Installation manual
Read the instructions prior to performing any task!
REMKO HGM / HGU
PWM controlled heating cycle groups
0181-2023-05 Edition 5, en_GB
Instructions for Technicians
Translation of the original
Read these operating instructions carefully before commis-
sioning / using this device!
These instructions are an integral part of the system and must
always be kept near or on the device.
Subject to modifications; No liability accepted for errors or mis-
prints!
Table of contents
1 Safety and usage instructions............................................................................................................. 4
1.1 General safety notes....................................................................................................................... 4
1.2 Identification of notes...................................................................................................................... 4
1.3 Personnel qualifications.................................................................................................................. 4
1.4 Dangers of failure to observe the safety notes................................................................................ 4
1.5 Safety-conscious working............................................................................................................... 4
1.6 Safety instructions for the operator................................................................................................. 5
1.7 Safety notes for installation and inspection tasks........................................................................... 5
1.8 Unauthorised modification and changes......................................................................................... 5
1.9 Intended use................................................................................................................................... 5
1.10 Safety-conscious working............................................................................................................. 5
1.11 Warranty........................................................................................................................................ 5
1.12 Transport and packaging.............................................................................................................. 6
1.13 Environmental protection and recycling........................................................................................ 6
2 Technical data........................................................................................................................................ 7
2.1 Unit data for pump groups HGM / HGU.......................................................................................... 7
2.2 Unit dimensions and pump group components HGM..................................................................... 8
2.3 Unit dimensions and pump group components HGU...................................................................... 9
2.4 Pumps data................................................................................................................................... 10
2.5 GRUNDFOS pump dimensions.................................................................................................... 12
2.6 GRUNDFOS pump power curve................................................................................................... 12
2.7 REMKO pump dimensions............................................................................................................ 13
2.8 REMKO pump power curve.......................................................................................................... 13
3 Unit description................................................................................................................................... 14
4Operation of the REMKO pump without PWM signal...................................................................... 15
5 Assembly............................................................................................................................................. 17
5.1 Wall installation............................................................................................................................. 17
5.2 Mounting the probe....................................................................................................................... 17
5.3 Mounting the actuator................................................................................................................... 18
5.4 Gravity brake in T-piece................................................................................................................ 18
5.5 Progressive characteristic curve / mixing valve behaviour............................................................ 19
6 Installation........................................................................................................................................... 19
6.1 Hydraulic connection..................................................................................................................... 19
6.2 Electrical wiring............................................................................................................................. 21
7 Troubleshooting.................................................................................................................................. 25
8 Commissioning................................................................................................................................... 26
9 Maintenance........................................................................................................................................ 27
10 View of the unit and spare parts........................................................................................................ 28
10.1 HGM............................................................................................................................................ 28
10.2 HGU............................................................................................................................................ 29
11 Index..................................................................................................................................................... 30
3
1 Safety and
usage instructions
1.1 General safety notes
Carefully read the operating manual before com-
missioning the units for the first time. It contains
useful tips and notes such as hazard warnings to
prevent personal injury and material damage.
Failure to follow the directions in this manual not
only presents a danger to people, the environment
and the system itself, but will void any claims for
liability.
Keep this operating manual and the refrigerant
data sheet near to the units.
1.2 Identification of notes
This section provides an overview of all important
safety aspects for proper protection of people and
safe and fault-free operation.The instructions and
safety notes contained within this manual must be
observed in order to prevent accidents, personal
injury and material damage.
Notes attached directly to the units must be
observed in their entirety and be kept in a fully
legible condition.
Safety notes in this manual are indicated by sym-
bols. Safety notes are introduced with signal words
which help to highlight the magnitude of the danger
in question.
DANGER!
Contact with live parts poses an immediate
danger of death due to electric shock. Damage
to the insulation or individual components may
pose a danger of death.
DANGER!
This combination of symbol and signal word
warns of a situation in which there is immediate
danger, which if not avoided may be fatal or
cause serious injury.
WARNING!
This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may be fatal or cause
serious injury.
CAUTION!
This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may cause injury or mate-
rial and environmental damage.
NOTICE!
This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may cause material and
environmental damage.
This symbol highlights useful tips and recom-
mendations as well as information for efficient
and fault-free operation.
1.3 Personnel qualifications
Personnel responsible for commissioning, opera-
tion, maintenance, inspection and installation must
be able to demonstrate that they hold a qualifica-
tion which proves their ability to undertake the
work.
1.4 Dangers of failure to observe
the safety notes
Failure to observe the safety notes may pose a risk
to people, the environment and the units. Failure to
observe the safety notes may void any claims for
damages.
In particular, failure to observe the safety notes
may pose the following risks:
nThe failure of important unit functions.
nThe failure of prescribed methods of mainte-
nance and repair.
nDanger to people on account of electrical and
mechanical effects.
1.5 Safety-conscious working
The safety notes contained in this manual, the
existing national regulations concerning accident
prevention as well as any internal company
working, operating and safety regulations must be
observed.
REMKO HGM / HGU
4
1.6 Safety instructions
for the operator
The operational safety of the units and compo-
nents is only assured providing they are used as
intended and in a fully assembled state.
nThe units and components may only be set up,
installed and maintained by qualified per-
sonnel.
nThe existing regulations concerning accident
prevention must be adhered to.
nDo not operate units or components with
obvious defects or signs of damage.
nContact with equipment parts or components
can lead to burns or injury.
nEnsure that electrical energy does not pose a
risk.
nRegulations of the VDE and the local energy
supply company must be adhered to.
1.7 Safety notes for installation and
inspection tasks
nThe operator must ensure that all inspection
and installation work is carried out by author-
ised and qualified personnel who have thor-
oughly read the operating manual.
nWorks on the pump/system may only be car-
ried out whilst at a standstill as a matter of prin-
ciple.
nAppropriate hazard prevention measures must
be taken to prevent risks to people when per-
forming installation, repair, maintenance or
cleaning work on the units.
nThe setup, connection and operation of the
units and its components must be undertaken
in accordance with the usage and operating
conditions stipulated in this manual and comply
with all applicable regional regulations.
nRegional regulations and laws as well as the
Water Ecology Act must be observed.
nThe power supply should be adapted to the
requirements of the units.
nThe units and components must be kept at an
adequate distance from flammable, explosive,
combustible, abrasive and dirty areas or
atmospheres.
nSafety devices may not be modified or
bypassed.
1.8 Unauthorised modification and
changes
The operational safety of the pump group that was
delivered is guaranteed only with intended use in
accordance with section 1.9 of the operating
instructions. Under no circumstances should the
threshold values specified in the datasheet be
exceeded.
Modifications or changes to units and components
are not permitted and may cause malfunctions.
Safety devices may not be modified or bypassed.
Original replacement parts and accessories
authorised by the manufacturer ensure safety. The
use of other parts may invalidate liability for
resulting consequences.
1.9 Intended use
The heating cycle group is only approved for oper-
ation as a heating cycle group. It serves to trans-
port the operating medium of water into closed
heating cycles.
Any different or additional use is a non-intended
use. The manufacturer/supplier assumes no lia-
bility for damages arising from a non-intended use.
The user bears the sole risk in such cases.
Intended use also includes working in accordance
with the operating and installation instructions and
complying with the maintenance requirements.
The threshold values specified in the technical
data must not be exceeded.
1.10 Safety-conscious working
The safety notes contained in this manual, the
existing national regulations concerning accident
prevention as well as any internal company
working, operating and safety regulations must be
observed.
1.11 Warranty
For warranty claims to be considered, it is essential
that the ordering party or its representative com-
plete and return the "certificate of warranty" to
REMKO GmbH & Co. KG at the time when the
units are purchased and commissioned.
The warranty conditions are detailed in the "Gen-
eral business and delivery conditions". Further-
more, only the parties to a contract can conclude
special agreements beyond these conditions. In
this case, contact your contractual partner in the
first instance.
5
1.12 Transport and packaging
The devices are supplied in a sturdy shipping con-
tainer. Please check the equipment immediately
upon delivery and note any damage or missing
parts on the delivery and inform the shipper and
your contractual partner. For later complaints can
not be guaranteed.
WARNING!
Plastic films and bags etc. are dangerous
toys for children!
Why:
- Leave packaging material are not around.
- Packaging material may not be accessible to
children!
1.13 Environmental protection and
recycling
Disposing of packaging
All products are packed for transport in environ-
mentally friendly materials. Make a valuable contri-
bution to reducing waste and sustaining raw mate-
rials. Only dispose of packaging at approved
collection points.
Disposing of the units and their components
For the manufacture of the units and components,
only recyclable materials have been used. Help
protect the environment by ensuring that the units
or components (for example batteries) are not dis-
posed of in household waste, but only in accord-
ance with local regulations and in an environmen-
tally safe manner, e.g. using authorised disposal
and recycling specialists or council collection
points.
REMKO HGM / HGU
6
2 Technical data
2.1 Unit data for pump groups HGM / HGU
Technical properties
Pump group HGM HGU
Maximum operating temperature °C 95
Operating pressure, max. bar 10
Heating cycle side, external thread Inches G 1 1/2" AG
Storage cycle side, external thread Inches G 1 1/2" AG
Pump scope of delivery Grundfos UPM 4 / 25-75-180
Pump (alternative) Wilo Para RS 25/8 SC
Pump (alternative)
Compatible media Water, water-Glycol mixture (maximum 30%)
Thermometer measurement range °C/°F 0-120°C / 30-250°F
Weight kg 6.9 5.85
Materials
Pump group HGM HGU
Ball valve and check valve
Body made of brass: UNI EN 12164 - CW617N UNI EN 12164 - CW614N
Hydraulic seals PTFE, Viton, EPDM
Motorised mixing valve
Body made of brass: UNI EN 12165 - CW617N ---
Turning part made of brass: UNI EN 12164 - CW614N ---
Hydraulic seals EPDM
Insulation half-shells
Body EPP
Body, seal kg/m360
Body, therm. conductivity (20°C) W/mK 0.039
Body, therm. conductivity (40°C) W/mK 0.041
7
2.2 Unit dimensions and pump group components HGM
Dimensions
L
H
G
G1
Fig. 1: Pump group HGM unit dimensions (all measurements in mm)
Pump group G G1 L H
HGM 1 1/2" AG 1 1/2" AG 125 mm 370 mm
Components
1
=
2
=
5
=
3
=
4
=
2
1
4
3
6
75
4
Fig. 2: Pump group components HGM
1: Circulation pump Grundfos UPM 4 / 25-75-180
2: Ball valve, blue
3: Ball valve, red
4: Thermometer
5: Motorised mixing valve
6: Adapter pipe
7: Insulation
REMKO HGM / HGU
8
2.3 Unit dimensions and pump group components HGU
Dimensions
L
H
G
G1
Fig. 3: Pump group HGU unit dimensions (all measurements in mm)
Pump group G G1 L H
HGU 1 1/2" AG 1 1/2" AG 125 mm 370 mm
Components
1
=
2
=
5
=
3
=
4
=
2
1
4
3
6
75
4
Fig. 4: Pump group components HGU
1: Circulation pump Grundfos UPM 4 / 25-75-180
2: Ball valve, blue
3: Ball valve, red
4: Thermometer
5: Shut-off valve
6: Adapter pipe
7: Insulation
9
2.4 Pumps data
Technical data for GRUNDFOS pump
Pump group HGM / HGU
Pump type Grundfos UPM 4 / 25-75-180
Control signal PWM
Maximum delivery volume m34.5
Maximum delivery height m 7.5
Speed rpm 1200 - 4450
Mains voltage 1~230V ± 10% in accordance with DIN IEC 60038
Energy Efficiency Index (EEI) £ 0.23
Frequency Hz 50/60 Hz
Insulation class F
Enclosure class IP 44
Rated input P1 W 5 - 70
Nominal width for pipe connection Rp Inch
es
1"
Connection flange thread G Inch
es
1 1/2"
Permitted ambient temperature °C + 40
Maximum relative humidity £ 95%
Permitted conveying media
Heating water (in accordance with VDI 2035/VdTÜV
Tch 1466)
Water/glycol mixture, maximum mixture ratio is 30% (in
mixtures with glycol, the delivery data of the pump must
be corrected according to the higher viscosity and
depending on the mixture ratio percentage.)
Ethylene/propylene glycol with corrosion protection
inhibitors
- Standard oxygen binding agent
- Standard corrosion protection agent
- Standard combination products
- Standard cooling brines
Media temperature °C +2 °C to +110 °C (TF 110)
Maximum operating pressure at the pump bar 10.0
Weight kg 2.0
The Grundfos UPM 3 pump must be stored as a PWM-controlled pump in the REMKO Smart-Control
controller. The control signal of the pump must be checked in the expert level of the REMKO Smart-Con-
trol controller in the respectively enabled circuit under the parameter “Pump type” and adjusted if neces-
sary.
REMKO HGM / HGU
10
Technical data for REMKO pump
Pump group HGM / HGU
Pump type REMKO APE 20-8-180S
Control signal PWM
Maximum delivery volume m34.5
Maximum delivery height m 7.5
Speed rpm 1000 - 4000
Mains voltage 1~230V ± 10% in accordance with DIN IEC 60038
Energy Efficiency Index (EEI) £ 0.23
Frequency Hz 50/60 Hz
Insulation class F
Enclosure class IP 44
Rated input P1 W
Nominal width for pipe connection Rp Inch
es
1"
Connection flange thread G Inch
es
1 1/2"
Permitted ambient temperature °C + 40
Maximum relative humidity £ 95%
Permitted conveying media
Heating water (in accordance with VDI 2035/VdTÜV
Tch 1466)
Water/glycol mixture, maximum mixture ratio is 30% (in
mixtures with glycol, the delivery data of the pump must
be corrected according to the higher viscosity and
depending on the mixture ratio percentage.)
Ethylene/propylene glycol with corrosion protection
inhibitors
- Standard oxygen binding agent
- Standard corrosion protection agent
- Standard combination products
- Standard cooling brines
Media temperature °C +2 °C to +110 °C (TF 110)
Maximum operating pressure at the pump bar 10.0
Weight kg 2.0
The REMKO pump must be stored as a PWM-controlled pump in the REMKO Smart-Control controller.
The control signal of the pump must be checked in the expert level of the REMKO Smart-Control con-
troller in the respectively enabled circuit under the parameter “Pump type” and adjusted if necessary.
11
2.5 GRUNDFOS pump dimensions
Fig. 5: Pump dimensions
Series
Grundfos UPM 4 /
25-75-180
Dimensions [mm]
L1 L3 B1 B2 H1 H2 H3
180 90 72 45 36 92 128
2.6 GRUNDFOS pump power curve
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6
Q [m³/h]
0
1
2
3
4
5
6
7
[m]
H
0
10
20
30
40
50
60
[kPa]
p
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Q [l/s]
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6
Q [m³/h]
0
10
20
30
40
50
[W]
P1
2
1
3
3
4
Fig. 6: Circulation pump Grundfos UPM 4 / 25-75-180 - capacity range
1: Pressure [kPa]
2: Height [m]
3: Medium flow rate [m3/h]
4: Speed
External control via analogue-In PWM signal
The tolerances of each curve are in acc. with EN 1151-1:2006
REMKO HGM / HGU
12
2.7 REMKO pump dimensions
Fig. 7: Pump dimensions
Series
REMKO APE
20-8-180S
Dimensions [mm]
L1 L2 L3 G H1 H2 H3
94 127 99 1 1/2" 110 180 60
2.8 REMKO pump power curve
1
2
3
Fig. 8: Circulation pump REMKO APE 20-8-180S - capacity range
1: Height [m]
2: Medium flow rate [m3/h]
3: Speed in %
External control via analogue-In PWM signal
The tolerances of each curve are in acc. with EN 1151-1:2006
13
3 Unit description
These pump groups HGM / HGU enable circulation
of the heat conducting medium via the inlet. The
pump group HGM regulates the temperature of the
heat conducting medium via a motorised mixing
valve. This pump group with controllable tempera-
ture is therefore ideal for operating normal heating
systems with temperature regulation. Temperature
regulation of the inlet takes place depending on the
inlet and return temperatures of the installed
probes.
The pump groups comprise the following: Pump,
ball valve for inlet and return flow, thermometer for
inlet and return flow, check valve against the
heating cycle and thermal insulation.
The two insulation half-shells [1, 2] serve as heat
insulation for the pump group and therefore enable
energy to be saved. The pump insulation was
developed to guarantee heat insulation and to pre-
vent the electric motor from overheating. The
check valve that is integrated into the body of the
return flow's ball valve prevents incorrect circula-
tion when the pump is switched off.
1
4
3
2
1
2
34
5
A
B
Fig. 9: Unit components
A: HGM / B: HGU
1: Front part of the insulation
2: Rear part of the insulation
3: Unit inlet equipped with secondary circuit ball
valve and a thermometer
4: Unit return flow equipped with secondary circuit
ball valve and a thermometer
REMKO HGM / HGU
14
4 Operation of the REMKO pump without PWM signal
LED indicator
If no PWM signal input is present, the pump runs at the maximum constant power as per the curve. If the
PWM signal input is present, it runs according to the PWM speed control logic.
The following image shows an overview of the operating panel.
2
11 2 3 4 5
1: LED indicator with 5 LEDs 2: Function button
After switching the device on, all green LED indicators flash three times and the speed control mode is
shown as follows:
A
B
A: No PWM signal B: With PWM signal
Fault display / fault diagnosis
Malfunction Description Indicator
Protection from
blocked rotors
If the rotor shaft of the electric pump is
stuck, the electric pump tries to restart,
and restarts every 5 seconds. When
attempting the restart, the electric pump
reports a block fault and the control panel
displays an error code. The pump
restarts in this cycle 5 times and then
stops.
15
Fault display / fault diagnosis (continued)
Malfunction Description Indicator
Electrical surge /
Undervoltage pro-
tection
If the input voltage is below 165 V or
above 275 V, the electric pump goes into
the protective state and switches off,
reports an electrical fault and displays an
error code on the control panel in order
to not exceed the range and not cause
any damage. When the voltage is
between 160 V and 270 V again, the
electric pump is put back into operation.
Protection against
phase loss
If a phase loss of the electric pump
occurs, the electric pump tries to restart,
and restarts every 1 second. When
attempting to restart, the electric pump
reports an electrical fault and the control
panel displays an error code. The pump
restarts in this cycle 5 times and then
stops.
Overcurrent protec-
tion (short circuit)
If the event of a short circuit, overheating
and other faults, the electric pump tries to
restart, and restarts every 1 second.
When attempting the restart, the electric
pump reports an electrical fault and the
control panel displays an error code. The
pump restarts in this cycle 5 times and
then stops.
More functions
Mode Description Indicator
Automatic venting
function
The pump vents the air when the button
is pressed for a long time, when the LED
indicators light up LED1+LED2+LED3 in
the indicator range (LED lights up alter-
nately), release the key to activate the
automatic venting function, all LED lights
in the indicator range flash and the auto-
matic venting function is left after 5 sec-
onds
Manual restart func-
tion
If the LED indicators light up in the indi-
cator range
(LED1+LED2+LED3+LED4+LED5),
release the key to call up the manual
restart function, and the
LED2+LED3+LED4+LED5 indicators in
the indicator range flash and the manual
restart function is automatically cancelled
after operating for 5 minutes. This func-
tion is used to unclog the pump (e.g if it
does not run for a long time in the
summer).
REMKO HGM / HGU
16
5 Assembly
5.1 Wall installation
NOTICE!
–Do not use any grease or oils during
assembly, since they can destroy the seals.
If necessary, dirt particles as well as grease
and oil residue must be flushed out of the
supply lines.
–When selecting the operating medium, the
general state-of-the-art must be taken into
consideration (e.g. VDI 2035).
–Protect against external forces (e.g. shock,
impact, vibration).
Proceed with the wall installation as follows:
nRemove the pre-installed pump group from the
packaging.
nPull out the retaining springs.
nRaise the inlet and return line and pull it out of
the mounting bracket.
nRemove the rear insulating cladding.
nDraw the fastening points of the mounting
bracket on the wall and drill two ø10 mm holes.
nPlace the dowels and screw the mounting
bracket [1] tight using the screws and washers.
nAlign the mounting bracket [1] horizontally.
nSlide the rear insulating cladding onto the
mounting bracket [1].
nInsert the inlet and return line into the mounting
bracket and secure them with retaining springs.
1
5.2 Mounting the probe
nThe probe [2] is inserted into the intended hole
in the mounting bracket [1] from below.
1
2
nMount the pump group and ball valves [3] and
secure them with retaining springs [4].
nFix the probe [2] and cable in place with a
cable tie.
2
3
4
17
5.3 Mounting the actuator
Mounting the actuator to the valve
DANGER!
All electrical installation work is to be performed
by specialist companies. Disconnect the power
supply when connecting the electrical terminals.
nIn order to remove the actuator, the clip [5]
must be pulled from the servomotor. Then the
actuator can be removed from the valve.
5
NOTICE!
When mounting the actuator, the adjustable
handle of the drive must be in the maximum
position and the indent of the carrier [6] must be
at 3 o’clock for the left inlet and 9 o’clock for the
right inlet.
nBefore mounting, the clip must be positioned in
the actuator. Then place the actuator on the
valve and push it down.
nSlide the clip in to fix the actuator in place.
6
5.4 Gravity brake in T-piece
The gravity brake in T-piece is transverse in opera-
tion. The gravity brake can be vented for service
and maintenance work.
nTo vent the gravity brake, turn the adjusting
screw in the flow direction.
nAfter completing the service work, turn the
adjusting screw back into the operating posi-
tion.
A
B
A: Operating position
B: Maintenance position
REMKO HGM / HGU
18
5.5 Progressive characteristic curve / mixing valve behaviour
The progressive mixing valve in the PGM can control the water quantity better than a linear mixing valve due
to its special characteristics. With a valve opening of 50%, a linear mixing valve has a flow rate of 50%.
The progressive mixing valve with the same kvs value has a flow rate of 18% with a valve opening of 50%.
The progressive mixing valve can therefore precisely control small flow rates. The “vibration” of the mixing
valve is prevented due to the high degree of control.
2
1
A
B
1: Linear mixing valve
2: Progressive mixing valve
A: Flow rate [%]
B: Valve opening [%]
6 Installation
6.1 Hydraulic connection
CAUTION!
Each individual hydraulic component must be
installed by qualified personnel because the
high temperatures and pressures of the liquid
can cause personal injury.
The following is an example illustration.
This example illustration makes no claim to being
complete and is no substitute for professional plan-
ning.
19
AB
CD
A: Heating return
B: Heating supply flow
C: Boiler return
D: Boiler inlet
HGM 2
S 11
S 12
HGM 1
A13
A24
A25
A46
A02
A20
A21
A41
S 14
S 06
HGU
A03
A42
S 08
S 09
1
A
2 3
A: KPS storage tank
1: Unmixed heating cycle
2: Mixed heating cycle
3: Mixed heating cycle
REMKO HGM / HGU
20
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