
Hot water temperature, secondary E.1, T FriwaMini Basic and Premium: Regulation
stops. FriwaMidi, FriwaMaxi, FriwaMega: The hot water temperature at terminals 2, ^ is used for regulation. An error on E.1, T has no long-term effect on regulation.
Medium flow rate, secondary E.1, V‘ Regulation stops.
Check the temperature probe Pt1000
DANGER!
Danger of death due to electric shock!
Before opening the unit, ensure that all cables that lead to the unit are disconnected from the mains and cannot be inadvertently connected to the mains!
1. Remove the terminal cover.
2. Disconnect the temperature probe.
3. Measure the resistance of the temperature probe with an ohmmeter and compare them with the table
below. Slight variations are permitted.
4. Attach the terminal cover.
Correlation between temperature and resistance
Temperature [°C]
-30 -20 -10 0 10 20 30 40 50 60 70
Resistance [Ω] 882 922 961 1000 1039 1078 1117 1155 1194 1232 1271
Temperature [°C]
Resistance [Ω] 1309 1347 1385 1423 1461 1498 1536 1573 1611 1648 1685
33
80 90 100 110 120 130 140 150 160 170 180
REMKO fresh water station Controller

9 Index

A
Activate function ........................17
Alarms
Checks .............................30
Possible causes ......................30
Remedial measures ...................30
C
Cable specification .......................8
Call the setting menu ....................15
Commissioning, setting the time ............29
Customer service .......................30
D
Dismantling the controller .................25
Display functions ........................16
Display, overview ........................9
E
Environmental protection ...................6
Error
Elimination ..........................30
General ............................30
Messages ...........................32
on the probe .........................33
Temperature sensor ...................33
F
Functions .............................16
I
Intended use ............................6
K
Key variable
Clock control ........................18
End time of a time window ..............18
Examples ...........................17
Flow control .........................19
Set ................................17
Speed control for the circulation pump .....19
Start time of a time window .............18
Temperature control ...................18
Operating mode
Automatic ...........................14
Change ............................12
Manual mode ........................13
Off ................................13
P
Packaging, disposal ......................6
Pictograms for functions ..................10
R
Recycling ..............................6
Reset to factory setting ...................16
S
Safety
Dangers of failure to observe the safety
notes ...............................4
General .............................4
Identification of notes ...................4
Instructions for the operator ..............5
Note for inspection work .................5
Note for installation work ................5
Personnel qualifications .................4
Safety-conscious working ..............4, 6
Unauthorised modification ...............5
Unauthorised replacement part manufacture
Set functions ...........................16
Set the domestic hot water target temperature . 16
Setting menu ...........................10
Setting menu - overview ..................15
Setting the time ......................16, 29
Switch on thermal disinfection ..............16
Symbols of the system diagram .............9
. 5
T
Troubleshooting and customer service .......30
U
Unit data ...............................7
Unit disposal ............................6
W
Warranty ...............................6
O
Opening and closing the housing ...........23
34
Consulting
Thanks to intensive training, our consultants are always completely up-to-date in terms of technical knowledge. This has given us the reputation of being more than just an excellent, reliable supplier: REMKO, a partner helping you find solutions to your problems.
Distribution
REMKO offers not just a well established sales network both nationally and internationally, but also has exceptionally highly­qualified sales specialists. REMKO field staff are more than just sales representatives: above all, they must act as advisers to our customers in air conditioning and heating technology.
SFlbCustomer Service
Our equipment operates precisely and reliably. However, in the event of a fault, REMKO customer service is quickly at the scene. Our comprehensive network of experienced dealers always guarantees quick and reliable service.
REMKO INTERNATIONAL
… and also right in your neighbourhood! Make use of our experience and advice
We reserve the right to make technical changes, and provide no guarantee as to the accuracy of this data!
REMKO GmbH & Co. KG Air conditioning and heating technology
Im Seelenkamp 12 D-32791 Lage Postfach 1827 D-32777 Lage Telephone +49 5232 6 06-0 Telefax +49 52 32 606-2 60 E-mail info@remko.de Website www.remko.de
Loading...