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

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

Solar Thermal / Solar Cylinder EN-RATIOfresh-250-400_TI-MA-0809-11214900 1

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

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

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

EN-RATIOfresh-250-400_TI-MA-0809-11214900 3

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

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

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.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 5

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

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

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.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 7

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.

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

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.

EN-RATIOfresh-250-400_TI-MA-0809-11214900 9

+ 19 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual