Fresh water controller
745.089 | Z01 | 11.30 | Subject to change due to technical improvements!
EN
Installation and operating instructions
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Contents
General safety instructions .................................... 3
EC declaration of conformity.................................3
1 Proper usage ......................................................... 4
2 About this manual .................................................4
2.1 Contents ................................................................... 4
2.2 Target audience ........................................................ 4
3 Installation ............................................................ 5
3.1 Opening / Closing the casing .................................... 5
3.2 Mounting the casing ................................................ 6
3.3 Establishing the electrical connections......................7
3.4 Terminal pin assignments ........................................ 11
4 Structure ..............................................................12
4.1 Casing ..................................................................... 12
4.2 Display .................................................................... 12
5 Operation ............................................................. 14
5.1 Operating buttons .................................................. 14
5.2 Display when operating .......................................... 14
5.3 Setting the hot water temperature ......................... 14
6 Modes of operation ............................................. 15
6.1 Changing the mode of operation ........................... 15
6.2 "Off" mode .............................................................. 15
6.3 “Manual” mode ...................................................... 15
6.4 “Automatic” mode .................................................. 16
7 Deinstallation and disposal .................................18
8 Troubleshooting ................................................... 18
8.1 General faults ......................................................... 19
8.2 Fault messages .......................................................20
9 Technical data ......................................................21
9.1 Controller ............................................................... 21
9.2 Cable specifications ................................................ 21
Exclusion of liability ............................................. 22
Legal guarantee ...................................................22
Notes ................................................................... 23
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General safety instructions
• This document is part of the product.
• Use the device only after reading and understanding this document.
• Keep this document in a safe place for the entire service life of the device. Pass this
document on to subsequent owners and operators of the device.
• Adhere to all safety instructions. Consult (further) professional personnel in the
event of any ambiguities.
• The measures described in this document may only be performed by qualified
technical professionals. Exception: End-customers may operate the device when they
have previously been trained by a technical professional.
• The system can be damaged by improper operation of the device.
• The device must not be connected to the power supply if it has an open or damaged
casing.
• Factory labels and markings must never be altered, removed or rendered unreadable.
• Observe the prescribed conditions of use, see Section: Technical data.
• This device is not intended for:
– Children
– Persons with physical, sensory or mental impairment
– Persons without sufficient experience or knowledge unless they are instructed in
the use of the device, and initially supervised, by a person responsible for their
safety.
EC declaration of conformity
This product conforms to the applicable European directives with regard to its design
and its operating behaviour. This conformity has been verified. Further information in
this regard can be obtained from your dealer.
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1 Proper usage
The fresh water controller, subsequently referred to as the controller, is an independently installed electronic temperature controller for on-surface installation. Integration
into a pump assembly is possible when the technical specifications of the controller are
adhered to.
The maintenance-free controller is exclusively intended for controlling and monitoring
fresh water stations.
2 About this manual
2.1 Contents
This manual contains all information required by a technical professional for setting up
and operating the controller.
2.2 Target audience
The target audience of this manual are technical professionals who:
• have the knowledge of terminology and the skills necessary for setting up and operating fresh water stations.
• have the necessary training, knowledge and experience, and knowledge of the applicable regulations in order to evaluate and recognise the dangers inherent in the
following work:
– Installing electrical equipment
– Cutting to size and connecting data communication cables
– Cutting to size and connecting mains grid power supply cables
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3 Installation
Note
The following section describes only the installation of the
controller
tions of each respective manufacturer when installing external components (pumps,
3.1 Opening / Closing the casing
3.1.1 Removing the front panel
by the grooves at the sides
and pull forwards
(Fig. 1).
3.1.2 Mounting the front panel
and then press it onto the casing until it latches
3.1.3 Removing the terminal cover
Danger
3.1.4 Mounting the terminal cover
Tighten the screw
to a torque of 0.5 Nm.
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3.2 Mounting the casing
√ The mounting location must satisfy the prescribed conditions of use; more informa-
tion on this is provided in the Technical data section.
√ The mounting surface is vertical and allows good access for installation.
Danger
Risk of death by electrocution!
• Disconnect the controller from the power supply before opening the casing.
• Make sure that the power supply cannot be unintentionally switched on when the
casing is open.
• Do not use the casing as a drilling template.
1. If necessary, remove the terminal cover
2. Screw in the screw for the upper mounting hole (Fig. 2) until the screw head has
a clearance of 5 ... 7 mm from the mounting surface.
3. Hang the controller on the screw by the upper mounting hole and align it vertically.
4. Mark the position of the lower mounting hole through the casing.
5. Remove the controller and prepare the mounting hole for the lower screw.
6. Hang the controller by the upper mounting hole and then fasten the screw in the
lower mounting hole .
7. Mount the terminal cover.
Fig. 2: Rear side of the controller with the upper and lower mounting holes
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3.3 Establishing the electrical connections
Danger
Risk of death by electrocution! Make sure that the following conditions are satisfied
when performing the work described in this section:
• All cables leading to the controller must be disconnected from the power supply and
it must be ensured that they cannot be unintentionally reconnected during installation.
• Each connection terminal must only be connected to a single conductor.
• The protective earth conductors (PE) from the mains cable and pump and valve
cables must be connected to the protective earth conductor terminal block.
• All cables must be laid so that persons cannot stand on them or trip over them.
• The cables must satisfy the requirements listed in the Technical data section.
• The local power supply must match the specifications on the type plate of the con-
troller.
• The power supply cable is to be connected to the mains power as follows:
– using a plug connected to a wall mains socket or
– via an isolating mechanism allowing complete isolation in the case of permanent
wiring.
• The power supply cable must be laid in conformance to all applicable legal guidelines and regulations of the local electricity supplier.
Notice
Danger of damage and malfunction.
• Connect only components that do not overload the controller inputs and outputs;
more information is provided on the type plate and in the Technical data section.
• Speed control must be deactivated at output R1 when an external relay is con-
nected.
Notes
• Lay the sensor cables at least 100 mm away from any power supply cables.
• Use shielded sensor cables when inductive sources are present, e.g. high-voltage
lines, radio transmitters, microwave devices.
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3.3.1 Position of the connection terminals
Fig. 3: Terminal clamps in the lower part of the controller (terminal cover removed)
Power connection terminal block:
L
1x phase conductor (mains input)
R1
1x output (TRIAC, for pump)
N
2x neutral conductor (common neutral conductors for mains power input
and output)
Note
Output R1 is protected by an electronic fuse.
Protective conductor terminal block:
PE
4x protective earth (common protective earth for power connection
terminal block)
Signals terminal block:
PWM R1 1x control output (for controlling a high-efficiency pump)
2x mass connection (common mass)
X
not used
A 1x 4-pin straight connector socket (for polarity-safe Molex plug to Grundfos Direct
SensorsTM VFS or RPS *))
B 1x pin strip, for internal use only
Cable openings on the rear side of the casing
Upper strain relief clamps (2 identical plastic links, each with 2 strain relief clamps,
supplied in the scope of delivery)
Lower strain relief clamps
Cable openings at the bottom of the casing
*)
Grundfos Direct SensorsTM is a registered trademark of the Grundfos group.
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3.3.2 Preparing the cable openings
The cables can be fed through openings in the rear wall of the casing or at the bottom
of the casing. The openings are pre-punched and must be prepared as required before
installation.
Prepare the cable openings in the rear wall of the casing as follows:
1. Break out the cable openings (Fig. 3) using a suitable tool.
2. Deburr the edges.
Prepare the cable openings at the bottom of the casing as follows:
1. Cut the required cable openings (Fig. 3) at the left and right using a suitable knife
and break them out.
2. Deburr the edges.
3.3.3 Connecting the cables
√ All cables are voltage-free.
√ The cable openings have been prepared.
X Observe the following points when connecting the cables:
• Connect the cable conductors to the correct terminals as described in the following
Terminal pin assignments section.
• Mains input and output: First connect PE, then N and L.
• Strain relief:
– First clamp the lower strain relief clamps and then the upper strain relief
clamps.
– When using the upper strain relief clamps, use the plastic links as described
below.
– If the opening in the strain relief clamp is too large, e.g. in the case of thin ca-
bles, turn over the strain relief clamping bar (with the bend facing down).
– Only use the strain relief clamps for cables entering the bottom of the casing.
Use external strain relief clamps when feeding cables through the rear of the
casing.
3.3.4 Inserting/Removing plastic links
Insert the plastic links as follows:
1. Insert the right plastic link with the latching protrusion first (Fig. 4).
2. Press the other side of the plastic strip down , until the spring clamp latches into
place.
3. Insert the left plastic strip the other way around (latching protrusion to the left,
spring clamp to the right).
Fig. 4: Inserting the right plastic link
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Remove the plastic links as follows:
1. Insert a flat-blade screwdriver under the right plastic link between the casing and
the spring clamp , (Fig. 5).
2. Carefully push the screwdriver to the left . Lever the spring clamp to the right
until the plastic link is free.
3. Pull out the plastic link upwards by hand .
4. Remove the left plastic link accordingly.
Fig. 5: Removing the right plastic link
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3.4 Terminal pin assignments
The following diagram describes the controller terminals used for connecting external
components.
LR1
N
PE PE
PWM
R11
230 V
230 V
1
3
4
2
Fig. 6: Terminal pin assignments for the connected components
Mains input
Power supply of the pump/high-efficiency pump
Grundfos Direct Sensors
TM
Control cable for the high-efficiency pump
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4 Structure
4.1 Casing
11
13
2
16
15
14
ESC
SET
No. Element
See
Section
Mode button (under
front panel)
5.1
6
, SET, ESC, operating
buttons
5.1
Display 4.2
Front panel 3.1
Terminal cover 3.3.1
1)
Terminal cover fastening screw –
1)
Section 3.3.1 describes the terminals under the
terminal cover.
Fig. 7: Front view of the controller
4.2 Display
4.2.1 Overview
error
v
1
2
3
4
Fig. 8: Overview of the display areas (all elements visible)
System graphics
Settings menu
Pictograms for functions
Operational and setting values
The display areas are described below.
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4.2.2 Symbols used
The following table describes the symbols used in Fig. 8.
Symbol Description Symbol Description
Pipework Pump, switched on
External heat exchanger Pump, switched off
Domestic water outlet Temperature sensor (Grundfos
Direct SensorsTM)
Storage tank Measuring device for the volume
flow (Grundfos Direct SensorsTM)
Pump is speed controlled
1)
Manual operation
1)
Symbol is visible while the function/parameter is being edited in the settings menu.
4.2.3 Settings menu
The settings menu ( in Fig. 8) contains the entry Para (parameter).
4.2.4 Operational and setting values
The display of the operational and setting values ( in Fig. 8) consists of the following
elements:
1
2
3
4
error
Error display
Additional information:
on, off: Switching state/condition on, off
max, min: Maximum value, minimum value
Σ: Summed operational value since first commissioning, cannot be reset
Δ: Summed operational value since last reset to 0
Display of:
• Measurements
• Settings
• Error codes
• Additional information, e.g. software version
Physical unit of the value displayed in : °C, l/min
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5 Operation
5.1 Operating buttons
The device is operated using the , , SET, ESC and buttons as follows:
• Scrolling up through the menu
• Increases the setting value by 1 step
• Scrolling down through the menu
• Decreases the setting value by 1 step
SET
• Selects a setting to be changed (setting value flashes)
• Confirms a setting value or jumps one level down in the menu
structure
• Calls up the settings menu (not in manual mode)
ESC
• Discards an entered setting
• Jumps up by one operating level
Sets the operating mode
Note
We recommend that you write down all settings that you have changed, e.g. in the
Notes section.
5.2 Display when operating
• A flashing component in the system graphic means: The displayed operational or
setting value applies to the flashing component.
Exception: always flashes in manual mode.
• A flashing symbol is indicated in the figures by
.
• Displays that are automatically alternately displayed are shown overlapping in the
figures. Example: Figure in Off mode section.
5.3 Setting the hot water temperature
The controller attempts to adjust the hot water temperature to the set value. The hot water temperature can be
changed in the settings menu via the parameter P:01
within the following limits.
Minimum:
Maximum:
Factory setting:
20 °C
90 °C
50 °C
Set the hot water temperature as follows:
√ Automatic or Off mode is selected.
1. Press and hold SET for two seconds. The settings menu is displayed, P:01 flashes.
2. Press SET. The set hot water temperature is displayed, the symbol of the external
heat exchanger flashes.
3. Press SET. The hot water temperature value flashes.
4. Press to change the value.
5. Press SET to adopt the change.
6. Press ESC. P:01 flashes.
7. Press ESC. The status display appears.
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6 Modes of operation
6.1 Changing the mode of operation
Notice
Danger of pump damage if run dry. Only switch the system to manual or automatic
mode when the system is filled.
1. Remove the front panel.
2. Press the button for 2 seconds to change the mode of operation.
3. Repeat step 2 if necessary.
4. Mount the front panel.
Off Manual Automatic
2 s 2 s 2 s
6.2 "Off" mode
Functionality
• The output is switched off (output/control output without power).
• OFF and the software version are displayed alternately.
See example in Fig. below: Software version St 1.3
• Backlighting is red.
• Settings menu can be called up.
• The Off mode is preset when the device is delivered.
Operation
X Press and hold the SET button for 2 seconds to call up the settings menu ( ).
6.3 “Manual” mode
Functionality
• Backlighting is red, spanner symbol flashes.
• The controller output (pump) can be manually switched. Possible switching states:
0: off
1: on
A: Automatic operation as per the settings in the settings menu
• Current temperatures and operating hours can be displayed (status display).
• When changing to manual mode the output is switched to A. R1 is displayed. Ex-
ception: Initial commissioning (output at 0).
• Typical application: Functional test (maintenance), fault-finding.
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Operation
Switch the output on and off as follows ( ):
1. Press SET. The switching state flashes.
2. Press to change the switching state.
3. Press SET to adopt the change.
Display the current temperatures, flow rate values and operating hours as follows:
1. Press ESC. The temperature/flow rate/operating hours are displayed and the associated component flashes (
, display is not illustrated).
2. Press to select a different component.
3. Press SET to leave the display.
SET
SET
SET
SET
SET
ESC
33
2
6.4 “Automatic” mode
Functionality
Automatic is the normal mode of operation and the system is automatically controlled.
The following actions are possible:
• Display status (status display): Display the status of external components (temperatures, switching states, run times).
• Display stored min./max. values (temperature sensors) or sum/difference values (operating hours1) of the pumps and valves)
Summed values (symbol ∑): Operating hours since first commissioning. Summed
values cannot be reset.
Difference values (symbol Δ): Operating hours since the last reset to 0.
• Reset the stored min./max./difference values.
• Call up the settings menu.
1)
Summed switch-on times of the output
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Operation
√ The controller shows the status display.
You can display the status of external components as follows:
X Press to display the status of other components ( , component flashes).
You can display and reset the stored min./max./difference values as follows:
1. Press as required, in order to display other components (
, component
flashes).
2. Press SET. The min./max./difference values are displayed alternately
.
3. If desired, press and hold the SET button for 2 seconds to reset the currently (!)
displayed value .
4. Press ESC. The status display is shown.
5. Repeat steps 1 to 4 if necessary.
Access the settings menu as follows:
X Press and hold SET for 2 seconds . The settings menu appears.
SET
SET
7
2 s
SET
SET
7
2 s
SET
SET
7
2 s
SET
6
2 s
SET
6
2 s
SET
6
2 s
4
5
v
v
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7 Deinstallation and disposal
Danger
Risk of death by electrocution!
• Disconnect the device from the power supply before opening the casing.
• All work on an open device must be performed by professional personnel.
1. Deinstall the controller in the reverse sequence to installation; more information on
this is provided in the Installation section.
2. Dispose of the device in accordance with the local regulations.
8 Troubleshooting
Danger
Risk of death by electrocution!
• Immediately disconnect the device from the mains supply when it can no longer be
operated safely, e.g. in the case of visible damage.
• Disconnect the device from the mains power before opening the case.
• All work on an open device must be performed by professional personnel.
Notes
The controller is a quality product, conceived for years of continuous trouble-free operation. Observe the following points:
• Faults are often caused by connected components and not by the controller.
• The following notes on fault identification indicate the most common causes of
faults.
• Only return the controller when you are absolutely sure that none of the problems
listed below is responsible for the fault.
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8.1 General faults
Display Possible cause Solution
Controller not functioning at all
Display empty/dark Controller power supply is inter-
rupted.
• Check the controller power
cable.
• Check the fuse for the
power supply.
Pump is not running but drinking water is being drawn off.
The pump symbol rotates. Pump power supply is interrupted. Check the pump power cable.
Pump has seized up. Get the pump working again.
The pump symbol does not
rotate.
Hot water temperature has
been reached.
No fault.
• The pump symbol does not
rotate.
• Display is red.
•
flashes
Manual mode is switched on,
output R1 is set to 0 (off).
Switch to automatic mode.
• The pump symbol does not
rotate.
• The display flashes red.
Short circuit or interruption of
the temperature sensor.
• On the controller, request the
current values from the connected temperature sensors.
• Check the sensors and
cables.
Pump is running but drinking water is not being drawn off.
The pump symbol rotates. Pump is running due to block-
age protection.
No fault.
Grundfos Direct Sensors
TM
shows a flow but no drinking
water is being drawn off.
Grundfos Direct SensorsTM is
not grounded correctly.
Ground Grundfos Direct
SensorsTM: Connect a cable
between the terminal (see
on Page 8) and the metal
pipe in the direct vicinity of
Grundfos Direct SensorsTM.
• The pump symbol rotates.
• Display is red.
•
is displayed.
Manual mode is switched on,
output R1 is set to 1 (on).
Switch to automatic mode.
No heat transport in heat exchanger, pump is running, drinking water is being drawn off.
The pump symbol rotates. Air in system. Check the primary circuit for air.
The isolating valve is closed. Check/open the isolating valve.
Heat exchanger is dirty or calci-
fied.
Flush/clean the heat exchanger
in accordance with the manufacturer's instructions.
Pump shows cycle behaviour.
– Air in system. Check the primary circuit for air.
The isolating valve is closed. Check/open the isolating valve.
Heat exchanger is dirty or calci-
fied.
Flush/clean the heat exchanger
in accordance with the manufacturer's instructions.
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8.2 Fault messages
Faults are displayed as shown below, the backlighting is red.
Display (example) Description Solution
An interruption was detected
at a sensor input of Grundfos
Direct SensorsTM (temperature
or volume flow).
Check the cable and Direct
SensorsTM connected to the
sensor input.
A short-circuit was detected
at a sensor input of Grundfos
Direct SensorsTM (temperature
or volume flow).
Check the cable and Direct
SensorsTM connected to the
sensor input.
The target hot water tempera-
ture has not been reached. Possible causes:
• The storage tank is not
heated up.
• The isolating valve in the
primary circuit is closed.
• Air is in the pipes.
• The pump is faulty.
• The heat exchanger is dirty
or calcified.
• Heat up the storage
tank.
• Check the isolating
valve.
• Bleed the pipes.
• Check the pump.
• Decalcify/clean the heat
exchanger.
A short-circuit exists at output
R1, the pump flashes. Possible
causes:
• The pump is faulty.
• Wiring fault
• Check the pump.
• Check the wiring to R1.
Output R1 is overloaded, the
pump connected to output R1
flashes. Cause: The permissible
values for R1 specified on the
type plate have been permanently exceeded, the output has
been switched off.
Check the electrical data of
the pump, replace pump if
necessary. R1 is automatically switched on again.
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9 Technical data
9.1 Controller
Inputs/outputs
Rated voltage (system voltage) 115 ... 230 V~, 50/60 Hz
Own consumption < 1 W (Standby)
Output R1
Quantity
Type
Switching current
1
TRIAC
1.1 (1.1) A each
Signal inputs/outputs
Signal input Direct Sensors
TM
Quantity
Supply voltage
Output current
1
5 V= +5 %
≤10mA
Signal output PWM R1
Type
Max. load
PWM, 250 Hz, 11 ... 12 V;
characteristics: 0% PWM = pump off,
100% PWM = maximum speed
10 mA
Hydraulic schemes (systems)
Quantity 1
Display
Type LCD display with backlighting
Application conditions
Degree of protection IP22, DIN 40050 [without front panel: IP20]
Protection class I
Ambient temperature 0 ... +50 °C, when wall-mounted
Physical specifications
Dimensions L x W x H 110 x 160 x 51 mm
Weight 350 g
Software class A
Type of action type 1.Y
Type of fastening for permanently connected cables
type X
Degree of pollution 2
Ball pressure test temperature casing pan: 125 °C; other casing parts: 75 °C
Overvoltage category class II (2500 V)
9.2 Cable specifications
Mains cable
Mains cable type
External diameter of mantle
Conductor cross-section
single strand (solid)
fine strand (with core end sleeves)
H05 VV-... (NYM…)
6.5 mm to 10 mm
≤2.5mm
2
≤1.5mm
2
Diameter of the internal strain relief 6.5 mm to 10 mm
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Exclusion of liability
The manufacturer can neither monitor the compliance with this manual nor the conditions and methods during the installation, operation, usage and maintenance of the
controller. Improper installation of the system may result in damage to property and, as
a result, to bodily injury.
Therefore, the manufacturer assumes no responsibility and liability for loss, damage or
costs which result from or are in any way related to incorrect installation, improper operation, incorrect execution of installation work and incorrect usage and maintenance.
Similarly, we assume no responsibility for patent right or other right infringements of
third parties caused by usage of this controller.
The manufacturer reserves the right to make changes to the product, technical data or
installation and operating instructions without prior notice.
Legal guarantee
In accordance with German statutory regulations, there is a 2-year legal guarantee on
this product for the customer.
The seller will remove all manufacturing and material faults that occur in the product
during the guarantee period and affect the correct functioning of the product. Natural
wear and tear does not constitute a malfunction. No legal guarantee can be offered if
the fault can be attributed to third parties, unprofessional installation or commissioning,
incorrect or negligent handling, improper transport, excessive loading, use of improper
equipment, faulty construction work, unsuitable construction location or improper operation or use. Legal guarantee claims shall only be accepted if notification of the fault
is provided immediately after it is discovered. Guarantee claims are to be directed to the
seller.
The seller must be informed before guarantee claims are processed. For processing
a guarantee claim an exact fault description and the invoice / delivery note must
be provided.
The seller can choose to fulfil the legal guarantee either by repair or replacement. If the
product can neither be repaired nor replaced, or if this does not occur within a suitable
period in spite of the specification of an extension period in writing by the customer, the
reduction in value caused by the fault shall be replaced, or, if this is not sufficient taking
the interests of the end customer into consideration, the contract is cancelled.
Any further claims against the seller based on this legal guarantee obligation, in particular claims for damages due to lost profit, loss-of-use or indirect damages are excluded,
unless liability is obligatory by law.
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Notes
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745089
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