Remko Heizkreisgruppe-HGU User manual

Brand: Remko

Model: Heizkreisgruppe-HGU

Type: User manual

This manual is also suitable for

Heizkreisgruppe-HGM

Assembly and operating instructions

Read the instructions prior to performing any task!

REMKO Heating cycle groups

HGM / HGU

0181-2018-03 Edition 2, en_GB

Instructions for the Technician

Installation and operating instructions (translation of the orig-

inal)

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 Pump unit data.............................................................................................................................. 10

2.5 Pump unit dimensions................................................................................................................... 11

2.6 Pressure losses............................................................................................................................. 11

2.7 Delivery heights and electrical power............................................................................................ 12

3 Unit description................................................................................................................................... 13

4Installation and assembly.................................................................................................................. 14

4.1 Installation..................................................................................................................................... 14

4.2 Wall installation............................................................................................................................. 14

4.3 Installation on the distributor......................................................................................................... 16

4.4 Mounting the actuator .................................................................................................................. 17

4.5 Gravity brake................................................................................................................................. 18

4.6 Replace the inlet and the return flow............................................................................................. 18

4.7 Replacement of the pump............................................................................................................. 19

4.8 Positioning of the electric cables................................................................................................... 19

4.9 Electrical wiring............................................................................................................................. 20

4.10 Installation example.................................................................................................................... 22

5 Troubleshooting.................................................................................................................................. 23

6 Exploded view and spare parts......................................................................................................... 25

6.1 HGM.............................................................................................................................................. 25

6.2 HGU.............................................................................................................................................. 26

7 Index..................................................................................................................................................... 27

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 Heating cycle groups

1.6 Safety instructions for the oper-

ator

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.

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 Heating cycle groups

2 Technical data

2.1 Unit data for pump groups HGM / HGU

Technical properties

Pump group HGM HGU

Maximum operating temperature °C 95

Max. operating pressure bar 10

Heating cycle side, internal thread Inches 1"

Storage cycle side, external thread Inches 1 1/2"

Pump Wilo Stratos Para 25 / 1-7 T1

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

2.2 Unit dimensions and pump group components HGM

Dimensions

250 200

385 180

Fig. 1: Unit dimensions for pump group HGM

Pump group G G1 L H

HGM 1" IG 1 1/2" AG 125 mm 340

Components

Fig. 2: Pump group components HGM

1: Circulation pump Wilo Stratos Para 25 / 1-7 T1

2: Ball valve

3: Ball valve with integrated check valve

4: Thermometer

5: Motorised mixing valve

6: Extension

7: Insulation

REMKO Heating cycle groups

2.3 Unit dimensions and pump group components HGU

Dimensions

250 200

385 180

Fig. 3: Unit dimensions for pump group HGU

Pump group G G1 L H

HGU 1" IG 1 1/2" AG 125 mm 340

Components

Fig. 4: Pump group components HGU

1: Circulation pump Wilo Stratos Para 25 / 1-7 T1

2: Ball valve

3: Ball valve with integrated check valve

4: Thermometer

5: Ball valve

6: Insulation

2.4 Pump unit data

Technical data

Pump group HGM / HGU

Pump type Wilo Stratos Para 25 / 1-7 T1

Maximum delivery volume m34.5

Maximum delivery height m 7.0

Speed rpm 1200 - 4450

Mains voltage 1~230V ± 10% in accordance with DIN IEC 60038

Energy Efficiency Index ( EEI ) £ 0.23

Frequency Hz 50/60 Hz

Insulation class F

Enclosure class IP 44

Rated input P1 W 5 - 70

Nominal width for pipe connection Rp Inch

Connection flange thread G Inch

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

Permitted medium temperature °C 95

Maximum operating pressure at the pump bar 6.0

Weight kg 2.4

REMKO Heating cycle groups

2.5 Pump unit dimensions

b4b5

Fig. 5: Pump unit dimensions

Wilo Stratos Para

25 / 1-7 T1 l0a1a2a3l1l2l3b4b5

Dimensions in mm 180 116 32 94 90 56 138 42 41

2.6 Pressure losses

[m3/h] B[m3/h]

[mbar]

a a

Fig. 6: Diagram of pressure losses in the pump group HGM / HGU

1: Operational mode; constant differential pressure

2: Operational mode; variable differential pressure

A: Resistance / delivery height [mbar]

B: Delivery rate [m3/h]

a: Mixing valve R 3/4

2.7 Delivery heights and electrical power

Fig. 7: Delivery heights and electrical power of the Wilo Stratos Para 25 / 1-7 T1pump

1: External operating mode via analogue-in 0-10V

2: External operating mode via pump shaft model

(PSM)

REMKO Heating cycle groups

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 probes S12

and S11.

The pump groups comprise the following: Pump,

ball valve for inlet and return flow, thermometer for

inlet and return flow, check valve against the

heating cycle and thermal insulation.

The pump group HGM also has an integrated

mixing valve

The 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.

Fig. 8: 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

5: Wall bracket

4 Installation and assembly

4.1 Installation

CAUTION!

Each individual hydraulic component must be

installed by qualified personnel because the

high temperatures and pressures of the liquid

can cause personal injury.

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).

Possible installations include:

nWall installation

nInstallation on the distributor

After installation, all installation areas must be

checked for leaks.

4.2 Wall installation

CAUTION!

Observe the distance between the piping and the

wall specified in point 7.

1. Remove the pre-installed pump group from

the packaging.

2. Open the insulation cover half-shells by

pulling the front side [1] and the rear side [2]

apart.

3. Remove the insulation.

REMKO Heating cycle groups

110 mm

o 8 mm

45 mm

A: Dowel hole = 8 mm

4. Attach the rear side [2] of the insulation half-

shell to the wall bracket. Install the inlet [4]

and the return flow [5] on the wall bracket by

lifting the insulation slightly. The distance

between the pipe axis and the wall surface is

thus around 54 mm.

5. Use the screw connection enclosed in the

packaging to install the piping for the inlet

and the return flow; ensure that the connec-

tions are suitable for the pipe dimensions

(connections with flat seals are recom-

mended). If a pump is connected in a series

to the pump group (e.g. boiler pump), in prac-

tice, a fixture to separate the heating cycles

hydraulically is to be installed, in order to pre-

vent a malfunction of the two pumps or the

heat pump.

6. Turn the controller of the return flow's ball

valve (7) to an angle of 45°; in this position,

the ball valve bypasses the check valve and

nullifies the effect of the valve. This improves

the flow of the water and the air that is to be

bled in the filling phase. Fill the system and

check for leaks.

7. Open the ball valve of the return flow [7].

8. Install the electric cables (see the positioning

of the cables section).

9. Insert the pump's insulation.

10. Close the pump group using the insulation

half-shell [1+2].

4.3 Installation on the distributor

The pump groups can be installed on distributors

with an integrated hydraulic compensator, on

standard distributors with a separate hydraulic

compensator and on series distributors. For

optimum installation, the nozzles of the distributor

should be at least 60mm away from the wall.

1. First carry out installation steps 1-4 for wall

installation.

2. To aid installation, start the installation in the

middle of the distributor and then continue

with the outer connections; install the inlet [4]

and the return flow [5] on the distributor using

the screw connection enclosed in the pack-

aging or using the required connecting

pieces (flat-sealing connections are recom-

mended).

3. Insert the insulation half-shell [2]; if the dis-

tributor is installed too close to the wall, you

must insert the rear side [2] of the two insula-

tion half-shells before you install the inlet and

the return flow [4] and [5].

REMKO Heating cycle groups

4. Insert the insulation by pushing down the top

side of the rear insulation half-shell.

5. Continue as described in point [9] for wall

installation.

6. Open the ball valve of the return flow again.

7. Install the electric cables (see: positioning of

the cables section).

8. Close the pump group using the front part of

the insulation [1].

4.4 Mounting the actuator

The actuator is installed as follows:

1. Mount the rotation lock [1] on the mixing

valve housing.

2. Attach the adapter [2] onto the mixing valve

plug [3] until it stops. Observe the flat area!

3. Set the mixing valve plugs so that the nose of

the adapter [a] faces down in the axis direc-

tion of the connection thread. The mixing

valve plugs seal the inlet (full bypass mode,

cold) in this position.

4. Set the actuator [4] on the mixing valve axis.

5. Set the rotation direction indicator [5] on the

actuator according to the figure.

6. Attach the hand adjustment handle [6] with

the arrow marking in the blue area [b] on the

mixing drive shaft (condition when delivered:

anti-clockwise against the stop, operational

position "A" Automatic).

7. Attach the screw [7] with the serrated washer

and tighten the screw.

6 7

Fig. 9: Mounting the 3-way mixing valve

4.5 Gravity brake

The fitting group is delivered pre-assembled. When

operating the heating system, the ball valve of the

return flow (blue) must be completely open.

Turn the controller of the return flow's ball valve to

an angle of 45°. In this position, the ball valve

bypasses the check valve and nullifies the effect of

the valve.

The gravity brake must be opened for commis-

sioning and maintenance work (filling and rinsing).

Blocking function not active: Stop valve open, flow

is possible in the both directions. During heating

operation, the gravity brake must be moved back

to the operating position.

When the circulation pump is switched off, a

low level of gravity circulation is still possible in

heating systems depending on the gravitational

force and despite the block valve. Block valves

are not sealed flow limiters.

4.6 Replace the inlet and the

return flow

Unmixed heating cycle group

In order to change the flow direction, proceed as

follows:

1. Loosen the connection [9]

2. Replace the inlet and the return line

3. Tighten the connections again

9 99

Fig. 10: Inlet

A: Left

B: Right

Mixed heating cycle group

In order to change the flow direction, proceed as

follows:

1. Loosen the connection [9] and the screw [6]

2. Remove the actuator [4]

9 99

4 4

Fig. 11: Inlet

A: Left

B: Right

3. Loosen the cover [10] and [11] using the

spanner SW46

4. Mount the mixing valve plugs [3] on the other

side

5. Tighten the cover again and apply a torque of

45 Nm

6. Mount the rotation lock [1] on the other side

7. Set the mixing valve plugs [3] so that the

nose [a] of the adapter [2] faces down. The

mixing valve plugs seal the downward outlet

(full bypass mode, cold) in this position

REMKO Heating cycle groups

8. Set the operating switch [8] to manual opera-

tion

9. Set the rotation direction indicator [5] on the

actuator [4] according to the figure

10. Attach the hand adjustment handle [7] on the

mixing valve axis

NOTICE!

The hand adjustment handle can only be lightly

pressed into a locking position. Do not use any

force. Turn the hand adjustment handle clock-

wise until it stops. The arrow marking of the

hand adjustment handle is in the blue area.

11. Set the actuator on the mixing valve axis

12. Insert the screw [6] with the serrated lock

washer and tighten the screw applying a

torque of > 5 Nm

7 8

13. Set the operating switch back to Automatic

operation

4.7 Replacement of the pump

The pump groups are constructed in such a way

that pumps of different types and brands can be

connected. If pumps and cable connections from

other manufacturers are to be used, minor

changes to the insulation may be required. They

can be made by the installer.

4.8 Positioning of the electric

cables

The electric cables must be installed by qualified

personnel, in order to avoid endangering people's

safety and material damage. The insulation half-

shells were developed in such a way to ensure the

greatest degree of flexibility possible with regard to

cable arrangement in the insulation. There are

appropriate recesses for cable harnesses and

these enable side access to the insulation (2).

4.9 Electrical wiring

DANGER!

All electrical installation work is to be performed

by specialist companies. Disconnect the power

supply when connecting the electrical terminals.

The pump and the mixing vale must be connected

to the I/O module of the heat pump according to

the wiring diagram that is enclosed in the heat

pump documentation folder.

The mixing valve must be wired on the I/O module

as follows:

Brown mixing valve cable (mixing valve opens)

Black mixing valve cable (mixing valve closes)

Blue mixing valve cable on N (neutral conductor)

If the controller used requires an inlet/return flow

sensor, they must be inserted in the designated

immersion sleeves.

All the connecting and sensor cables must be

routed downward in the heating cycle station. To

do this, corresponding slots are cut out on the rear

of the thermal insulation shell, where the cable can

be clamped. The inlet and return flow sensor must

be secured against slipping out using the locking

screw.

The correct mixing valve running direction for

the heating cycle station HGM

If, after the unit has been reinstalled, the wrong

running direction has been set on the mixing valve

motor (controller adjusts to hot and the mixing

valve moves to position 0, instead of 10, the two

connections (brown and black cable) of the mixing

valve motor must be interchanged.

Remove the mixing valve motor

To disassembly the mixing valve motor, lift up the

cover on the rotating head of the motor and com-

pletely unscrew the screw in the rotating head. The

mixing valve motor cannot be removed.

REMKO Heating cycle groups

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Remko Heizkreisgruppe-HGU User manual

Brand: Remko

Model: Heizkreisgruppe-HGU

Type: User manual

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Heizkreisgruppe-HGM

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