Page 1
Assembly and operating instructions
REMKO PUMP GROUPS HGM / HGU
Instructions for the Technician
0041-2013-06 Edition 2, en_GB
Read the instructions prior to performing any task!
Page 2
Made by REMKO
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)
Page 3
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................................................................................................................................... 5
1.10 Safety-conscious working............................................................................................................. 4
1.11 Warranty........................................................................................................................................ 5
1.12 Transport and packaging.............................................................................................................. 6
1.13 Environmental protection and recycling........................................................................................ 6
2 Technical data....................................................................................................................................... 7
2.1 Unit data for pump groups HGM / HGU.......................................................................................... 7
2.2 Unit dimensions and pump group components HGM..................................................................... 8
2.3 Unit dimensions and pump group components HGU...................................................................... 9
2.4 Pump unit data.............................................................................................................................. 10
2.5 Pump unit dimensions................................................................................................................... 11
2.6 Pressure losses............................................................................................................................. 11
2.7 Delivery heights and electrical power............................................................................................ 12
3 Unit description................................................................................................................................... 12
4
Installation and assembly.................................................................................................................. 13
4.1 Installation..................................................................................................................................... 13
4.2 Wall installation............................................................................................................................. 13
4.3 Installation on the distributor......................................................................................................... 15
4.4 Positioning of the electric cables................................................................................................... 16
4.5 Setting the mixing valve for the pump group HGM....................................................................... 17
4.6 Installation of the actuator for the pump group HGM.................................................................... 18
4.7 Replacement of the pump............................................................................................................. 19
4.8 Pump group layout........................................................................................................................ 20
4.9 Electrical connection..................................................................................................................... 21
4.10 Installation example.................................................................................................................... 22
5 Troubleshooting.................................................................................................................................. 23
6 Spare parts list for pump groups HGM / HGU.................................................................................. 25
7 Index..................................................................................................................................................... 27
3
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REMKO PUMP GROUPS HGM / HGU
1
1.1
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.
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.
Safety and usage instructions
General safety notes
Identification of notes
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 installation and
operating manual, the existing national regulations
concerning accident prevention as well as any
internal company working, operating and safety
regulations must be observed.
4
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Safety instructions for the oper-
1.6
ator
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.
Safety notes for installation and
1.7
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.
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.
1.9
Intended use
Due to the type and design of the pump group, it is
only approved for operation as a heating cycle
group. It serves to transport the operating medium
of water into closed heating cycles.
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
The safety notes contained in this installation and
operating manual, the existing national regulations
concerning accident prevention as well as any
internal company working, operating and safety
regulations must be observed.
1.11
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.
Safety-conscious working
Warranty
Unauthorised modification and
1.8
changes
The operational safety of the pump group that was
delivered is guaranteed only with intended use in
accordance with section 1.9 of the operating
instructions. Under no circumstances should the
threshold values specified in the datasheet be
exceeded.
5
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REMKO PUMP GROUPS HGM / HGU
1.12
The devices are supplied in a sturdy shipping container. Please check the equipment immediately
upon delivery and note any damage or missing
parts on the delivery and inform the shipper and
your contractual partner. For later complaints can
not be guaranteed.
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
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.
Transport and packaging
WARNING!
Environmental protection and recycling
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.
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2
2.1
Technical properties
Pump group HGM HGU
Maximum operating temperature °C 90
Max. operating pressure bar 10
IG threaded connections UNI EN 10226-1
AG threaded connections UNI ISO 228-1
Pump Wilo Stratos Para 25 / 1-7 T1
Compatible media Water, water-Glycol mixture (maximum 30%)
Thermometer measurement range 0-120°C, 30-250°F
Weight kg 6.9 5.85
Materials
Technical data
Unit data for pump groups HGM / HGU
Pump group HGM HGU
Ball valve and check valve
Body made of brass: UNI EN 12164 - CW617N UNI EN 12164 - CW614N
Hydraulic seals PTFE, Viton, EPDM
Motorised mixing valve
Body made of brass: UNI EN 12165 - CW617N ---
Turning part made of brass: UNI EN 12164 - CW614N ---
Hydraulic seals EPDM
Insulation half-shells
Body EPP
Body, seal
Body, therm. conductivity (20°C) W/mK 0.039
Body, therm. conductivity (40°C) W/mK 0.041
kg/m
3
60
7
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2
1
4
3
6
7
5
4
1
=
2
=
5
=
3
=
4
=
REMKO PUMP GROUPS HGM / HGU
2.2
Unit dimensions and pump group components HGM
Dimensions
Fig. 1: Unit dimensions for pump group HGM
Pump group G G1 L H
HGM 1" IG
Components
1 1/2" AG
125 mm 363 mm
Fig. 2: Pump group components HGM
1: Circulation pump Wilo Stratos Para 25 / 1-7 T1
2: Ball valve
3: Ball valve with integrated check valve
4: Thermometer
5: Motorised mixing valve
6: Extension
7: Insulation
8
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2
1
4
3
6
5
4
1
=
2
=
=
3
=
4
2.3
Unit dimensions and pump group components HGU
Dimensions
Fig. 3: Unit dimensions for pump group HGU
Pump group G G1 L H
HGU 1" F
Components
Fig. 4: Pump group components HGU
1: Circulation pump Wilo Stratos Para 25 / 1-7 T1
2: Ball valve
3: Ball valve with integrated check valve
1 1/2" M
4: Thermometer
5: Ball valve
6: Insulation
125 mm 363 mm
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REMKO PUMP GROUPS HGM / HGU
2.4
Pump unit data
Technical data
Pump group HGM / HGU
Pump type Wilo Stratos Para 25 / 1-7 T1
Maximum delivery volume
Maximum delivery height m 7.0
Speed rpm 1200 - 4450
Mains voltage 1~230V ± 10% in accordance with DIN IEC 60038
Energy Efficiency Index ( EEI ) £ 0.23
Frequency Hz 50/60 Hz
Insulation class F
Enclosure class IP 44
Rated input P1 W 5 - 70
Nominal width for pipe connection Rp
m
Inch
es
3
4.5
1"
Connection flange thread G
Permitted ambient temperature °C + 40
Maximum relative humidity £ 95%
Permitted conveying media
Permitted medium temperature °C 95
Maximum operating pressure at the pump bar 6.0
Weight kg 2.4
Inch
es
Heating water (in accordance with VDI 2035/VdTÜV
Water/Glycol mixture: maximum mixture ratio is 1:1 (in
mixtures with Glycol, the delivery data of the pump
must be corrected according to the higher viscosity and
depending on the mixture ratio percentage.)
Ethylene/propylene glycol with corrosion protection
- Standard oxygen binding agent
- Standard corrosion protection agent
- Standard combination products
- Standard cooling brines
1 1/2"
Tch 1466)
inhibitors
10
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b4
b5
l
2
l
0
l
1
l
3
a
1
a
2
a
3
21
A
B
A
[m3/h]
B
[m3/h]
[mbar]
[mbar]
a a
2.5
Pump unit dimensions
Dimensions
Fig. 5: Pump unit dimensions
Wilo Stratos
Para 25 / 1-7 T1
Dimensions in
mm
l
0
180 116 32 94 90 56 138 42 41
a
1
a
2
a
3
l
1
l
2
l
3
b
4
b
5
2.6
Pressure losses
Fig. 6: Diagram of pressure losses in the pump group HGM / HGU
1: Operational mode; constant differential pres-
sure
2: Operational mode; variable differential pressure
B:
Delivery rate [m3/h]
a: Mixing valve R 3/4
A: Resistance / delivery height [mbar]
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2
1
2
1
4
3
5
REMKO PUMP GROUPS HGM / HGU
2.7
Delivery heights and electrical power
Fig. 7: Delivery heights and electrical power of the Wilo Stratos Para 25 / 1-7 T1pump
1: External operating mode via analogue-in 0-10V
2: External operating mode via pump shaft model (PSM)
3
These pump groups HGM / HGU enable circulation
of the heat conducting medium via the inlet. The
pump group HGM regulates the temperature of the
heat conducting medium via a motorised mixing
valve. This pump group with controllable temperature is therefore ideal for operating normal heating
systems with temperature regulation. Temperature
regulation of the Inlet takes place depending on
the inlet and return temperatures of probes S12
and S11.
The pump groups comprise the following: Pump,
ball valve for inlet and return flow, thermometer for
inlet and return flow, check valve against the
heating cycle and thermal insulation.
The pump group HGM also has an integrated
mixing valve
The pump group with the heating cycle mixing
valve consists of the components displayed in
Fig. 8:
n Front part of the insulation (1)
n Rear part of the insulation (2)
n Insulation of the pump (3)
n Unit inlet (4) equipped with secondary circuit
n Unit return flow (5) equipped with secondary
Unit description
ball valve, a motorised mixing valve and a thermometer
circuit ball valve with an integrated check valve
and a thermometer
Fig. 8: Unit components
The two insulation half-shells (1, 2) serve as heat
insulation for the pump group and therefore enable
energy to be saved. The pump insulation was
developed to guarantee heat insulation and to prevent the electric motor from overheating. The
check valve that is integrated into the body of the
return flow's ball valve prevents incorrect circulation when the pump is switched off.
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2
1
3
2
4
4.1
Possible installations are:
n Wall installation
n Installation on the distributor
Installation and
Installation
CAUTION!
Each individual hydraulic component must be
installed by qualified personnel because the
high temperatures and pressures of the liquid
can cause personal injury.
assembly
4.2
Wall installation
CAUTION!
You must adhere to the distance between the
piping and the wall specified in point 7.
1. Remove the pre-installed pump group from
the packaging.
2. Open the insulation cover half-shells by
pulling the front side (1) and the rear side (2)
apart.
3. Remove the insulation (3).
4. Remove the inlet (4) and the return flow (5).
5. Cut out the openings on the rear side of the
insulation (2).
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2
4
5
6
7
3
REMKO PUMP GROUPS HGM / HGU
6. Install the pump group wall bracket on a suit-
able wall. The wall bracket is equipped with
long holes to aid height adjustment. Fix the
wall bracket to the wall using the enclosed
wall plugs.
9. Turn the regulator of the return flow's ball
valve (7) to an angle of 45°; in this position,
7. Attach the rear side (2) of the insulation halfshell to the wall bracket. Install the inlet (4)
and the return flow (5) on the wall bracket by
lifting the insulation slightly. So, the distance
between the pipe axis and the wall surface is
around 54 mm.
the ball valve bypasses the check valve and
nullifies the effect of the valve. This enables
the water and the air that is to be bled in the
filling phase to flow better. Fill the system
and check for leaks.
10. Open the ball valve of the return flow (7).
8. Use the screw connection enclosed in the
packaging to install the piping for the inlet
and the return flow; ensure that the connections are suitable for the pipe dimensions
(connections with flat seals are recommended). If a pump is connected in a series
to the pump group (e.g. boiler pump), in practice, a fixture to separate the heating cycles
hydraulically is to be installed, in order to prevent a malfunction of the two pumps or the
heat pump.
11. Install the electric cables (see the positioning
of the cables section).
12. Insert the pump's insulation (3).
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1
45
13. Close the pump group using the insulation
half-shell (1).
4.3
Installation on the distributor
The pump groups can be installed on distributors
with an integrated hydraulic compensator, on
standard distributors with a separate hydraulic
compensator and on series distributors. For
optimum installation, the nozzles of the distributor
should be at least 60mm away from the wall.
1. First carry out installation steps 1-4 for wall
installation.
2. To aid installation, start the installation in the
middle of the distributor and then continue
with the outer connections; install the inlet (4)
and the return flow (5) on the distributor
using the screw connection enclosed in the
packaging or using the required connecting
pieces (flat-sealing connections are recommended).
3. Insert the insulation half-shell (2); if the distributor is installed too close to the wall, you
must insert the rear side (2) of the two insulation half-shells before you install the inlet and
the return flow (4 and 5).
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2
2
3
2
1
2
REMKO PUMP GROUPS HGM / HGU
Positioning of the electric
4.4
cables
The electric cables must be installed by qualified
personnel, in order to avoid endangering people's
safety and material damage. The insulation halfshells were developed in such a way to ensure the
greatest degree of flexibility possible with regard to
cable arrangement in the insulation. There are
appropriate recesses for cable harnesses and
these enable side access to the insulation (2).
4. Insert the insulation (3) by pushing down the
top side of the rear insulation half-shell (2).
5. Continue as described in point (9) for wall
installation.
6. Open the ball valve of the return flow again.
7. Install the electric cables (see: positioning of
the cables section).
8. Close the pump group using the front part of
the insulation (1).
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1
2
3
Setting the mixing valve for the
4.5
pump group HGM
The motorised mixing valve enables temperature
regulation of the inlet by mixing hot or cold liquid.
Regulation can be carried out manually using the
rotary regulator or using an actuator.
2. Move the rotary regulator (1) to the position
where the arrow points to the value 10. This
is the position in which there is no temperature mixing.
The mixing valve that is integrated into the HGM
has an integrated bypass that can be regulated.
The bypass with the electrical actuator enables the
advantages of inlet temperature control to be utilised. It enables the inlet temperature to be regulated if the return flow of the mixing valve is completely closed. (Maximum fluctuation performance)
The mixing valve has a turning angle of 90°.
In this way, it restricts the height of the temperature
in the regulation area and prevents fluctuating temperatures, dangerous temperature spikes (e.g. in
systems with underfloor heating) and continuous
changes to the turning direction of the motor.
Attention: If there are large temperature differences between the temperature in the buffer tank
and the temperature in the heating cycle, it is possible that the setpoint will not be reached even if
the bypass is open. Obviously, the best possible
regulation should be used.
To ensure precise calibration of the temperature,
the heating cycle must be put into operation with
the planned maximum inlet temperature. This is
the only way to retain the setting precisely in operation.
1. Install the rotary regulator (1) with the supplied screw.
3. Activate the pump.
4. Loosen the bypass screw (2).
5. Position the bracket regulator (3) in order to
set the operating temperature and ensure
that the bypass is closed completely as
shown in the left picture in the diagram below
and completely open as shown in the middle
picture. Tighten the screw (2).
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2
4
3
5
1
2
8
1
REMKO PUMP GROUPS HGM / HGU
6. If regulation of the bypass is insufficient,
move the rotary regulator to the position that
enables the desired temperature to be
reached. Even if the rotary regulator was to
be destroyed manually, the bypass still limits
the inlet temperature.
Installation of the actuator for
4.6
the pump group HGM
The Actuator for the pump group is delivered with
the components shown in the diagram.
Fig. 9: Installation of the actuator
1: Actuator
2: Ring with scale
3: Adapter for the mixing valve
5: Screw for fixing the drive
1. The ring with scale (2) is the reference point
for the hot water proportion and must be
aligned as shown in the right picture of the
following diagram.
2. Insert the correctly-aligned ring (2) into the
guide of the actuator (1).
3. Press and turn the rotary knob of the actuator
fully in a clockwise direction and then release
it.
4. Insert the adapter and screw in the locking
screw.
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4
3
5. Use the indent on the adapter as the reference point.
6. Align the indent of the adapter (3) so that it
corresponds to value 10 on the mixing valve.
8. Install the actuator cable and the heating
cycle circulation pump on the regulator of the
heat pump.
You can obtain information about the terminal connections from the installation
instructions of the heat pump in the "Terminal
connections/legend" chapter.
4.7
Replacement of the pump
The pump groups are constructed in such a way
that pumps of different types and brands can be
connected. If pumps and cable connections from
other manufacturers are to be used, minor
changes to the insulation may be required. These
can be made by the installer.
7. Install the actuator (1) in the position as
shown in the diagram and fix everything with
the locking screw.
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2
4
3
1
2 1
21
REMKO PUMP GROUPS HGM / HGU
4.8
Pump group layout
The distribution group with the motorised mixing
valve can also be connected in a way that differs
from the standard installation (inlet on the right and
at the top). The possible installation configurations
depend on the type of pump installed. The connection options are shown in the diagrams below.
1. Loosen the rotary valves (see the arrow) and
uncouple the extension (2). Ensure that the
flange is flat-sealing.
2. Transpose the installation positions of the
pump (1) and the extension (2).
Fig. 10: Pump group layout
1-4: Diagrams 1-4
As shown in diagram 1, the distribution group with
the motorised mixing valve is delivered in the
standard configuration; this means that the pump
is on the right and the inlet on the top. The heating
cycle group can be configured using the process
shown in diagrams 2, 3 and 4.
3. Insert the flat seal and close the valves.
4. If necessary, turn the pump motor (this
applies to pumps that enable the motor to be
aligned).
NOTICE!
Leave the ball valve with the red grip on the
inlet with the pump and the ball valve with the
blue grip on the return flow due to the flap
valve. Adhere to the flow direction of the pump.
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PE N A20 A21
-SMTIO
A20
Mixer 230V
M
N Open
-A20
Mixer
-Heating
cycle floor
bl
br
sw
L-XN PE
A41 GND
-SMTIO
A41
Pump 0-10V
1
M
U N
-A41
Pump
Heating cycle floor
-Power supply A41
br
bl
gnge
ws
br
L
-X
N
PE
A42 GND
-SMTIO
A42
Pump 0-10V
1
M
U N
-A42
Pump
Heating cycle radiator
-Power supply A42
br
bl
gnge
-Heating cycle radiator
ws
br
-Heating
cycle floor
Heating cycle floor
Closed
4.9
Electrical connection
Terminal connections when connecting to REMKO Heat pumps, types WKF & WKF-compact
Fig. 11: Remko HGM / HGU connection terminals
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Pump floor cycle
-Heating
cycle pump
heating cycle
-Heating
cycle pump floor
floor heating
Heating cycle pump floor
Heating cycle pump radiator
Pump radiator cycle
Unregulated 230 V
Unregulated 230 V
A
B
C
D
B
AB
A
HGM
HGU
KK
HK
FB
REMKO PUMP GROUPS HGM / HGU
Fig. 12: Connection terminals for installing unregulated circulation pump heating cycles
4.10
Installation example
Fig. 13: Example hydraulic diagram
A: Outdoor unit
B: WFK indoor unit
C: Storage tank
D: Second heat generator (max. 20 kW)
FB: Floor heating cycle
HK: Heater heating cycle
KK: Cooling cycle
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5
Fault
description
Pump does
not run when
power supply
is switched
on
Pump makes
noises
Power
supply
undervoltage
Power
supply overvoltage
Motor
jammed
Troubleshooting
Cause Remedy
Electrical fuse
defective, pump
has no power
Cavitation
caused by insufficient inlet pressure
Power supply
overloaded
Faulty feed from
the energy
supply company
e.g. due to
deposits
Check the fuses, eliminate the power interruption.
Increase the system pressure within the permissible area, check the
delivery height setting and set a lower height if necessary
The motor is switched off in the case of overvoltage or undervoltage. It
starts again automatically as soon as the voltage is again in the permitted area. SSM relay is active. Off: 165 V AC / On: 195 V AC
Faulty feed from the energy supply company. The motor is switched off
in the case of overvoltage or undervoltage. It starts again automatically
as soon as the voltage is again in the permitted area. SSM relay is
active. Off: 265 V AC / On: 245 V AC
If the motor jams, a maximum of 5 restarts at 30 second intervals take
place. If the motor remains jammed, it is switched off permanently. It can
only be switched back on again by switching off the power for more than
30 seconds and then switching it on again. The unjamming programme
runs during each start process. The SSM relay is active as long as the
internal error counter is not ZERO.
Motor overload
Short circuit/
earth
leakage
Contact error The module is
Running
empty
Deposits in the
pump
Motor defective The motor is switched off after a short circuit. It is switched on again
not connected
correctly. Connection between
motor and
module interrupted
Air in the pump The motor is switched off after a defined period of time when running
If the power consumption of the motor exceeds the limit for more than 60
seconds, the "Overload" error is reported. The motor is stopped and
started again after a 30 second pause. If no overloading occurs within
the next 2 minutes, the internal error counter is reset. Otherwise, the
motor is switched off permanently after 5 unsuccessful restarts. This can
only be reset by switching the power off for more than 30 seconds. The
SSM relay is active as long as the internal error counter is not ZERO
after 30 seconds. The motor is switched off permanently after 5 short circuits. This can only be reset by switching the power off for more than 30
seconds. The SSM relay is active as long as the internal error counter is
not ZERO
If the contact between the motor and the module fails, the motor is
switched off. A restart occurs after 30 seconds. After the motor has been
switched off for the fifth time, it is switched off permanently. This can
only be reset by switching the power off for more than 30 seconds. The
SSM relay is active as long as the internal error counter is not ZERO.
under dry running conditions. It starts again after a delay of 30 seconds.
If no dry run occurs within the next 2 minutes, the internal error counter
is reset. Otherwise, the motor is switched off permanently after 5 unsuccessful restarts. This can only be reset by switching the power off for
more than 30 seconds. The SSM relay is active as long as the internal
error counter is not ZERO.
23
Page 24
REMKO PUMP GROUPS HGM / HGU
Fault
description
Module overtemperature
Cable break Control is defec-
Cause Remedy
The air supply to
the module
cooling element
is restricted
tive, control line
is defective
The motor is switched off if an overtemperature situation occurs. A
restart occurs after 30 seconds. After the motor has been switched off
for the fifth time, it is switched off permanently. This can only be reset by
switching the power off for more than 30 seconds. The SSM relay is
active as long as the internal error counter is not ZERO.
A cable break is registered for the pumps that are controlled via a 0-10 V
signal and that are equipped with software with a cable break function if
the inbound control signal is less than 0.5 V. The pump turns at minimum speed.
24
Page 25
21
9
3
4
5
7
8
10
6
11 13
12
6
Spare parts illustration
Spare parts list for pump groups HGM / HGU
We reserve the right to modify the dimensions and design as part of the ongoing technical development
process
25
Page 26
REMKO PUMP GROUPS HGM / HGU
Spare parts list
No. Description Description HGM HGU
1 Ball valve, red
2 Ball valve, blue
3 Ball valve
4 Mixing valve
Thermometer
5
with dual scale
6 Actuator
With integrated thermometer 0-120°C (30 250°F). Pump connection with rotary nut 1 ½“ IG.
Flat seal D45 x d33.3 x 2.,
dimension: G 1"1/2 UWM x G 1"
With integrated thermometer 0-120°C (30 250°F). Pump connection with rotary nut 1 ½“ IG.
Flat seal D45 x d33.3 x 2.,
dimension: G 1"1/2 UWM x G 1"
Pump connection with rotary nut 1 ½“ IG. Flat
seal D45 x d33.3 x 2.,
dimension: G 1"1/2 AG x G 1"1/2 UWM
With integrated controllable bypass. Pump connection with rotary nut 1 ½“ IG. Equipped with
plastic rotary grip for manual control. Flat seal
D45 x d33.3 x 2., dimension: G 1"1/2 AG x G
1"1/2 UWM x 1" AG, flow: 6 and 10 m3/h
Scale: 0 - 120°C (30 - 250°F), dimension: D 52
mm
Actuator for mixing valve with three-point regulator, speed 120s/90°, turning angle 90°, torque
10 (Nm), voltage 230V, frequency 50Hz. Complete with locking screw and pin to fix the
actuator. Speed: 120 s (90°), Controller: 3-point
EDP
number
1120960 1120960
1120962 1120962
--- 1120961
1120969 ---
1120965 1120965
1120970 ---
EDP
number
7 Connection-fitting set
8 Wall-mounted bracket
9 Rotary regulator
Circulation pump Wilo
10
Stratos Para 25 / 1-7
Extension
11
with T-connection
12 Extension for HGM Dimension: G 1"1/2 x G 1"1/2 1120967 ---
13 Extension for HGU Dimension: G 1"1/2 x G 1"1/2 --- 1120964
When ordering spare parts, please always state the EDP no., unit number and unit type (see name plate)!
Sockets with flat seal.
Dimension: G 1" x G 1"1/2 UWM
For pump group including screws and wall plugs.
Hole distance: 90 mm
With locking screw for manual regulation of the
mixing valve
Heavy-duty model (EEI <0.23 in accordance with
EVP guidelines) equipped with a 1m-long cable.
Dimension: G 1"1/2 x G 1"1/2.
Distance: 180 mm. Maximum delivery height: 7 m
Dimension: G 1"1/2 UWM x G 1"1/2 AG x G 1"
UWM
1120963 1120963
1120966 1120966
1120972 ---
1120909 1120909
1120971 ---
26
Page 27
7
C
Components............................................... 8, 9, 12
D
Delivery heights................................................. 12
Dimensions ......................................................... 9
E
Electrical connection.......................................... 21
Electrical power.................................................. 12
Electric cabling................................................... 16
Environmental protection..................................... 6
I
Installation
Installation example........................................... 22
Installation of the actuator.................................. 18
Install the actuator.............................................. 18
Intended use........................................................ 5
P
Packaging, disposal............................................. 6
Positioning of the electric cables........................ 16
Pressure losses................................................. 11
Pump group layout............................................. 20
Pump group materials.......................................... 7
Index
Pump.............................................................
Pump group.................................................... 8
Installation example...................................... 22
Installation of the actuator............................. 18
Installation on the distributor......................... 15
Positioning of the electric cables................... 16
Pump group layout........................................ 20
Replacement of the pump............................. 19
Setting the mixing valve................................ 17
Wall installation............................................. 13
11
R
Recycling............................................................. 6
Replacement of the pump.................................. 19
Replace the pump ............................................. 19
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, 5
Unauthorised modification ............................. 5
Unauthorised replacement part manufacture.. 5
Set the mixing valve........................................... 17
Setting the mixing valve..................................... 17
T
Technical properties of the pump groups............. 7
U
Unit data
Pump............................................................. 10
Pump groups................................................... 7
Unit dimensions................................................... 9
Pump............................................................. 11
Pump group.................................................... 8
Unit disposal........................................................ 6
W
Wall installation.................................................. 13
Warranty.............................................................. 5
27
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REMKO PUMP GROUPS HGM / HGU
28
Page 29
29
Page 30
REMKO PUMP GROUPS HGM / HGU
30
Page 31
Page 32
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 52 32 606-0
Telefax +49 5232 6 06-260
E-mail info@remko.de
Website www.remko.de
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