Wagner & Co RATIOfresh 250, RATIOfresh 400 Technical Information Installation Instructions

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TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

Wagner & C

RATIOfresh Freshwater Station 250/400

Hygienic Water Heating

A continuous flow process is used to heat potable water quickly and on demand to a preset temperature.

Excellent Performance

The RATIOfresh 250 unit delivers hot water at up to 25 l/ min. Thelarger station RATIOfresh 400 even reaches a tap ping capacity of 40 l/min and thus is suitable for multi-fam ily homes with up to 20 individual apartments.

Functional Design

A modern powder-coated metal casing houses all compo nents in a compact design.

Adaptive Microprocessor Controlling

The microprocessor “learns“ the water withdrawal patterns of users.This meansthefreely selectable hotwatertemper ature can be maintained precisely even with fluctuating flow or inlet temperatures within the primary circuit. This also offers various options of regulating hot water circulation.

Easy Assembly and Maintenance

The station is suitable for mounting on the wall or the storage tank (in conjunction withall RATIO buffer cylinders and the additionally available tank expansion kit). Flat sealing connections simplify assembly and installation aswell as all service tasks. After the hydraulic integration, the ready-toplug-in station can beoperatedimmediatelyasdelivered.

Numerous Application Options

The freshwater station can be combined with almost any heat source. Oil, gas, wood logs and pellet boilers are as suitable as asolar installation orlocal or districtheating dis tribution systems. All ittakesis a buffer cylinder whosether mal stratification is supported by minimal return tempera tures within the primary circuit.

Protection from Legionella Pneumophila Bacteria

If required, the hot water and the circulation piping net work can be thermally disinfected. Time, temperature, and duration of the disinfection process are individually adjustable.

Content

1. Technical Information .................2

1.1 TechnicalData ......................2

1.2 Scope of Delivery ....................3

1.3 Accessories .......................3

2. Safety Information ...................6

2.1 Operator Qualifications ................6

2.2 Intended Use ......................6

2.3 Standards andGuidelines ...............7

2.4 Installation Recommendations ............7

Figure 1 RATIOfresh Freshwater Station 250/400.

3. Installation ........................8

3.1 Prior to theInstallation .................8

3.2 Wall Mounting ......................8

3.3 Storage Tank Mounting ................8

3.4 Connecting Potable Water ...............9

3.5 Connecting Circulation .................9

3.6 Installing thePrimaryCircuit .............10

3.7 Switching thePrimaryReturn Flow ..........11

3.8 Connecting theController ..............11

3.9 Closing theHousing..................11

4. ControllerOperation .................13

4.1 Controller Displays ..................13

4.2 Controller Settings...................13

4.3 Controller SettingTables ...............14

5. Initial Startup......................19

6. Notes for Operators ..................20

7. Maintenance and Care ................22

8. Troubleshooting....................23

9. System Solutions – Example .............27

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1. Technical Information

1.1 Technical Data

Table 1 Technical Data

Feature RATIOfresh 250

Variation Copper soldered heat exchanger Stainless steel soldered heat exchanger

Order no. 150 300 65 150 301 77

Nominal tapping capacity 10 °C → 45 °C (sec.) 10 °C → 60 °C (sec.)

Coefficient of performance (NL) 10 °C → 45 °C (sec.), 82 °C (prim.) acc. to DIN 4708 T3 10 °C → 60 °C (sec.), 85 °C (prim.) 10 °C → 60 °C (sec.), 75 °C (prim.)

Nominal hot water temperature 25 – 70 °C

Circulation return 5 – 70 °C/5–25K

Pressure loss, Dp secondary < 370 mbar (with 25 l/min)

Voltage supply 230V/50Hz

Fuses

Dimensions of housing (HxWxD) 940x350x181mm

Color (powder-coated)

Max. permissible pressure 6 bar (primary), 10 bar (secondary)

Max. permissible temperature 95 °C (primary and secondary)

Capacity of water space 1.1 l (primary) / 1.2 l (secondary)

Max. electrical power consumption / standby operation mode

Protection class IP 44

Weight 26 kg

25 l/min 61 kW 87 kW

=13

=11

Operating voltage 230 V, control fuse 100 mAT / 250 V, power fuse 2 AT/250 V. To replace internal fuses, de-energize the device, remove the screws on the controller, and lift off cover (fig. 8, 9, 10).

Upper section: RAL 7035 (light gray) Bottom section: RAL 7021 (black-gray)

2 x 200 W (when connecting two pumps) / 0.6 W

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Table 2 Technical Data

Feature RATIOfresh 250

Variation Copper soldered heat exchanger Stainless steel soldered heat exchanger

Order no. 150 300 66 150 301 78

Nominal tapping capacity 10 °C → 45 °C (sec.) 10 °C → 60 °C (sec.)

Coefficient of performance (NL) 10 °C → 45 °C (sec.), 82 °C (prim.) acc. to DIN 4708 T3 10 °C → 60 °C (sec.), 85 °C (prim.) 10 °C → 60 °C (sec.), 75 °C (prim.)

Nominal hot water temperature 25 – 70 °C

Circulation return 5 – 70 °C/5–25K

Pressure loss, Dp secondary < 490 mbar (with 40 l/min)

Voltage supply 230V/50Hz

Fuses

Dimensions of housing (HxWxD) 940x350x181mm

Color (powder-coated)

Max. permissible pressure 6 bar (primary), 10 bar (secondary)

Max. permissible temperature 95 °C (primary and secondary)

Capacity of water space 1.6 l (primary) / 1.2 l (secondary)

Max. electrical power consumption / standby operation mode

Protection class IP 44

Weight 28 kg

40 l/min 98 kW 139 kW

= 19,5

=17

=11

Upper section: RAL 7035 (light gray) Bottom section: RAL 7021 (black-gray)

2 x 200 W (when connecting two pumps) / 0.6 W

1.2 Scope of Delivery

Table 3 Delivery Scope

Freshwater station, ready for plug-and-play, 4 dowel sets for wall mounting; 4 solder connection sets LT 22-1; installation instruction

1.3 Accessories

Table 4 Accessories

Item Order no.

Solder connection set LT 28.1 ¼“, swivel nut, gasket and solder connection 22mm

Threaded connection set GT 1 ¼“, swivel nut, gasket and threaded connection

RATIOfresh RS 232 PC interface cable 150 400 22

Cylinder mounting kit for CIRCO 139 000 28

Motor actuated 3 way valve 1“ M 160 101 44

Motor actuated 2way ball valve 819 201 33

139 000 44

130 100 88

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Frontal view

350

4 Primary

flow

7 Hot water

Side view

110

100

240

Drill pattern

254

2-Heat ex

changer

6 Cold water

9 Single-jet meter

570

940

8 Circulation

3 Circulation pump

ø55

1 Controller

10 Housing

5 Primary

return

Top/bottom view

181

ø55

Figure 2 RATIOfresh freshwater station viewed sectionally, with dimensions and drilling template.

521

827

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Housing cover

Top section of housing

Wagner &Co

Figure 3 Cross-section of RATIOfresh freshwater station with dimensions and drill hole pattern (page 4) 1 Adaptive microprocessor controlto regulatehotwater and circulation,display2x16 characters,plasticfoil keypad with3 keysand 4 LED,2 power outputs, 3temperaturesensors and 2 immersionsleeves made from chrome-plated brass; 2 Plate heatexchanger made from stainless steel,cop per-soldered, flat-sealing connection T1" (OT)–quickly disassembled formaintenance,specially embossed platestructuretoavoid lime deposits;

3 Circulation pump in primary return, especially energy-saving design, easy to service due to flat-sealing integration; 4 Primary flow connection T 1" (OT,flat-sealing) made from brass, with shut-off valve; 5 Primary return connection T1" (OT, flat-sealing) made from

brass, with pump shut-offslider incl. backflow preventer; 6 Cold watersupplyconnection T 1" (OT, flat-sealing) made frombrass ; 7 Hot wateroutlet connection T 1" (OT, flat-sealing) made from brass; 8 Circulation return connection option T ½" (IT) closed with plug; 9 Single-jet meter – brass, chrome-plated, connections ¾" (OT,flat-sealing),QN 2.5 m³/h; 10 Bottom section of housing made from powder-coated sheet steel with keyhole drills for wall mounting; 11 Housing cover made from powder-coated sheet steel, removable; 12 EPP shell insulation (expanded polystyrene) for plate heat exchanger; 13 Temperature sensor hot water; 14 Temperature sensor circulation return; 15 Temperature sensor storage cylinder; 16 Power switch to select pump output level; 17 Backflow preventer (in ball valve); 18 Temperature sensor primary; 19 Mains plug.

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2. Safety Information

The following safety information is intended to protect you from hazards and dangers that may suddenly occur when the device is handled incorrectly, either deliberately or un knowingly. We differentiate between general safety infor mation, explained onthis page, and special safetyinforma tion, which is listed throughout the text of this manual. The following symbols are important!

DANGER – possibility of personal injury The following may occur during assembly or installation: hazardous electrical shock, scalding, bruising/contusions, and other adversehealth effects. Please complywiththe in structions marked with this symbol in the documentation.

CAUTION – possibility of property damage This symbol indicates hazards that may result in damage to components or a significant reduction of the functionality of the system. Please follow the described assembly steps and comply with the sequence of these steps.

NOTE – additional information This symbol indicates useful notes, tips to make work easier,and other information that may help you with the installation or operation.

2.1 Operator Qualifications

station is designed insuch a way that the lowestpossiblere turn temperatures are reached, which exhibit only a minor difference to the cold water temperature.

Thermal Disinfection

The Legionella Pneumophila Bacteria protection function

can be used to disinfectthe entire hotwater and circulation

piping network thermally and during freely selectable times (day or week program). You choose between once per week (Mon-Sun) or daily. This function serves to pre vent the formation of bacteria and viruses in the potable water network. The station uses an external relay output to activate the buffer storage auxiliary or backup heating if the required primary temperature (= disinfection temp. + hysteresis

) is not detected by the sensor T

picts “DISINFECTION.” If the required temperature exists within the primary circuit (data logging with the tempera

ture sensor “T starts. The freely selectable disinfection temperature (e.g. 65 °C) ismaintained across asettable time duration (e.g. 20 min) and across all flooded hot water andcirculation pipes. Unexpected malfunctions during the disinfection phase are indicated to theuser in plaintextand additionally witha visual signal (LED light, fig. 10, no. 4). Potable water hygienists recommend a material tempera ture of 70 °C or higher for a duration of at least3 minutes to disinfect the piping network. The disinfectiontemperature, however, should be a few degrees higher or the disinfection time somewhat longer to ensure proper disinfection occurs. Do not forgetto raise the branchlines to the hotwater tapping points to the required temperatures by withdrawing water several times for several minutes. Before activating the disinfection function, check whether the hot water or circulation network can sustain such high temperature stress (e.g. damaging galvanized steel pipes) and whether the carbon hardness of the potable water is within an acceptable range. The hot water users are at risk of scalding injuries while the disinfection program is running. The disinfection should therefore be carried out at night.

”), the thermal disinfection program

buffer

. The display de

buffer

All tasks and activities involving the transport, installation, as well as operation and servicing must be performed by qualified technicalpersonnel. We do not assume responsi bility or liabilityfordamages resulting from noncompliance with these instructions.

2.2 Intended Use

Function

Heated water from a storage tank is used with a plate heat exchanger to prepare hot water with a constant tempera ture.Thecooled down return water is layeredintothe lower section of the storage tank. This is controlled demand-dependent. Only when potable water is withdrawn and detected by the single-jet meter, the circulation pump feeds the exchanger with a variable hot water volumestream from the storagetank so thata de fined tapping temperature is maintained. The return temperature is the resultof the storagetank tem perature, the pump speed, and the plate heat exchanger design. The heat exchanger of the RATIOfresh freshwater

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Circulation

The temperature difference is calculated from the circula tion flow and return temperature and compared with the

preset nominal difference. If the temperature difference is too small, the control detects an oversupply of the circula tion and reduces the output of the circulation pump based on the deviation. If the temperature difference is too great, the control increases the output of the circulation pump based on the deviation. The mass flow is then varied through a pulsed modulation of the pump output. If an ad justable return temperature is exceeded, the controller switches the pump off.

Standby Temperature Control

The RATIOfresh freshwater station is also equipped with a standby temperature control in addition to the circulation function. The control activates the primary pump and sup plies the station with hot water to maintain the preset standby temperature at the primary flow outlet port re gardless of a withdrawal of hot water. This function serves to preheat the plate heat exchanger; this means that hot water is thus much more quickly avail able at the desired nominal temperature in case water is withdrawn. This function also protects from frost if the standby temperature is set to a lower value of 10 °C. The standby temperature control is only activated if the cylin der temperature is sufficiently high.

2.3 Standards and Guidelines

The following standards and guidelines must be observed and complied with when installing hydraulics and/or per forming electrical wiring: IEC 364 or CENELEC HD 384, DIN VDE 0100 and IEC-Report 664, DIN VDE 0110 and na tional accident prevention rules and regulations, as well as VDE 0100, VDE 0160 (EN 50178), VDE 0113 (EN 60204), and local rules and specifications of your energy provider or utility company. Specifications outlined by DVGW W551 concerning pro tection from the Legionella pneumophila bacteria must be observed for multi-family home installations. A circulation must be operated between hot water heater and tapping point for potable water volumes greater than 3 liters. The hot water outlet temperature of the RATIOfresh station must always be set to ≥ 60 °C.

2.4 Installation Recommendations

Connecting the Circulation

The freshwater station RATIOfresh is designed to be con nected toa circulation line. The circulation pumpmust be a commercially available stepped wet pump. E-pumps or

pumps with integrated motor protection or ON/OFF switching electronics may not be operated.

Connecting the Primary Circuit

The pipingof the primarycircuit should be as short as pos

sible to achieve the rapid heating of the heat exchanger when water is tapped. The max. permissible pressure loss within the primary circuit may not be exceeded when lines are longer.

A bleeder is to be installed at the highest point of the pri mary circuit. The primary flow should be withdrawn at the hottest pointof the buffer storagetank, and the primary re turn should bereturnedas close tothe bottom ofthe buffer storage tank as possible. Gravity circulations may occur depending on the length, design, and insulation state of the primary circuit.This con

tinuously withdraws energy from the standby section of the buffer cylinder.

A gravity brake with low admission pressure must be in stalled on-site in addition.

Thermal Disinfection / Protection from Legionella Pneumophila Bacteria

Please note that the “Disinfection” function only can be used as intended if the cylinder temperature sensor can correctly measure the derivative temperature within the connected auxiliary heating range. The sensor should thus be attached 10 cm below the actual tapping point on the buffer cylinder (on the tank wall as depicted in fig. 7). Please also notethat increased temperatures within the hot water networkand associated pipes pose a risk of scalding injuries while the disinfection program is running!

The tank must be installed in a frost-free room with short lines to the consumer. De-energize the control unit as outlined by the manual be fore working on the pump or the control unit. Controller and pump carry electricity even if the controller switches the pump off!

Cold and Hot Water Line

A safety valve (cf.fig. 5) is required in the cold water supply line as specified by DIN 4753 T1. Amin.thread diameter of DN 15 must be selected for a heating output of max. 75 kW. Thesafety valve can beomittedonly if atypeapprovedflow monitor limits the water temperature to 95 °C. The valve must be designed for a blowing-off pressure that corre sponds with the permissible working overpressure.In case of 10 bar and higher waterline pressures, install a pressure reducer behind the water meter. When heating the fresh water station without watertap,wateris dripping out offthe safety valve. Use a siphon funnel to catch and dispose off this water. Do not install a shut-off between safety valve and freshwa ter station. A drain valve should be installed for mainte nance and service tasks. The functionality of the safety valve must be checked regularly in accordance with DIN

4753.Theexhaust vent may neverbeclosed or restricted. A corresponding water filter meeting current technology standards is to beinstalledinto the cold watersupplyline.

Protection from Corrosion and Lime Buildup

All water-conducting parts are basically subject to corro sion and lime buildup, especially if temperatures exceed

60 °C and with aggressive water. Hot water temperatures thus should never exceed 60 °C. Significant lime deposits are not expected with carbonate hardness below approx. 10° dH and temperatures less than 60 °C. If your potable water is harder than this, we recommend on-site lime buildup reducing measures. If the plate heat exchanger must be decalcified on a regular basis, irrigation cocks (fig.

6) should be installed during the system assembly. The plate heat exchanger of your freshwater station is made from copper soldered stainless steel plates. Steel pipes may thus not be used in the flow direction (towards

the freshwater station) since copper is water soluble in minute particles and causes pitting when deposited on steel.

Water with low hydrocarbon content and high portion of neutral salts (e.g. soft water containing chloride) can cause dezincification of the installed brass elements.

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3. Installation

3.1 Prior to the Installation

Before assembly, please compare thedelivered compo

●

nents with the parts list in table 3. You need the following tools: drill, stone drill (12 mm),

●

voltage meter, screwdriver, folding meter-rule, wrench size 10, monkey wrench, ratchet with size 13 socket. Materials/components needed on-site: sets of union

●

connectors to connect primary and potable water cir cuit, a safety subassembly to install into potable water network if needed, a circulation pump if needed, pipe material, and insulation material. Open the RATIOfresh freshwater station as depicted in

●

fig. 8 byremoving the housing coverin the lowersection from the lower part and lift out off the snap-in groove.

3.2 Wall Mounting (fig. 4)

Transfer the hole pattern to thewallas depicted in fig.4.

●

Drill holes (1) with a 12-mm stone drill and insert in

●

cluded plugs (2). Insert screws (3) to adistance of 1 cmand insert housing

●

(4) into keyholes (5) and attach screws. Tighten screws (3) firmly.

●

254

827

3.3 Storage Tank Mounting (fig. 5)

The RATIOfresh freshwater station is suitable for mounting directly on all buffer cylinders (RATIO-H series) using the additionally available tank expansion kit (cf. accessories, table 4):

● Remove the insulation of the RATIO-H (1) cylinder and

snap the mounting plate (3) with the U-shaped ends (4) into the second (2)andfifthconnection (5) from the top.

●

Screw down the mounting plate withthe included 1 1/2" flat swivel nuts (6).

●

Then screw the included 3 hexagonal carriage bolts (7) halfway into the mounting plate, attach lower part of housing with keyhole drill holes (fig. 4) and tighten with the carriage bolts (7).

Figure 4 Wall mounting

1 Holes; 2 Plugs; 3 Screws; 4 Bottom section of housing ; 5 Keyholes.

Figure 5 Tank mounting

1 RATIO-H cylinder; 2 Second connection from top; 3 Mounting plate; 4 Bracket; 5 Fifth connection from top; 6 1¼" flat swivel nut; 7 Hexagonal carriage bolts.

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3.4 Connecting Potable Water (fig. 6)

Cold and hot water connections must be connected to the freshwater station in accordance with the rules and regula tions issued by the local water utility or water provider. We recommend connecting to the potable water network in the manner illustrated in fig. 6.

A safety subassembly (3) with safety, shut-off, and check

●

valve must be installed in the cold water supply (2) in acc. with DIN 1988. Make sure there is no shut-off be tween the RATIOfresh station (1) and the safety sub assembly (3). To connect the piping to the cold water supply (7) of the station, please use the connection sets with 1" swivel nuts (4), soldered connection 22 mm (5), and flat seal (6) or threaded connection sets as an alter native, both available as additional accessories. The hot water outlet of the station (8)mustbe connected

●

to thehot water network with soldered or threaded con nection sets and well insulated as well. Do not forget flat seals (6)! Potable water with a high content of lime may require

●

that the heat exchanger is flushed regularly. This re quires installing irrigation cocks (9) and (10) into the cold andhot water lines in closeproximity to thestation! After irrigation cock (10) in the hot water line, an addi tional shut-off cock(11)isneeded for flushing thepipes.

3.5 Connecting Circulation (Optional, fig. 6)

DVGW 551 specifies a circulation element or system in

larger hot water networks. The circulation return (21) must be installed directly before tapping point (22).The circula tion pump (23) is supplied with voltage and controlled by the controller. Chapter 3.7 provides information about the correct connection of the power cable (24). Please note that a backflow preventer (integrated inthefigureof the cir

culation pump) must be installed in the circulation line.

Remove the 1/2" plug (26) at the circulation return con

●

nection of the station (25) and attach the circulation re turn line asperconnection diagram.Use a 1/2" threaded connection (27).

1/2 AG

Wagner& Co

Figure 6 Potable water connection

1 Bottom section of housing; 2 Cold water supply; 3 Safety subassembly ; 4 1" swivel nut ; 5 22-mm soldered connection; 6 Flat seal; 7 Cold water supply; 8 Hot water outlet; 9 Irrigation cock; 10 Irrigation cock; 11 Shutoff valve; 21 Circulation return; 22 Tapping point; 23 Circulation pump; 24 Connection cable to circulation pump; 25 Circulation return connection; 26 ½" plug; 27 ½" threaded sleeve.

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3.6 Installing the Primary Circuit (fig. 7)

In order for the RATIOfresh freshwater station to yield the desired output, it must be suppliedwith a sufficient volume of hot water either from a buffer storage tank or a district heating system. Table 14 lists the required primary flow temperatures.

The primary circuit may never be serviced by another pump even only temporarily!

Route primary flowline(1) from the hotstorage tank sec

●

tion to the RATIOfresh-freshwater station and connect with soldered orthreadedconnection sets. At theRATIO cylinder use 18-1½" connection sets with swivel nut (4), soldered or threaded connection (3) and flat seal (2), and connection sets22-1¼" with swivelnut (7), soldered or threaded connection(6)and flat seal(5)at the station. Install a bleederif lines in theprimaryflow are installed in an upward direction!

Connect the primary return line (8) and route to the cor

●

responding storage tank connection that matches the temperature level. Table14 lists the return temperatures of the station in dependency of the operating condi tions. Routecableofthetemperaturesensor(9) marked

●

” from the freshwater station along theprimary flow

“T

prim

and attach sensor in the aux. heating section of the buffer cylinder approx. 10 cm below the actual tapping point of the primary flow. Use the uppermost position of

the connector block (10) at the RATIO buffer cylinder.

The sensor must correctly detect thecylinder temperature. Check the correct position of the sensors after the initial startup!

Wagner&Co

6 7

10 cm

Figure 7 Primary circuit installation 6-1 Primary flowline; 6-2 Flat seal; 6-3 Soldered or threaded connection; 6-4 Swivel nut; 6-5 Flat seal; 6-6 Soldered or threaded union; 6-7 Swivel nut; 6-8 Primary return line; 6-9 Temperature sensor T

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; 6-10 Connector block.

buffer

3.7 Switching the Primary Return Flow (fig. 15)

When the RATIOfresh freshwater unit is used in systems that are continuously operated at water temperatures >= 60 °C and work with circulation nets, we recommend the controlled switching of the return flow to the buffer cylin der. Thus it can be avoided that during periods of low hot water drawing, hot water enters the lower part of the the buffer cylinder where it could cause unwanted mixing. The switching canbe carried outby a 3-wayvalve (see solu tion shown infig.15).Thevalveshould have short switching times (<30 s) and low pressure loss. (e.g. Wagner & Co 3way-valve, order no. 160 101 44). Control should be based upon temperature difference, e.g. via solar controller SUNGO SXL.

3.8 Connecting the Controller (fig. 9)

and opens contact 11-13. Once the boiler is no longer needed, contact 11-12 is opened again and contact 1113 is closed again. If contact 11-12 is closed, the third LED from the left (cf. 10-3) is continuously green. fig. 9 also depicts the control fuse (16) (400mAT / 250 V)

●

and the output fuse (17) (6.3 AT / 250 V). Hold controller housing cover before the bottom sec

●

tion of the housing, reattach the flat ribbon cable to the display board (3), attach the coverto the bottom section, press down the 4 Phillips screws (cf. 10-9) and turn to wards the right by 90°.

3.9 Closing the Housing (fig. 8)

To close themetalhousing,insertthe housing cover (1)into the snap-ingroove (2) at the bottom sectionof the housing (3) and then snap the two snap-in plugs (4) at the bottom into sockets (5).

All tasks and activities involving the transport, installation, as well as operation and servicing must be performed by qualified technical personnel.

The controller is for the most part prewired. A fourth tem perature sensor and a circulation pump can be connected in addition tothe mains connection.If the disinfection func tion is utilized, the auxiliary heating of the buffer cylinder must be activated via the external switching output.

● To openthe controller turnthe 4 Phillipsscrews (cf. 10-9)

to the left by 90° and remove cover of housing. Remove the flat ribbon cable plug to the display board from socket (3) and set aside the cover of the controller to avoid damaging it.

● Remove the plug (4) to the mains connection from

socket (5), route themains cable (cable cross-section 3 x

0.75 to 1.5), e.g. along the primary return and a free PG gland (cf. 10 no. 10), into the station. Attach phase, zero conductor,and potential ground to plug(4) and then in sert this plug into socket (5).

●

If needed, connect the circulation pump with plug (6) in the same way and plug into socket (7) (required cable cross-section: 3 x 0.75 to 1.5).

●

A fourth temperature sensor (type KTY, cf. accessories) can be connected via plug (8) and socket (9).

●

A RS 232 interface cable available as an accessory can be connected to plug (12) (socket (13)). It is also possi ble tolog all measured values, the currentcontroller sta tus, and thecurrent pump output. This requires connect ing the 9-pin D-SUB plug of the data cable to the serial RS 232interface of a computer.Possible logging utilities are a terminal program such as included with Windows 95, 2000, or XP (All Programs -> Accessories). Use these transfer settings: RS 232 Port = COM1/COM2, Emula tion = ANSI, Transfer rate = 19200 bit/s, Data bits = 8, Stop bits = 1, Parity = None, Protocol = No protocol (XON/XOFF, RTS/CTS).

●

The additional external switching output of the RATIOfresh freshwater station onplug (14) socket (15)is intended for the activation of the aux. boiler heating for the disinfection operation. Please note that the current applied to this potential-free switching contact may not exceed a current intensity of max. 0.5 A. If a boiler de mand is triggered, the controller closes contact 11-12

Figure 8 Close housing

1 Housing cover; 2 Snap-in groove; 3 Bottom section of housing ; 4 Snap-in plug; 5 Snap-in socket.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 11

at rest

11 12 13

activated

11 12 13

Hot-/cold water sensors

Hot water sensor (blue)

Mass (brown) Circulation / cold water

sensor (blue)

Primary circuit sensors

Buffer cyl. sensor (blue)

Mass (brown)

Primary flow sensor (blue)

Low voltage area

12 1311

230 V

Optional circulation pump

Grounding (yellow/green)

Zero (blue)

Phase (black or brown)

Primary pump cable

Grounding (yellow/green)

Zero (blue)

Phase (black or brown)

Single jet meter

Mass (brown

Impulse (green)

not used

Optional data cable

Plus 5V (yellow)

TxData (white)

RxData (green)

Mass (brown)

+5V

+15V

Mains connection

Grounding (yellow/green)

Zero (blue)

Phase (black or brown)

Figure 9 Controller connection 3 Socket flatdata cable; 4/5 Mains(plug/socket); 6/7Circulationpump (plug/socket); 8/9 Primarycircuit sensor (plug/socket); 10/11 Meter (plug/ socket); 12/13 Data cable (plug/socket); 14/15 External switching output for heating circuit control (plug/socket); 16 Micro-fuse, 250V/T6,3 A; 17 Micro-fuse, 250V/T400 mA; 18/19 Secondary sensor hot/cold water (plug/socket); 20/21 Primary pump (plug/socket).

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4. Controller Operation

4.1 Controller Displays (fig. 10)

Thecontroller of theRATIOfreshfreshwaterstation features a permanently backlitLCD display (5)with2 lines, LCD- Dis play (5),4 LEDs depicting information about the operating status of the station (1) to (4) and 3 control buttons (6), (7), and (8). Open thecover of thecontroller by unscrewing the four Phillips screws (9)!

IMPORTANT Only open the controller housing cover when unit is deenergized! Only qualified technical personnel!

A steady green LED (1) is based on the output of thepri

●

mary circuit pump (max. output), with longer green phases (medium output), or with shorter green phases (low output). LED (2) indicates the operating status of the circulation

●

pump (if connected) in the same manner. A steady green LED (3) indicates that the external

●

switching output to activate the auxiliary heating (only disinfection function) is closed. A steady red LED (4) indicates that the disinfection tem

●

perature was less than required during the disinfection time or that the primary circuit temperature fell below the required temperature level.

● Use keys < (6) and > (8) to browse within the info level

and depict all currenttemperatures and pumpoutputs.

Wagner& Co

8 7 6

4.2 Controller Settings (fig. 10)

● Use key ■ (7) to switch from the info level to the menu

level.

● Use keys < and > to select the desired setting menu.

● Press key ■ to switch to the value level where the set

nominal values are listed in square brackets.

●

Select the desired menu item with the < and > keys and release for changewiththe ■ key:the square keys are no longer depicted.

●

Use the < and > keys to set the new nominal value and press the ■ key to save.

●

Exit themenu level with the menuitem “END …“ and se lect with the < and > keys and press the ■ key. This re turns you to the next higher level.

Info Level

Menu level

Value level

Setting level

Temp. Warmwasser

Temp. hot water Ist: 47°C

Actual: 46°C

Temp. Warmwasser

Settings: Ist: 47°C

HOT WATER

Pump 1 mode

[AUTO]

Temp. hot water Nominal: [45]°C

Temp. Warmwasser

Temp. hot water Ist: 47°C

Nominal: [45]°C

Settings: End ...

End ...

post

Temp. hot water Nominal: [50]°C

Temp. Warmwasser

Temp. hot water Ist: 47°C

Nominal: [50]°C

Figure 10 Controller display and controller configuration 1 LED, primary circuitpump; 2 LED,circulation pump; 3 LED,Aux.heat ing activation; 4 LED, temperature; 5 LCD display; 6 Left key; 7 Center key; 8 Right key; 9 Phillips screws.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 13

4.3 Controller Setting Tables

Table 5 Info Level (use the < and > keys to select the desired display, use the

Menu Description Range

TEMP. HOT WATER

Actual: ## °C

TEMP. CIRCULATION

Actual: ## °C

TEMP. VESSEL

Actual: ## °C

PRIMARY FLOW

Actual: ## °C

P 1 – HOT WATER

Output: ### %

P 2 – CIRCULATION

Output: ### %

TAPPING/AREA

###%/##

MONDAY

##:##:##

Temperature at hot water connection of station. While water is being withdrawn, the hot water temperature is displayed, otherwise the standby temperature.

Circulation return temperature (with active circulation function or cold water temperature [without circulation system])

Derivative temperature in aux. heating section of the buffer cylinder. The RATIOfresh controller corrects the hot water control function based on this measured value.

Temperature at primary flow connection of the unit. While water is drawn, the flow temperature is displayed, otherwise the stand-by temperature is shown.

Output of primary circulation pump in % 0 to 100 %

Output of circulation pump in % 0 to 100 %

Tapped volume in % of the set max. tapping volume. The range number indicates the tapping slot reached when withdrawing water [01 – 10], see also

-> max.tap volume.

Day of the week and current time, in hours:minutes:seconds

key to switch to the menu level)

-20 to 120 °C

0to100%

Monday – Sunday, 00:00 to 24:00

Table 6 Menu Level (use the < and > keys to select the desired menu and confirm with the

Menu Description

SETTINGS:

HOT WATER

SETTINGS:

CIRCULATION

SETTINGS:

DISINFECTION

SETTINGS:

TIME

SETTINGS:

MAINTENANCE

SETTINGS:

MANUAL FUNCTION

SETTINGS:

LANGUAGE

SETTINGS:

DEFAULTS

END

key)

Settings for the primary circuit pump, nominal hot water temperature, and standby temperature, details in Table 7

Settings for the circuit pump operating mode, determining the time frame for the circulation operating, circulation return temperatures, details in Table 8

Settings for the thermal disinfection, time, duration, temperatures, details in Table 9

Setting of day of the week and time, details in Table 10

This menu serves to change control parameters with special applications and requires input of a code to prevent accidentally changing these parameters (code available upon request), details in Table 11

This menu is used for maintenance tasks directly affecting the operating mode of the primary circuit pump and the circulation pump, details in Table 12

Presetting the desired language for all displays, details in Table 13

Activate this menu with the ■ key and select “YES” with the < or > keys to restore all values of all menu items to the factory settings indicated in Tables 7 to 13 (factory settings). Important! All customized settings are deleted and replaced with the default settings! Select “END” to return to the menu level.

Select this menu item with the < and > keys and press the ■ key to return to the info level.

14 EN-RATIOfresh-250-400_TI-MA-0809-11214900

Table 7 Value Level – HOT WATER SETTINGS (use the < and > keys to select the desired menu item, use the with the

key)

key to switch to the setting level, use < and > to change values, save

Designation Description Range Base value Your value

PUMP 1 – MODE

[AUTO]

P 1 MIN CAPACITY

[010] %

TEMP. HOT WATER

Nominal: [45] °C

TEMP. CIRCULATION

Nominal: [45] °C

Software can be used to set the operating mode of the primary circuit pump and is used for manual operation of the pump.

The min. output indicates the pump capacity used to control the hot water in standby and circulation. This value cannot be less than 10% because the pump bearings no longer have a sufficient amount of water available for use with a value below 10 %.

Setting the desired nominal hot water temperature 25-70 °C 50 °C

Setting the desired circulation flow temperature concerning the temperature measured as the hot water temperature sensor

OFF ON

AUTO

10–70% 10%

25-70 °C 45 °C

This is the temperature maintained by the system if no water is withdrawn and the circulation function is not active.

TEMP. STANDBY

Nominal: [40] °C

The lowest set value of 10 °C ensures protection from frost for the RATIOfresh freshwater station. The current buffer cylinder temperature must be higher than the

10-70 °C 40 °C

nominal standby temperature by at least5Korthehold function is deactivated.

Setting the tap volume max. occurring in this system on a regular basis. For example, if you use a shower with 10 l/min and two water faucets each with 5 l/min, the max. tapping volume to be expected on a regular

MAX. USAGE

Nominal: [20] l/min

basis amounts to approx. 20 l/min. Set [20] l/min as the max. tap volume. The selected tapping volume range (here: 0 l/min to 20 l/min) is divided by the control into 10 time slots and an internal control value is adjusted for each time window during the adaptation process.

20 to 80 l/min

20 l/min

Selecting an unfavorable max. tap volume value can thus adversely affect the control performance. The actual max. output of the station is not reduced by this setting.

END Use the < and > keys to select and then confirm returning to the menu level with the ■ key.

Table 8 Value Level – SETTINGS: CIRCULATION

Designation Description Range Base value Your value

Setting the mode for the hot water circulation. The “continuous” mode controls the circulation continuously and adjusts circulation to the specified temperature difference between hot water outlet and circulation return. The “time” mode starts the control of the circulation pump as soon as

MODE

[time]

the withdrawal of water is detected (brief opening of a tapping point suffices). The control ends if the “post-event time” (see below) has expired after the hot water has been withdrawn.

continuous time

continuous

Programming the time slots makes it possible to combine both control modes: When selecting “time” and programming the time slots, the circulation control functions outside of the time window according to the detection of the withdrawal of water and within the time window according to the temperature difference.

PUMP 2 – MODE

[AUTO]

P2 – MIN CAPACITY

[010] %

FOLLOW-UP TIME

[010] min

Software can be used to set the operating mode of the circulation pump and is used for the manual operation of the pump.

This setting indicates the min. pump capacity used to control the circulation. The value must be adjusted depending on used pump type and check valve.

The follow-up time is only adjustable if the “time” circulation mode is selected. Set the time in minutes for which the circulation time is to run after the end of a tapping.

OFF ON

AUTO

10–70% 10%

0 – 255 min 10

EN-RATIOfresh-250-400_TI-MA-0809-11214900 15

Table 8 Value Level – SETTINGS: CIRCULATION

Designation Description Range Base value Your value

The time slots 1 to 4 are depicted in the menu only if the circulation mode “time” has been selected.

TIMESLOT WEEKDAY

slots 1-4

TIMESLOT WEEKEND

slots 1-4

TIMESLOT 1 (2,3,4)

Start: [00:00] Time

TIMESLOT 1 (2,3,4)

Stop: [00:00] Time

TARGET GAP

Nominal: [10] K

MAX. TEMPERATURE

Nominal: [40] °C

Sub-menu for setting the circulation times on weekdays (Monday to Friday)

Sub-menu for setting the circulation stimes on weekends (Saturday and Sunday)

First switching on point for the circulation pump in “time” mode. Press the ■ key to release the time for changes. Use < and > to set the hours first and then use ■ to switch to the minute input and change the minutes with < and > and then use ■ to return to the time window level.

First switching off point for the circulation pump in “time” mode. Follow the procedure already described.

The nominal difference indicates the temperature difference in K, which is to be maintained between hot water outlet and circulation return.

This adjustable value indicates the circulation return temperature in °C. If this value is exceeded, the circulation pump switches off.

00:0024:00

00:00

5–25K 10K

5–70°C 40°C

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

Table 9 Value Level – DISINFECTION SETTINGS

Designation Description Range Base value Your value

The disinfection can be displayed and activated only when the cylinder temperature sensor is connected. Based on the current measured value, the demand for aux. heating is carried out via the external potential-free output. Risk of scalding during the disinfection cycle!

Select operating mode for the disinfection of the hot water system.

MODE

Nominal: [OFF]

When in automatic mode (AUTO), the hot water and circulation network are thermally disinfected at the selected time. Select a time outside of the typical tapping times to reduce the risk of scalding! With the operating mode ON, the disinfection is activated continuously

AUTO ON OFF

OFF

(e.g. for testing the function), with OFF is it completely deactivated.

STARTING TIME

[23:00]

STARTING DAY

[Monday]

SYSTEM TEMP

Nominal: [65] °C

DURATION

[020] min

Enter the time when disinfection is to start.

Setting the week program. Disinfection can also be started on a predefined day (Mon-Sun) or every day.

The system regulates the circulation pump so that the set system temperature is reached in the circulation return. The hot water temp. is then adjusted to a temperature that is 50 % higher than the hysteresis of the aux. heating.

Disinfection duration in minutes. This is the duration for which the system temperature is maintained in the circulation return. The LED diode (9-4) lights up red if the system duration falls below this value during this time.

00:00 – 24:00

Mon to Sun, daily

23:00

Sun

55–80°C 65°C

0 – 60 min 20 min

Aux. heating hysteresis. The external (potential-free) switching output of the controller is closed as soon as the temperature in the aux. heating section of the buffer drops below the sum of disinfection temp. and

TEMP. RISE

[10] K

hysteresis.

The boiler serving for the aux. heating must be connected in a way that it starts the boiler charge function when the potential-free contact is

5–15K 10K

closed. Since the max. temperature of the boiler is not monitored, the boiler temperature limitation must be set in a way as to prevent excess temperatures in the system.

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

16 EN-RATIOfresh-250-400_TI-MA-0809-11214900

Table 10 Value Level – SETTINGS: TIME

Designation Description Range Base value Your value

WEEKDAY

[Monday]

TIME [00:00]

Make sure the day of the week and the time are set correctly especially when using the circulation and disinfection function.

Monday to Sunday

00:00 – 24:00

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

Table 11 Value Level – SETTINGS: SERVICE

Designation Description Range Base value Your value

CODE NUMBER 800174

MON-005

RS232-INTERVAL

[003] s

This menu serves to change control parameters with special applications and requires input of a code to prevent accidentally changing these parameters. The code is available upon request. Use

0 – 255

the < and > keys to set the correct code.

Setting the output interval of the serial interface. 1 – 255 s 3 s

Compensation factor to affect the sensitivity of the hot water control in

PRIMARY FACTOR

[20]

dependency of the buffer cylinder temperature. If the compensation factor is set to 0, compensation is not active and that also applies to when neither primary flow sensor nor buffer cylinder sensor are

0 – 240 20

connected.

Kp CIRCULATION

[05] K

IMPULSE/LITRE

[35 ]

Kp VOL

[05] K

RATIOfresh type

[250-400]

Boost factor of pump in relation to the determined temperature difference hot water-circulation return

1–10K 5K

Impulse value of the volume flow sensor 0 – 100 35

Boost factor of pump in relation to drawn water volume. 1 - 50 K 5 K

Controlling variation - this selection resets all values to factory setting.

250/400/ 800

250/400

Start values for calculation of pump power. For all 10 tapping slots start values are set. They are the base of calculating the required pump force. The actual temperatures and tapping volumes are incorporated

ADAPTATION VALUES

in the calculation. The individual values can be examined and changed by selecting the respective sub-menus. If not all slots are reached during controlled tapping while commissioning the system (chap. 5.6), the adaptation values can be set directly. The power of the pump continuously increases over the ten tapping slots. Each slot must have a higher value than the previous one.

Adaption value of the first tapping slot. On the left the current hot water temperature is shown. In the centre you can see the tapping slot currently in use. On the right, the momentary adaptation value can be

ADAPT. VALUE 1

60 °C 01 [08]

seen. In order to make an adjustment, the adaptation value (display: top) related to the current tapping slot (display: centre) should be selected. Increasing this value will also increase the initial pump power

5–90 8

of the slot. Setting the value to high results in risk of scalding, since the controller only starts with the adaptation after 10 s and then reduces the pump power until the set water temperature is reached.

ADAPT. VALUE 2

60 °C 02 [15]

ADAPT. VALUE 10

60 °C 10 [71]

PUMP INTERVAL

[200] ms

Adaptation value of the second tapping slot 5 – 90 15

Adaptation value of the tenth tapping slot 5 – 90 71

200 – 600 ms

200 ms

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 17

Table 12 Value Level – SETTINGS: MANUAL OPERATION

Designation Description Range Base value Your value

P1 – HOT WATER

[AUTO]

P2 – CIRCULATION

[AUTO]

BOILER REQUEST

[AUTO]

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

Table 13 Value Level – SETTINGS: LANGUAGE

Designation Description Range Base value Your value

LANGUAGE

[English]

END Select this menu item with the < and > keys and press the ■ key to return to the menu level.

Software can be used to set the operating mode of the primary circuit pump and is used for the manual operation of the pump.

Software can be used to set the operating mode of the circulation pump and is used for the manual operation of the pump.

Software can be used to set the operating mode of the potential-free relay and is used for manual operation.

All menu items and displays are depicted in the selected language.

OFF ON AUTO

German, French, English, Italian, Spanish

AUTO

German

18 EN-RATIOfresh-250-400_TI-MA-0809-11214900

5. Initial Startup

5.1 Checking Installation

Check especially the following three points:

The correct connection of the pipes based on the con

●

nection diagrams in fig. 6 and fig. 7 as well as the de scribed assembly steps. The correct placement of the temperature sensor T

●

buffer

within the aux.heating section of the buffer cylinder. The controller uses this sensor to detect the available tem perature for the functions “circulation” and “standby”. Temperaturesensor T

also serves toactivate the aux.

buffer

heating boiler during the thermal disinfection process. If thedisinfection function isto beactivated,the external

●

switching output of the RATIOfresh freshwater station must be connected with the external switching input of the aux. heating boiler. In thiscase, the boileris fired and the storage charge pump starts when the RATIOfresh issues a boiler request.

5.2 Filling the Primary Circuit (fig. 11)

Now slowly fill the buffer cylinder and the primary circuit. This requires inserting the mains plug and switching the primary circuit pumpto the operation mode“Constant” us ing the “Manual Mode” menu.Open check valve (15)at the ball cock in the primary return (see fig.11 enlarged section for the correct position).Vent the primary circuit during the filling process.

5.3 Configuring the Controller (fig. 10)

Now configure the controller for the specific on-site conditions. fig. 10 provides an overview over the menu structure and explains the use of the control keys. Enter the corresponding values into the setting menus in the following order: “HOT WATER”, “CIRCULATION”, “DISINFECTION”, “SERVICE”, “LANGUAGE”, and “TIME”. Tables 7 to 13 pro vide assistance with selecting the respective values. To finish, enter the individual configuration into the “Your Value” column.

5.4 Selecting Pump Level (fig. 11)

The RATIOfresh freshwater station pump has three power levels (maximum, medium, and minimum). The setting key (16) is locatedon the upperside of thepump switching box. Select the matching level for the chosen max. tapping vol ume based on Table 14. The table values were calculated based on the assumption that the potable water flows in with a cold water temperature of 10 °C and is heated by the RATIOfresh station to a nominal temperature of 45 °C or 60 °C (incl. pressure loss of 0.7 m corrugated tube DN 16 between station and buffer and screw connections):

●

Select the volume flow from column 1, which is the max. volume you wish to withdraw from the hot water net work.

●

The pressure loss listed in column 2 occurs additionally in your hot waternetworkwith the indicated tapping rate due to the station.

90°

Open

Ready

Figure 11 Heat exchanger disassembly 2 1" swivel nut; 3 Heat exchanger; 4 1" swivel nut; 5 Shut-off valve;

6 1" swivel nut; 7 Ball valve; 8 Circulation pump; 9 1¼" swivel nut; 10 1" swivel nut; 11 1" swivel nut ; 12 Size 36 wrench; 14 Size 10 wrench; 15 Check valve; 16 Adjustment pump speed.

for operation

EN-RATIOfresh-250-400_TI-MA-0809-11214900 19

Hot water with the temperature indicated in column 3

●

must be available at minimum in the auxiliary heating section of the buffer cylinder in order to reach the de sired flow temperature withthe indicated maximumtap ping volume flow. Select from thelisted auxiliary heating temperatures. The volume flowindicated in column 4must be pumped

●

through the heat exchanger in the primary circuit in or der to reach the nominal hot water temperature. The heating water is cooled intheheat exchanger to the tem perature listed in column 5 and then supplied to the lower buffer cylinder section. Manually set the pump level (max – med – min) from

●

column 7. Adjust the set value “wMax. tap volume” in menu “hot

●

water” (Tab. 7). Select the regularly occurring max. vol ume flow. It should be significantly lower than the maxi mum volume flow for the heating of which the pump is set. Generally thetapping volume interval is dividedinto 10 time slots. For each time slot an internal control value is adapted during the adaptation process. An unfavour ably chosen maximum tapping value can therefore re duce the controller performance. The actual maximum performance of the unit is not affected by the settings.

3. After approx. 30 seconds, the controller starts to adjust

the hot water temperature to the desired temperature. Select the menu item “Hot Water Temp.” in the info level

of the controller and wait until the set nominal tempera

ture has been reached.

4. Then select once more the menu item “Tapping/Area”

and now continue opening the hot water tap until the display depicts “### % / 03”. Now the adjustment starts

already after 10 seconds. Return to the “Hot Water Temp.” menu and wait until the

hot water temperature has reached the set nominal value.

5. Continue with the remaining 7 tapping slots in this man

ner. If during controlled withdrawl no sufficient volume flow is available, the adaptation values of the tapping slots that

were not reached can also be set manually. For this pur

pose use the sub-menu "adaptation values" (Tab. 11). The required service code is available upon request. At the end of thecontrolled tapping, the controllerdelivers the desired temperature with small as well as with large

volumes of water being withdrawn.

6. Notes for Operators

5.5 Setting the Auxiliary Heating Temperature at the Heating Boiler

The value you determine for the aux. heating temperature of the heating boiler corresponds with the standby temperature in the buffer storage tank or the required temperature in the primary flow of the RATIOfresh station. This nominal temperaturefor the primary flow is listed in table 14 and depends on the selected max. tapping volume and pump level. Several combinations comprised of “Primary Flow Temperature”, “Primary Return Temperature”, and “Pump Power Level” are availableto you forthe individual weighting.

5.6 Perform Controlled Tapping

The RATIOfresh has an automatic adjustment function to ensure the desired temperature is always available regard less of the tapping volumes. A single-jet meter in the cold water supply measures the volume and passes the value to the controller in % of the “Max. Tap Volume”. The selected tapping volume rangeis divided into 10 equaltapping time slots. When different volumes are withdrawn within the set range, the controller “learns” to deliverthe desired temper ature in each of the 10 tapping slots. The current tapping volume range can be displayed in the info level of the con troller in the menu item “Tapping/Area”. To optimally adjust the hot water temperature to different tapping volumes, a controlled tapping should be per formed when initially starting up the system. Please follow these steps and adhere to the described sequence of these steps:

1. First, select the menu item “Tapping/Area” in the info level of the controller.

2. Open a hot water tap until the display depicts “### % / 02”.

After professionally trained and qualified service techni cians performed the initial startup, your freshwater station is triggered automatically to heat your potable water when hot water is withdrawn from the system. No other control steps are necessary if the system is operated as intended. Please note the following points:

Nominal Hot Water Temperature

The nominal temperature of the hotwater can bepreset on your freshwater station. Please follow the recommended steps of this manual.

Energy-Saving Operation

The pumplevel should be set as low as possible; the same applies to the nominal aux. temperature in the buffer cir cuit. Consult table 14.

Malfunctions and Defects

Please report anymalfunctions and defects immediately to a trained and qualified service technician!

Maintenance and Care

As with anyother technical equipment,yourfreshwatersta tion must be serviced and maintained regularly by trained

and qualified technicians. If you have very “hard water” the heat exchanger must be checked for lime buildup and

cleaned as needed. Consult Chapter “Maintenance and Care” for additional information.

Placing System in/out off Operation / Vacation

While you are on vacationorduring times when hotwater is not needed, we recommend de-energizing the freshwater station by unplugging it from the mains power network to avoid any unnecessary electricity consumption.

20 EN-RATIOfresh-250-400_TI-MA-0809-11214900

After a Power Outage

The current time and all other settings are saved even dur ing a poweroutage.However,you should check all settings and the time after power is restored to ensure the disinfec tion cycle is not started accidentally.

Table 14 PRIMARY TEMPERATURE AND PUMP LEVEL SETTINGS

Tapping volume flow (= HW) in l/ min

For RATIOfresh 250 at nominal hot water temperature of 45 °C

10 65

15 140

25 370

For RATIOfresh 250 at nominal hot water temperature of 60 °C

10 65

15 140

25 370

For RATIOfresh 400 at nominal hot water temperature of 45 °C

15 82

25 204

40 490

For RATIOfresh 400 at nominal hot water temperature of 60 °C

15 82

25 204

40 490

Pressure loss in secondary circuit (=HW side) in mbar

Required temperature in primary flow, in °C

50 13.0 23 98 min

60 8.1 16 65 min

50 21.9 26 241 med

60 12.8 18 96 min

60 23.4 22 199 med

70 17.3 18 157 min

65 14.5 30 117 min

75 9.4 21 27 min

65 24.9 34 305 max

75 15.1 24 125 min

75 28.2 29 386 max

80 24 26 285 med

50 19.1 22 115 min

60 12.1 16 58 min

55 26.2 21 203 max

65 18.4 17 109 min

65 31.5 20 287 max

75 24.7 17 181 med

65 21.2 29 138 med

75 14 20 71 min

65 30.4 28 269 max

75 25.2 24 189 med

85 33.7 24 328 max

90 30.4 22 269 max

Required primary volume flow, in l/min

Frost Protection

Make sure the heating system remains in operation in case

of frost and that all roomsare sufficiently heatedto prevent frost.

Return temperature in primary circuit

Pressure loss in primary circuit

Output level of the primary circuit pump.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 21

7. Maintenance and Care

The system should be checked annually:

Check all screw connections and soldered points for

●

leaks. In case of potable water with an increased carbonate

●

content, the heat exchanger should be checked regu larly for lime buildup. The following changes are indica tive of lime buildup: Return temperatures of the primary circuit are significantly above those listedinTable 14.The max. hot water volume flow that can be withdrawn has been reduced.The set nominal hot water temperature is no longer reached with frequent water withdrawals.

Decalcification of the Heat Exchanger (fig. 6, 11, 12)

If flushing spigots are installed in the cold and hot water lines, the heat exchanger canbe decalcified by flushing the system (fig. 11). If flushing spigots are not in place, the en tire heat exchanger must be removed from the station (fig.

11. This requires the following: De-energize the station!

●

Depressurize the potable water line by closing the shut-

●

off valves at the safety subassembly (fig. 6, no. 3) and in the hot water network (fig. 6, no. 11). Empty the potable water side of the heat exchanger using the drain spigot (fig. 6, no. 9) installed in the cold water supply line. Close shut-off valve (fig. 11, no. 5) in the primary circuit

●

flow and pump slider (fig. 11,no.7) to block primarycir cuit (fig. 11, no. 2, 9).

● Empty heat exchanger (fig. 11, no. 3) onthe primary side

by loosening the 1" bolt (fig. 11, no. 6) at the primary flow connection and (fig. 11, no. 10) at the primary return.

● To remove the heat exchanger, remove all four 1" swivel

nuts (fig. 11, no. 4, 6, 10, 11) using a size 36 wrench. Place heat exchanger over night into a commercially available decalcification solution or a 5 % vinegar solution followed by a thorough cleaning. Be careful when handling decalcification and vinegar solutions!

●

To flush the heat exchanger (fig.12), pump the cleaning fluid (fig. 12, no. 1) through the circuit‘s heat exchanger (fig. 12, no. 13) andthe filling spigot (fig. 12, no. 10) with a feed pump (fig. 12, no. 2) using the filling spigot (fig. 12, no. 9) and then neutralize it according to the instruc tions of the manufacturer of the cleaning fluid. Only use cleaningfluidsapproved for potable waterand perform the neutralization according to theinstructions! Be careful when handling any chemical solutions!

●

After reinstalling the heat exchanger or completing the flushing process, open all shut-off valves and spigots, apply voltage to the controller, and vent the primary cir cuit according to Chapter 5 Initial Startup.

90°

Figure 12 Heat exchanger decalcification

1 Cleaning fluid; 2 Feed pump; 3 Safety subassembly; 9 Filling spigot; 10 Filling spigot; 11 Ball valve; 13 Heat exchanger.

22 EN-RATIOfresh-250-400_TI-MA-0809-11214900

8. Troubleshooting

Table 15 Malfunction Cause Remedy

Hot water flow volume is insufficient.

No hot water.

Water does not get hot.

Hot water temperature is too low.

Hot water temperature is too high.

Shut-off valve in cold water supply partially closed.

Clogged cold water supply filter. Shut off the cold water supply, remove filter, clean filter.

Lime buildup on heat exchanger.

Shut-off valve in cold or hot water network closed.

Power outage or potable water station without power.

Fuses defective.

Primary circuit pump defective.

Air within the primary circuit prevents sufficient flow through the heat exchanger.

Flow through primary circuit insufficient.

Single-jet meter does not detect when water is withdrawn.

Incorrectly set nominal temperature. Change the nominal hot water temperature.

Aux. heating temperature set too low.

Incorrectly set power output level of the primary circuit pump.

Controller not yet adapted. Carry out a controlled tapping (see chapter 5.6).

Air within the primary circuit prevents sufficient flow through the heat exchanger.

Flow through primary circuit insufficient.

Incorrectly set nominal temperature. Change the nominal hot water temperature.

Primary circuit pump mode set incorrectly.

Disinfection operating mode set incorrectly (“On”).

Incorrectly set disinfection start time.

Controller not yet adapted. Carry out a controlled tapping (see chapter 5.6).

Incorrectly set power output level of the primary circuit pump.

Storage tank temperature temporarily increased significantly due to solar charging.

Gravity circulation in primary circuit (detectable only with brief tapping events).

Primary circuit temperature sensor attached at incorrect position.

Check all shut-off valves and spigots and open completely.

Check the heat exchanger for lime buildup and decalcify if necessary (see chapter 7).

Check all shut-off valves and spigots and open completely.

Check whether the display of the potable water station is illuminated. Plug the power plug of the potable water station into the wall socket.

Check fuses in controller of potable water station and replace if necessary.

Check the function of the primary circuit pump (manual operation).

Bleed the primary circuit (see chapter 5.2).

Check the entire primary circuit: Shut-off elements, power supply, pump and controller settings.

Check the function of the single-jet meter (e.g. with acoustic test of the pulse output using a multimeter).

Compare the set value with the recommendations in table 14 and correct as needed.

Bleed the primary circuit (see chapter 5.2).

Check the entire primary circuit. Shut-off elements, power supply, pump and controller settings.

Set the mode of the primary circuit pump to “Auto”.

Set the operating mode of the disinfection to “Auto”.

Change the disinfection start time. Select a time outside of the typical tapping times (e.g. at night).

Compare the set value with the recommendations in table 14 and correct as needed.

The potable water station automatically adjusts this next time water is withdrawn.

Check the setting of the gravity brake and possibly of the hydraulics (e.g. in case of multiuse of the buffer cylinder connections of the primary circuit).

Check the position of the storage cylinder temperature sensor and correct if necessary (see chapter 3.6).

EN-RATIOfresh-250-400_TI-MA-0809-11214900 23

Table 15 Malfunction Cause Remedy

Circulation pump defective. Check the function of the circulation pump (manual operation).

Shutoff elements closed. Check all shutoff valves and cocks and open completely.

Circulation system heating is insufficient.

Air in circulation system. Bleed the circulation system.

Min. output of the circulation pump too low to open the backflow

Increase the value of the min. output of the circulation pump.

preventer.

Defective single-lever mixer at tapping point.

Check whether the fluctuation occurs only at one tapping point.

If needed, replace single-lever mixer at this tapping point.

Controller not yet adapted. Carry out a controlled tapping (see chapter 5.6).

Hot water temperature fluctuates.

Incorrectly set power output level of the primary circuit pump.

Malfunctioning circulation, reduced volume flow, insufficient heat transfer, controlling no longer possible.

Compare the set value with the recommendations in table 14 and correct as needed.

Check the entire circulation system: Shut-off elements, pump, electrical connection, backflow preventer, and air in circulation system.

Only without circulation system: Very low tapping volume with very high primary circuit temperature falls

Reduce the primary circuit temperature.

below the controller limit range.

Incorrectly set circulation. Check the circulation settings.

It takes a long time until hot water emerges from the tapping point.

Circulation and standby function deactivated due to a primary circuit temperature that is too low.

Check the control/setting of the aux. heating. Increase the primary circuit temperature.

Circulation pump defective. Check the function of the circulation pump (manual operation).

Check the controller settings of the disinfection and restart disinfection manually. The LED goes out if the disinfection cycle runs successfully, in case of a power outage or disconnect from the mains power supply, or if you set the disinfection operating mode to “Off”. Increase the primary circuit temperature if

LED has a steady red light.

Disinfection temperature below required value.

necessary.

Primary circuit temperature too low. Check the control/setting of the aux. heating.

Date/time are incorrect. Power supply outage. Reset date and time.

Display depicts a temperature of 222 °C.

Temperature sensor defective.

Check the electrical connection of the respective temperature sensor. If necessary, replace the temperature sensor.

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EN-RATIOfresh-250-400_TI-MA-0809-11214900 25

26 EN-RATIOfresh-250-400_TI-MA-0809-11214900

9. System Solutions – Example

P1 : Solar circuit pump P2 : Cylinder charge pump P3 : Heating circuit pump P4 : Buffer discharge pump to heat potable water P5 : Circulation pump Vm : Mixing valve to maintain specific

min. return temperature

HKM : Heating circuit mixing valve

Hot water

Cold water

Circulation

T-storage

RATIO-H PG

Solar controller

Collector field

SUNGO

Heating circuit

RATIOfresh

HKM

P1P1

CIRCO

Figure 13 Solar installationforhot water heating andheatingsupport.System as heating buffersystemwith pellet boiler, buffer cylinder RATIO HP G, and RATIOfresh freshwater station. Water is heated using an electronically controlled flow process. The RATIOfresh controller maintains a constant withdrawaltemperatureand especially low buffer cylinderreturn temperatures as wellas speed-controls the hot watercirculationpump.The pellet boiler heats only the upper buffer cylinder section.

P1 : Solar circuit pump P2 : Secondary circuit pump P3 : Buffer discharge pump to heat potable water P4 : Cylinder charge pump P5 : Heating circuit pump P6 : Circulation pump

Vu1 : 3-way-valve, switching solar charging Vu2 : 3-way-valve, switching solar charging parallel with Vu1 Vr : 3-way-valve, return flow increase

Heating circuit

Solar controller

SUNGO

T-Storage

Collector field

CIRCO

RATIO-H PG

Buffer cylinder 2

Hot water

RATIOfresh

Ttw

Buffer cylinder 1

Oil or gas

heating boiler

Circulation

Cold water

RATIO-H PG

AABB

PWT

Vu1

BABA

Vu2

Figure 14 Solar installation for hotwater heatingandheatingsupport.System withoilorgas boiler,2 buffer cylinders RATIOHP, and freshwater sta tion RATIOfresh.Buffer cylinder 1 isfirst charged by thecollector field. Water isheatedusinganelectronically controlled flow process.The freshwa ter station controller not onlyensures anenergetically favorable discharging of the buffer cylinder when tappinghot water, italso runs the speedcontrolled hotwater circulation pump. If temperaturesinthe primary buffercylinder are sufficient, solar heatis used for heating by raising theheat ing return temperature.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 27

P1 : Solar circulation pump P2 : Buffer discharge pump to heat potable water P3 : Cylinder charge pump P4 : Heating circuit pump P5 : Hot water circulation pump Vr : 3-way switching valve

(temperature increase heating return)

Vu : 3-way switching valve

(return switching circulation mode)

Heating circuit

Tvl

Solar controller

Collector field

SUNGO

T-storage

Ttw

RATIO-H PG

P1P1

CIRCO

Oilorgas heating boiler

Circulation

Cold water

Hot water

RATIOfresh

Figure 15 Solar installation forhot water heating andheating support. Systemsolution in conjunction with oil or gasboiler,buffer cylinder RATIO HP G and freshwater station RATIOfresh. Water is heated using an electronically controlled flow process. The controller of the freshwater station maintains a constant withdrawal temperature and especially low buffer cylinder return temperatures. Solar energy for room heating is utilized by raising the return temperature of the heating circuit when the temperature in the buffer cylinder is sufficiently high.

P1 : Solar circulation pump P2 : Buffer discharge pump to heat potable water P3 : Cylinder charge pump P4 : Heating circuit pump P5 : Hot water circulation pump V1 : 3-way switching valve

(Hot water aux. heating or space heating)

Heating circuit

V2 : 3-way switching valve

(temperature increase heating return) V3 : Mixing valve for keeping a min. return flow temperature M1 : Heating circuit mixing valve HW : Hydraulic compensator RV : Regulating valve

Gas boiler

Solar controller

SUNGO

Collector field

P1P1

RATIO-H PG

CIRCO

Fireplace with heating inset

Circulation

Cold water

Hot water

RATIOfresh

Figure 16 Solar installationfor water heatingand space heatingsupport.System solution withgas boiler,open fireplace withheatinginset,RATIO HP Buffer Storage, fresh water station RATIOfresh and a floor heating circuit. Hot water preparation is done by electronically controlled flowthrough method. The fireplace heats theupper part of thebuffer storage,solar energy canheattheentirevolume of thestoragecylinder.When the temperatures in the storage are high enough, the return flow of theheatingcircuit is directed through the storage via theswitching valve V1. Theen ergy of the buffer storage is utilized for space heating. The solar controller additionally controls loading of the buffer via the fireplace inset.

28 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg ·

+49 6421 80 07-0 · Fax 8007-22

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