REMKO EWS300 User Manual

REMKO
TANK SYSTEMS

Tank for process hot water
EWS 300

Operation · Technology

Edition GB - W12

Contents

Safety notes

Environmental protection and recycling

Warranty

Intended use

Description

Operation

Decommissioning

Care and maintenance

Installation instructions for qualified personnel

Installation

Electrical connection

Before commissioning

Commissioning

4

5

5

5

5-6

6

6

6-7

8-9

10-13

14

14

15

Unit dimensions

Technical data

Read these operating instructions carefully
before commissioning / using the device!

These instructions are an integral part of the unit and must
always be kept in the vicinity of the installation location or
on the unit itself.

This operating manual is a translation of the German original.

Subject to modifications; no liability accepted for errors or
misprints!

16

17

3

REMKO EWS 300

Safety notes

Carefully read the operating manual
before placing the unit in service for
the first time. It contains useful tips
and notes ! such as hazard warnings
to prevent injury and material damage.
Failure to follow the directions in this
manual can result in endangerment
to persons, the environment and
the equipment itself and will void any
claims for liability.

■ Keep this manual in the vicinity of the

units.

■ The units and components should be

set up and installed only by qualified
personnel.

■ The set-up, connection, and operation

of the unit and its components must
be in accordance with the operating
conditions stipulated in this manual
and comply with all applicable local
regulations.

■ Modification of units and components

supplied by REMKO is not permitted
and can cause malfunctions.

■ Units and components may not be

operated in areas where there is an
increased risk of damage. Observe
the minimum clearances.

■ The electrical supply is to be adapted

to the requirements of the units.

■ The operational safety of units and

components is only assured if they are
fully assembled and used as intended.
Safety devices may not be modified
or bypassed.

■ Do not operate units or components

with obvious defects or signs of
damage.

■ The units and components must

be kept an adequate distance from
flammable, explosive, combustible,
abrasive and dirty areas or
atmospheres.

■ Installation, repair and maintenance

work may be carried out only
by authorised specialists. Visual
inspections and cleaning can be
performed by the operator as long
as power is disconnected from
the equipment.

■ To preclude any danger from the unit,

take appropriate hazard-prevention
measures when performing
installation, repair or maintenance
work or cleaning the units.

4

Environmental
protection and recycling

Intended use

Disposing of packaging

All products are packed for transport
in environmentally friendly materials.
You can make a valuable contribution
to reducing waste and sustaining raw
materials by only disposing of packaging
at approved collection points.

Disposal of
components

The manufacturing process for the units
is subject to continuous quality control.
Only high-grade materials are processed,
the majority of which are recyclable.
You can also contribute to environmental
protection by only disposing of
components in accordance with local
regulations and in an environmentally
safe manner, e.g. through authorised
disposal and recycling specialists or at
collection points.

Warranty

The warranty conditions are listed in
the "General terms and conditions".
Please contact your contractual partner in
the first instance.

The tanks are used for the storage of hot water.
Any different or additional use shall be classed
as non-intended use. The manufacturer/
supplier assumes no liability for damages arising
from such use. The user bears the sole risk in
such cases.
Intended use also includes working
in accordance with the operating
manual and installation instructions
and complying with the maintenance
requirements.

Description

The tanks are used for the storage of hot
water.
The tank volume can be adapted to your
particular needs by connecting several
tanks to form batteries.
The tank is enamelled and has a double­wound, smooth-pipe heat exchanger
with an especially large heat exchanger
surface area of 3.5m2.
In the inside tank a magnesium false
anode is installed in accordance with
DIN 4753.
The insulation of the hot water storage
tank EWS 300 is comprised of a 50 mm
thick PUR insulation (CFC, HCFC and
HFC free).
The tank is encased in a foil casing
(delivered separately for transport
protection).
A blank flange cover D180 is installed
for the retrofitting of a finned tube heat
exchanger or flange heating cartridge
(legionella protection).

5

REMKO EWS 300

The tank has connections for circulation
(3/4" IG) as well as a cold water supply
and hot water outlet (1" IG).

Operation

Manual operation is not necessary.

Decommissioning

Temporary shutdown

1. Disconnect all poles of the electrical
connection of the flange heating
cartridge if applicable.

2. Drain the tank in areas where it is at
risk from frost and before the
onset of winter.

3. After closing the shut-off valve in the
cold water supply, the water is
drained through the drain valve
of the safety combination while all
the hot water valves of the service
water fixtures are open.
Partial emptying is also possible
through the safety valve in the
expansion water funnel
(drip catcher). For this purpose
the safety valve is turned to the
"Test" position.

! ATTENTION

When placing the tank back into
service, ensure that it is filled with
water and that water which is free
of bubbles is escaping from the
valves!

Permanent decommissioning

Ensure that equipment and components
are disposed of in accordance with local
regulations, e.g. through authorised
disposal and recycling specialists or at
collection points.

REMKO GmbH & Co. KG or your
contractual partner will be pleased to
provide a list of certified firms near you.

Care and maintenance

Care

■

Only clean the units with a
damp cloth
(adding, for instance, a liquid
household cleaner.)
Do not use any harsh, scouring
or solvent-based cleaners.

Maintenance

! ATTENTION

When emptying the tank, hot
water may escape!

6

■

We recommend concluding a
maintenance contract with a
specialist firm, which includes annual
maintenance services.

NOTE

This ensures the operational reli­ability of your equipment!

■

Regularly check the function of

the safety valve.

The expansion water amount at
maximum heat (approx. 80°C) represents
approx. 3.5% of the tank capacity.
When the safety valve test knob is
lifted or turned to the “Test” position,
the water must flow unhindered out of
the safety valve body into the drainage
funnel.

! ATTENTION

This can cause the cold water sup­ply and parts of the storage tank
connection fitting to become hot!

If the tank is not heated or when warm
water is removed, no water should be
dripping from the safety valve. If this
does occur, either the pressure in the
water pipe is greater than the permitted
value, or the safety valve is defective.
If the pressure in the water pipe is higher
than permitted, a pressure relief valve
must be used.

In hard water areas, the limescale which
forms in the tank internal boiler and
the floating deposits of limescale must
be removed by a specialist after one
to two years of operation. Cleaning is
performed through the flange opening.

1.. Remove the heating flange.

2. Clean the tank.

3. Refit the flange, using a new seal.
Tighten the bolts in a crosswise
pattern to a torque of 20 Nm.

The special enamelled inner tank of
the water heater must not come into
contact with scaling solvent.
Do not use a descaling pump!

4. Thoroughly rinse out the unit.

5. Observe the heating process as per
initial operation.

The installed false anode must be
checked by a specialist at least once
every 2 years of operation and this
inspection must be documented.
If servicing tasks are performed, the
cleaning and servicing flange should be
opened, and the tank inspected for any
infiltration or soiling.

Only with the use of an external current
anode: The control lamp of the external
current anode must be monitored
regularly.
In the process, the following applies:
green = system OK
red flashing = malfunction (in this case
contact customer service).
For a faultless function, the tank must be
filled with water.

7

REMKO EWS 300

Installation instructions
for qualified personnel

General instructions prior to installation

■

Ensure that the area in which the
unit is to be operated is free of frost
and easily accessible for required
maintenance, repairs and even
for the possible replacement of
the unit (e.g. avoid overly narrow
thoroughfares and doorways).

■

When installing the tank in unusual
locations, such as in lofts, residential
units with floors that are sensitive
to water, storerooms, etc. take
account of the possibility of leaking
water, and ensure that a facility is in
place to catch the water, including
appropriate drainage methods.

■

The unit may only be positioned and
operated on level surfaces.

■

When planning the unit's installation
surface and selecting the installation
location, note the total weight of
the tank, including the weight of
the water (the nominal capacity),
in order to ensure that the statics
of the load-bearing surface are not
exceeded.

■

Ensure proper clearance from firing
systems.

■

Make sure that units with enclosures,

which are installed in small, tight

spaces or in suspended ceilings

have the connection block (water

and electric connections and heater

installation) still freely accessible and

that there us no buildup of heat.

■

Leave at least 500mm of space

free for the removal of the heating

flange.

Installation

NOTE

Installation may only be performed
by authorised specialists.
Preparation of the hot water must
be in compliance with the applica­ble standards.

■

Check the contents of the packaging
for completeness and check the
unit for visible transport damage.
Immediately notify your contractual
partner of any deficiencies.

■

In the selection and/or sequence
of the installation materials
used for the plant, any possible
electrochemical processes must
be taken into consideration in
accordance with the recognised good
practices (mixing installations!).

8

The potential equalisation of the piping
must take place in accordance with DIN

50927.
This type of corrosion results in
the formation of corrosion cells.
Voltage is present in corrosion cells
between the anode and cathode area.
The processes are dependent on one
another, however, their separation from
one another can vary greatly.
Corrosion cells can appear as a result
of different potentials, as the case is with
contact corrosion. Different metals are
in conductive contact with one another
through an ion-conducting medium
(water).
All metal plug-in (built-in) components
with large metal surfaces (e.g. condenser
plug-in heat pumps, fin-tube heat
exchangers, electric heaters) must be
electrically insulated from the tank.
For the protection of the above­mentioned plug-in (built-in) components
against the current-induced corrosion,
we recommend installing a defined
contact resistance of approx. 600 Ohm
(insofar as it has not already been
installed in the components at the
factory).

■

When installing a fin-tube heat
exchanger it must be absolutely
ensured that the corrosion protection
in the tank remains intact. Therefore,
an appropriate external current
anode or magnesium anode must be
installed if the magnesium anode is
removed with the flange plate from
the tank.

■

The hot water tanks may not be
transported with the fin-tube heat
exchanger installed.

■

The unit must be assembled on site.

■

For all connecting sockets, ensure
that the thread is fully engaged.

9

REMKO EWS 300

Installation

General Information

■

If aggressive water is an issue, please
note that special models of the tank
can be tested (address all queries to
your contractual partner)

■

In hard water areas, connect a
standard descaling device upstream
of the tank.

■

Drinking water quality is required
for the proper operation of the hot
water tank.

Operating units with electric
flange heating cartridges

If such units are equipped with a safety
temperature limiter which stops heating
the storage tank at a temperature of
max. 130°C. The choice of connection
components (connecting pieces,
circulation, safety valve combination,
etc.) must be such that, in the event
of a malfunction of the temperature
control, the connection components
will maintain temperatures of 130°C,
avoiding possible damage.

Water-side connection
(pressure-tight)

The hot water heaters are pressure­tight tanks for which pressure-tight
connections can be made.
If the line pressure is higher, a customer­provided pressure reducing valve must
be installed in the cold water supply.
Only pressure-tight fittings may be used.

The component-tested safety equipment
must be installed in the cold water line
(see the diagram on the following page).

A type-examination tested safety group
in accordance with DIN 1988 must be
installed in the water connection of the
cold water line (cold water supply) for
closed hot water heaters.

The water connection may only take
place through a tested diaphragm safety
valve or a diaphragm safety valve/
connection fitting combination (not a
piston valve) for pressure-tight tanks!
A safety valve combination is comprised
of a shut-off, testing, return, drain and
safety valve with expansion water drain
and is installed between the cold water
supply and cold water feed of the tank
in the sequence shown on the following
page:

10

Tank connection according to DIN 1988

Tank

Consumers

In order to ensure the faultless function
of the connection fitting, it may only
be installed in frost-protected rooms.
The discharge of the safety valve must
open and observable and the discharge
line from the drip catcher (expansion
water funnel) must be routed to the
sewer so that neither frost nor back-ups
from dirt or the like can cause a fault.

There may not be a shut-off valve or
any other type of flow restrictor installed
between the safety valve and the cold
water feed of the tank.
The safety valve must be set to a
triggering pressure which is below
the nominal pressure of the tank.

Drain valve

Safety

valve

Testing valve

Backflow

preventer

After the conclusive connection of
the tank, the cold water supply line must
be rinsed out.

After the water connection is made and
the bubble-free filling of the tank takes
place, the connected fitting must be
tested for function.
When lifting or turning (venting)
the safety valve test knob, the water
must be able to flow out properly
without being hindered by the expansion
tank drain funnel.
In order to check the return flow valve
the shut-off valve is closed and no water
may flow out of the open testing valve.
The testing of the safety valve must take
place in accordance with DIN 1988-8.

Pressure reducing valve

Shut-off valve

If applicable:

11

REMKO EWS 300

The operation of the tank takes
place through the hot water valve of
the service water fixture (mixing tap).
Therefore, the tank is under continuous
line pressure. In order to protect
the inner tank against excessive pressure
when heating up, the accumulating
expansion water is discharged through
the safety valve.

The return flow valve prevents the return
flow of the hot water into the cold
water network during a pressure drop in
the line and thereby protects the boiler
from heating up without water.

With the shut-off valve the tank can
be disconnected from the cold water
network and thus its pressure and can
be emptied through the drain valve if
necessary.

Circulation connect

Due to significant energy loss, a
circulation connection should be
avoided when possible. If a highly
branched service water network requires
a circulation line, this must be well
insulated and the circulation pump
controlled via a timer and thermostat.
The switching temperature of the
thermostat should be kept low (45°C).
The circulation connection piece has an
external thread.

Flange installation port

Depending on the system design, flange
heating cartridges or fin-tube heat
exchangers can be attached at the boiler
flange Ø180 (clear diameter Ø117 mm,
hole circle Ø150 mm, 8xM12).

■

Install the flange heating cartridges in such

a way that the sensor of the temperature

regulator is positioned at the top.

■

First tighten the nuts by hand.

■

Then tighten the nuts, in the

sequence specified below, to a

torque of 20 Nm to max. 25 Nm.

Fitting the flange installation port

Flange ring

Seal

Supporting disc

Flange plate

12

Central heating connection

Before being placed into service,
the register must be flushed in order
to remove any soiling (e.g. scale) from
the heating circuit.

Tanks with registers

The registers (heat exchangers) built
into the tank are suitable for connecting
to a water heater at any pressure and
temperature shown on the specification
label of the hot water tank.

Forced circulation through a pump is
required.

When installing a tank with a register,
a shut-off member must be installed in
the flow line to prevent back-heating
into the heating circuit when the central
heating and heat pumps are turned off
or in the case of electrical operation.

Corrosion protection

The enamelled boiler is protected with
a standard magnesium rod-type anode.
This anode is self-consuming and
therefore must be inspected every 2
years and replaced as necessary (for this
purpose, see DIN 4753). A maintenance­free external current anode (accessory)
can be installed on some models using a
reducing threaded connector IG 5/4"-IG
3/4" (accessory).

Temperature display, temperature
regulation for charging pump

With the installation of third-party control
units it must be ensured that the boiler
temperature cannot exceed 95°C during
operation.

NOTE

Installation may only be performed
by authorised specialists.

! ATTENTION

However, under no circumstances
may the supply and return lines
be blocked, as otherwise the water
in the register will not have room
to expand and there is a risk of
damage to the heat exchanger!

13

REMKO EWS 300

Electrical connection
Flange heating cartridge

■

The hot water heater must be filled
with water before being put into
service.

■

A mains connection must be installed
and appropriately fused according
to the circuit diagram affixed in
the terminal box for the unit.

■

A ground fault circuit interrupter
switch switch with a tripping current
of I∆N ≤ 30mA must be located
upstream from the supply circuit.

■

All cables and wires to and from
the unit must be fixed in place.

■

The electrical installation must have
an isolating device for all conductors
with contact opening of at least
3mm. (e.g. with a circuit breaker)

■

Details concerning the electrical
protection of the equipment are
provided in the technical data.

! ATTENTION

All electrical installation work is to be
performed by specialist companies.
Disconnect the power supply when
connecting the electrical terminals.

Before commissioning

Before being placed into service,
the register must be flushed in order
to remove any soiling (e.g. scale) from
the heating circuit.

The smooth pipe heat exchanger
(register) must be rinsed out properly
before the initial installation is carried
out (we also recommend the installation
of a dirt filter). If the smooth pipe heat
exchanger is not used while operating
the tank (e.g. only electric heating),
it must be filled completely with an
appropriate glycol mixture in order to
prevent corrosion from the accumulating
condensation water. The filled glycol heat
exchanger may not be closed on both
sides after filling (temperature-based
pressure expansion).

Before the warm water tank is connected
to the mains electricity supply and put
into service for the first time, it is vital
that it is filled with water.
During initial filling, the discharge valve
must be open. The storage tank is
fully filled, when water which is free of
bubbles starts to run out of the discharge
pipe of the valve.

14

Commissioning

NOTE

Commissioning should only be
performed and documented by
specially trained personnel.

1.

Check all connections, even those
which were sealed at the factory
(flange, anode sleeve), for leak­tightness.

2. Then check all pipes for any leaks
and, if necessary, fix them.

Heating the water in the tank causes its
volume to increase.
During the heating process,
the expansion water generated in
the internal boiler should drip out of
the safety valve.
This dripping is necessary to the function
of the unit, and must not be prevented
by retightening the valves.

4. Test the self-actuating shut-off of
the system, any installed electrical
heating attachments and/or
the boiler.

3. Test the safety module and valves
between the cold water supply and
hot water tank for function.

During initial filling, the discharge
valve must be open. The warm water
tank is fully filled, when water which is
free of bubbles starts to run out of the
discharge pipe of the valve.

Once the water has been heated
successfully, the set temperature,
the actual temperature of the water
produced and that shown on any
temperature indicator should be
approximately the same.

! ATTENTION

The warm water drain pipe as well
as parts of the safety equipment
may become hot.

15

REMKO EWS 300

Unit dimensions

EWS 300

H

G

I

E

C

B

F

We reserve the right to modify the dimensions and constructional design as part of the ongoing technical development process.

Unit type

EWS 300 1435 680 320 840 990 1160 345 1156 1050

Unit type

EWS 300 1595 450 3,5 22,6 170 2,2 5 590

* Energy consumption in standby according to DIN 44 532 with 50°C tank temperature
and 45°C tap temperature
** Screw-in heater installation depth

H ø D A B C E F G I

Tip

dimension

[mm]

max.

installation

length

[mm]

Dimensions in mm

Register

heating

surface

Contents

tube

register

[m²]

Weight

[l]

[kg]

BEVB*

[

kWh/d]

A

85

NLcount

according to

DIN 4708

[-]

16

ETE**

[mm]

Technical data

Unit type

Heat exchanger surface m²

Max. operating pressure bar 10

Max. permissible temp. °C

Max. issue quantity
with drawing at 45°C

Cycle outputs EWS 300

Supply temperature °C 55 55 55 55

Hot water temperature °C 45 45 45 45

Cold water temperature °C 10 10 10 10

Heating circuit flow rate l/h 600 1200 1800 2400

Cycle output kW

Supply temperature °C

Hot water temperature °C 50 50 50 50

Cold water temperature °C 10 10 10 10

Heating circuit flow rate l/h 600 1200 1800 2400

Cycle output kW

Supply temperature °C

Hot water temperature °C 55 55 55 55

Cold water temperature °C 10 10 10 10

Heating circuit flow rate l/h 600 1200 1800 2400

Cycle output kW

l/min

16,0 22,7 26,4 28,8

60 60 60 60

17,7 25,1 29,1 31,7

65 65 65 65

20,7 29,7 34,8 38,1

EWS 300

3,5

95

37

17

REMKO EWS 300

Notes

18

19

REMKO INTERNATIONAL

... and also right in your neighbourhood!
Benefit from our experience and advice

REMKO GmbH & Co. KG
Air conditioning and heating technology

Im Seelenkamp 12 D-32791 Lage
Postfach 1827 D-32777 Lage
Telephone [phone]
Fax [phone]
e-mail [e-mail]
Website www.remko.de

We reserve the right to make technical changes, and provide no warranty as to the accuracy of this data!