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HRS AQUASAVE A6 Series, Operating Instructions Manual

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HRS AQUASAVE A6 Series Operating Instructions Manual Download Page 8

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01923 232335

    www.hrshevac.co.uk

HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual

2.3

A63B - 3 Port Control Valve

One 3-port control valve, PN16
One primary shunt pump, PN10
One actuator, 24V AC feed-in and 0-10V DC controller current
One PID controller box with Pt100 temperature sensor
Primary piping, sized differently according to heat exchanger type
Control box support

The primary circuit is pre-assembled on the exchanger. Follow the assembly instructions in

17 Assembly of the 

charging kit to the AquaSTOR.

Control box
Actuator

Control valve

Piping

Primar

Balancing valve

Charging pump

y shunt pump

Summary of Contents for AQUASAVE A6 Series

Page 1: ...rol 10 12 Caxton Way Watford WD18 8JY t 01923 232335 Head Office mail hrs co uk www hrshevac co uk No 1 Rosemount Works Elland HX5 0EE t 01422 317070 North Factory 6 bar Storage 600 to 2 000 Litres HRS AQUASAVE 6 Bar Range A63B Operating Instruction Manual ...

Page 2: ...1 2 3 8 2 335 1250 2020 1135 1405 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 2 1 2 3 8 2 365 1500 2020 1220 1505 700 800 900 1000 1100 1 1 1 2 2 1 2 1 2 3 8 2 400 2000 2275 1305 1605 1200 1 1 1 2 2 1 2 1 2 3 8 2 540 Weight kg Connections Screwed BSP F Dimensions Volume Litres A 11 11 C D B 8 5 6 6 1 2 6 6 10 10 6 3 9 3 7 7 9 9 7 8 8 4 4 AquaSave A62B A63B Dimensional Details A B C D 1 2 3 4 5 6 7a 7b 8 600 191...

Page 3: ...ser instruction operator control panel Micro 3000 16 7 7 2 Home screen 17 7 3 Command symbols 17 7 4 Password and login 17 7 5 Setting the time and date 18 7 6 Changing the date format 18 7 7 Setting the daylight saving time 18 7 8 Saving changes 18 End user mode 19 8 8 1 Set the hot water temperature 19 8 2 Time programs 19 8 3 Changing time and temperature in a time program 20 8 3 1 Special days...

Page 4: ...6 3 Open the control box 44 16 4 Set the number of pumps 44 16 5 Pumps number 45 16 6 Add an extra sensor 45 16 7 Connect to 230V Triac output 45 16 8 Add relay 1 and relay 2 45 16 9 Add a remote control contact 45 Assembly of the charging kit to the AquaSTOR 46 17 17 1 Attaching the heat exchanger insulation 49 17 2 Wiring the seconary shunt pump 50 Flowcharts 51 18 18 1 Flowchart A60B 51 18 2 Fl...

Page 5: ...irect semi instantaneous system comprises 1 Storage tank stainless steel storage tank with a heat insulated cover 5 Connector hose between tank and charging pump thermally insulated 2 Plate heat exchanger 316 grade stainless steel copper welded 3 Balancing valve 6 Charging kit support 4 Charging pump A60B No Controls A62B 2 Port Control A63B 3 Port Control 1 2 3 4 5 6 6 6 5 5 4 4 3 3 2 2 1 1 ...

Page 6: ...anual 1 1 Working pressure and temperature AquaSave Model Type PRIMARY SIDE SECONDARY SIDE Max working pressure bar Max temperature C Max working pressure bar Max temperature C A60B 10 110 6 95 A62B 10 110 6 95 A63B 10 110 6 95 1 2 Packing format AquaSave is delivered in two packages storage tank exchanger kit ...

Page 7: ...onnection Follow the assembly instructions in 17 Assembly of the charging kit to the AquaSTOR 2 2 A62B 2 Port Control Valve One 2 port PN25 valve body One Pt100 temperature sensor One actuator 230V 3 points with return to zero One PID controller box with piping and support depending on the model selected The primary circuit is pre assembled on the exchanger Follow the assembly instructions in 17 A...

Page 8: ...r 24V AC feed in and 0 10V DC controller current One PID controller box with Pt100 temperature sensor Primary piping sized differently according to heat exchanger type Control box support The primary circuit is pre assembled on the exchanger Follow the assembly instructions in 17 Assembly of the charging kit to the AquaSTOR Control box Actuator Control valve Piping Primar Balancing valve Charging ...

Page 9: ... that the materials used in the installation have similar corrosion potentials 3 3 Basic assembly instrustions Assembly refer to the full instructions given in 17 Assembly of the charging kit to the AquaSTOR Connect the primary supply and return connections Connect the cold water supply hot water outlet and the recirculation system to the tank Fit the tank with a safety valve a drain valve in the ...

Page 10: ...er inlet fixture 3 4 Commissioning Flood the various circuits and flush bleed the pumps Power up Set the secondary charging flow rate using the setting valve read off setting NOTE When first heated the water in the tank will expand increasing the pressure A water hammer arrester type surge tank qualified for DHW systems may be fitted to prevent the relief valve from opening Check the water network...

Page 11: ...de 2 If a 3 way control valve is fitted wait for it to open completely 3 Adjust the secondary flow circuit as set out in the table below The flow rate can be read by pressing on the red pushbutton and reading the index marker against the float Flow controller Read off index marker Read off pushbutton P kW DHW T C 30 40 50 60 70 80 90 100 125 150 175 200 240 10 55 C 9 5 13 16 19 22 25 5 28 5 32 40 ...

Page 12: ...le Unit Type Primary pump type Primary pump consumption W A Secondary pump type Secondary pump consumption W TOTAL Control box 1 UP20 45N 115W 0 5A 125W 0 6A 2 UPS 32 80N 240W 1 05A 245W 1 15A 2 UP20 45N 115W 0 5A 125W 0 8A UPS 32 80N 240W 1 05A 250W 1 17A Magna 1 32 80 151W 1 22A UP20 45N 115W 0 5A 266W 2 02A Magna 1 32 80 151W 1 22A UPS 32 80N 240W 1 05A 391W 2 57A SINGLE PHASE 230 VOLTS GROUND ...

Page 13: ... only 6 Power supply the control box with 230VAC 50 Hz The control box with the controller Micro 3000 is called the secondary control box Human protections and protection against short circuits and over intensity must be installed in the main electric box 6 1 Controller components 1 Controller Micro 3000 3 Power Supply contact 2 Main switch 4 Printed Circuit Board ...

Page 14: ...A6 Range Installation Operating Instruction Manual 6 2 Electrical wiring diagram A62B NOTE When the remote control contact is open the unit operates normally If it is closed the unit is in standby NOTE 230V 3pts actuator wiring see 20 Special instructions for options ...

Page 15: ... uk 15 of 58 HRS Hevac Ltd AquaSave A6 Range Installation Operating Instruction Manual 6 3 Electrical wiring diagram A63B NOTE When the remote control contact is open the unit operates normally If it is closed the unit is in standby ...

Page 16: ...sing it To activate the line or change a highlighted value simply press the wheel Works like an Enter key Press to exit a level and return to the previous menu parameter Works like an ESC key Press to access the maintenance monitoring menu NOTE Requires a password Press to go to the Home screen Main Menu Press to access the Alarm Menu Not used Not used Relay 1 activated Relay 2 activated Active da...

Page 17: ...anual operation and can be switched into automatic operation Today function Datapoint value can be overridden for a particular time period within the next 24 hours Datapoint must have a daily time program assigned Time Program Datapoint has a daily time program assigned Daily time program can be selected and edited Edit Item datapoint time program etc can be edited Add Item datapoint time program ...

Page 18: ...to change starts to flash 4 Proceed in the same way to set the month date and time hour minute 7 6 Changing the date format In the Date Time menu the date format can be changed Choose between the following formats yyyy mm dd mm dd yyyy dd mm yyyy dd mm yyyy dd mm yyyy 7 7 Setting the daylight saving time Summer time Changing between summer winter time can be automatic or turned off You can also de...

Page 19: ...the risk of scalding increases Set points above 63 C result in an increased risk of precipitation of lime scaling on the surfaces of the heat exchanger 8 2 Time programs The time programs used in AquaSave are adjusted the same way Time programs SP_T_Sec_Outlet to be found in the menu 9 4 S1 Menu Secondary Outlet It is to set the DHW temperature ThTr_Activated to be found in 9 5 Thermal Treatment M...

Page 20: ... the new setting by pressing the wheel b Add a new time or set point choose c To delete a time or set point choose In this example the set point is 60 C at 22h00 You can choose to reduce the temperature during the night in this example the night temperature is set to 55 C 8 3 1 Special days Exception days so called special days can be defined The calendar in the controller controls the exceptions ...

Page 21: ... is possible to quickly define a one time temperature change a period of the day with a different setting When the change period has expired the temperature set point goes back to standard time schedule program 1 In the home screen use the wheel and mark the hourglass Press the wheel 2 Define the starting and ending time and the temperature set point value ...

Page 22: ... does not have any impact on the AquaSave Main Menu Description T_Secondary_Out Read Only Measured temperature ECS S1_PID_Setpoint Read Only DHW temperature setpoint T_Secondary_Inlet Read Only N A T_Primary_Outlet Read Only The temperature measured by S3 option T_Primary_Inlet Read Only N A T_Recovery1 Read Only N A T_Recovery2 Read Only N A T_Outdoor Read Only N A Configuration Sub Menu See 9 3 ...

Page 23: ...12 Nbr of Pumps 1 0 0 1 2 Primary pump s number MinSpeedP1P2 40 10 100 N A P34 Nbr of Pumps 1 0 1 Set to 1 Modbus Factor 1 1 10 100 To set displayed decimals on Modbus values 1 integer value eg 58 C 10 1 decimal e g 583 10 58 3 C 100 2 decimals e g 5836 100 58 36 C Relay 1 function 1 0 7 0 No action 1 General Default GD 2 High temp Alarm HA 3 Eco function E 4 Booster function B N A 5 Thermal Treat...

Page 24: ...ng I_Time AquaFirst 15 0 200 sec N A D_Time AquaFirst 2 sec 0 200 sec N A 9 5 Thermal Treatment Menu The function Thermal Treatment is disabled by default Activate it by setting TrTh_Activated to ON The clock program logically activates it automatically or not The thermal treatment starts when the thermal treatment is switch on inside the clock program and ends at the end of the thermal treatment ...

Page 25: ...econdary pumps are connected SS DS DD series they are still in operation during the Eco function Booster function is not available in AquaCompact Parameter Factory Setting Optional setting Description 0 1 E 2 B 3 E B 0 0 1 0 No function 1 Eco Function only 2 N A 3 N A Fct_Selection Normal Normal Eco Boost EcoBoost Playback function selected in 1 Eco 2 Booster 3 ECoBoost Eco Delay 5 min 1 30 min Sc...

Page 26: ... Depends on the HE type and Primary inlet temperature 9 9 230V Triac menu Accessing the 230C Triac menu requires login at Technician level This menu allows using a 230VAC Triac output Parameter Factory Setting Optional setting Description Multi P Off Off On Enable or Disable the 230V output as per clock program Pulse Duration 5 sec 1 3600 230V pulse duration in seconds Bypass 0 Off 1 ON N A N A N ...

Page 27: ...uto test time sequence Parameter Factory Setting Optional Setting Description Start AutoTest 0 0 1 Set 1 to start auto test When finished the value goes back to zero Pump_Fault_Reset Off Off On Set to On after an Auto test Pump time test 4 sec 1 600 sec Pumps activated this time value Valve time test 4 sec 1 600 sec Valve activated this time value Alarm time test 4 sec 1 600 sec Relays 1 and 2 tes...

Page 28: ...y occur after Auto test In this case clear the alarm according to 9 11 Clear alarm menu 9 11 Clear alarm menu Accessing the Clear Alarm menu requires login at Technician level All alarms are cleared the same way Parameter Factory Setting Optional Setting High_Alm_Reset Off Off On Select On to clear the alarm then return to Off or wait a few seconds for automatic return to Off Off the alarm is clea...

Page 29: ... to start stop a pump open close control valve for example 10 1 Change password for technician level NOTE To change the password you need the password for the Technician level level 3 1 Press key to access to Service Menu go to Login Installer press the wheel 2 Enter the current password press the wheel to validate 3 Mark Change Password then press the wheel 4 Go to Level 3 line and then click on ...

Page 30: ... is SP_T_Sec_Oulet main temperature program See 9 4 S1 Menu Secondary Outlet TSP_Amb Not used Multi Pulse See 9 9 230V Triac menu Therm treatment See 9 5 Thermal Treatment Menu Point Data Internal parameters I O visualisation Analog input Sensor values Pseudo Analog Can be set points or internal parameters Analog Output Valve output signal Binary input Ipsothermic contacts from pumps remote contac...

Page 31: ...Operating Hours in the menu The first time you enter this menu the list is empty 3 To add a variable to trend choose 4 Mark one variable to follow and press the wheel 5 Validate the variable by clicking in the Operating Hours box If this box is empty the variable is in the list but it is not recorded When you go back in the menu key you can see the list with Cmd_P1 parameter and on the right side ...

Page 32: ...S1 6 Validate the variable by ticking in the Trend Log box If this box is empty the variable is in the list but it is not record There are two different ways to record method a and b a Only the temperature change is recorded This saves memory and allows a longer sampling period compared to method b Select the record hysteresis In our case every 1 C temperature change is recorded The hysteresis val...

Page 33: ... to display S1 in this case and press the wheel Date time and temperature at the time can be read For example on 21 st of September at 14h22 was the temperature in S1 58 C 10 7 Point Data From the menu Point Data you can read or change binary or analog outputs start and stop pumps open or close control valve This sub menu is very similar with Autotest as it performs same actions in manual mode NOT...

Page 34: ... are important alarms like high temp Non Critical Alarms Lists all non critical alarm condition These alarms are more information like power failure For example in the alarm buffer you can read 15 52 SAFETY_FCT 15 51 SAFETY_Speed 15 41 SAFETY_Speed 15 40 SAFETY_FCT Note that the alarms are listed with the latest at the top Press a line to see more information about the alarm Displayed Meaning 19 0...

Page 35: ...larm Fouling heat exchanger Alarm 0 1 30 Ret_High_Alarm High temperature alarm on S2 0 1 31 ThermTr_Alarm Thermal treatment failed 0 1 32 SAFETY_FCT The safety function state 0 1 35 Disp_Leg_active Thermal treatment running 0 1 36 Remote_Control The unit is remotely controlled 0 1 37 ECOMode ECO function activated 0 1 42 Tank_load Tank loaded sensor S2 need to be connected 0 1 44 PA10_valve1 Prima...

Page 36: ...ne program name with a star at the end 3 Press the wheel a few seconds and the program will start after 1 minute Settings are now factory settings Note that on some software versions the displayed language can be changed 1 Rotate the wheel clockwise to display all available languages 2 Select and press the wheel 3 Select Factory line and press the wheel the controller will restart NOTE If another ...

Page 37: ...es on C and C respectively labelled 25 and 26 on controller C Bus terminal The connection via shielded cable is not required but can be performed with the terminal 24 For this it is necessary to unscrew the front panel 14 2 Connecting multiple Micro 3000 control boxes Rules to respect Max length between BMS and farer control box is 500 meters Connection C and C has to be done directly on the contr...

Page 38: ...to access to Service Menu go to Login Installer press the wheel 2 Enter the current password press the wheel to validate 3 Mark Next then press the wheel 4 Select Interface Config 5 Select Modbus 6 Select the variable to change Press the wheel to validate Device ID Modbus Address of the controller Baud Rate Com speed Parity None 0 Even Odd No of Stop Bits 0 1 ...

Page 39: ...t 01923 232335 www hrshevac co uk 39 of 58 HRS Hevac Ltd AquaSave A6 Range Installation Operating Instruction Manual 14 4 Modbus slave communication parameters ...

Page 40: ...rom the controller Check then replace if necessary Supply wires improperly tightened Check wires re tighten connections Actuator stroke restricted Dismount then clean the valve High alarm condition detected Charging pump stopped Refer to Pump not operating above Low recirculation flow rate Check and fix problem Alarm differential too low Check and set the controller Actuator not closing Refer to T...

Page 41: ... on the quality of the water and how much demand is placed on the system Flush out the tank on a regular basis Check regularly that the safety devices like safety valve etc are working properly Lime scaling on the connected devices Scaling of the secondary side will be evidenced by A high pressure drop on the secondary side of the exchanger that should not exceed 50 kPa on all models heat exchange...

Page 42: ...water cool down to preclude any risk of scolding or burns The AquaSTOR is fitted with a dismounting inspection hole In order to work on the inside of the tank use the shut off to isolate the exchanger kit isolate the installation s power circuit close the cold water inlet and drain out the tank Access is through the inspection hole once the tightening screws have been loosened NOTE Comply with all...

Page 43: ...ered plugs and isolate the secondary circuit using the gate valves Unclip the heat insulator at the top and bottom of the exchanger Isolate the exchanger and use the special connective fittings for cleaning removing the plugs CIP connector 3 4 The circulator systems and pumps require no specific maintenance action The motor driven control valves do not need any particular maintenance Run annual ch...

Page 44: ...of fuses to protect the different components against overload Extra fuses are included in the control box The service work must be carried out by an authorized service technician Turn off the power supply before starting to work F5 Fuse F5 1 Led 1 lit when pump P1 is power supplied F1 Fuse F1 2 Led 2 lit when pump P2 is power supplied F2 Fuse F2 3 Led 3 lit when pump P3 is power supplied F3 Fuse F...

Page 45: ... 10h00 for 5 seconds See 9 9 230V Triac menu Connected device must not exceed 230VAC 1A 16 8 Add relay 1 and relay 2 Relay 1 can be NO normally open or NC normally closed Relay 2 is always NO normally open Connect the relay 1 Operating mode Connections on PCB bottom terminal NO C NO 25 24 NC C NF 25 26 Connect relay 2 to the controller terminal 13 IN6 and 14 OUT6 See 6 2 Electrical wiring diagram ...

Page 46: ... photos are non binding changes are liable to made without notice 1 Unpack secondary charging kit and check all parts for damage 2 Tools required to install the secondary charging kit Adjustable spanner 10mm spanner Phillips No2 screwdriver 3 Connect the secondary isolation valve to the AquaSTOR 4 Connect the heat exchanger support to the support connection on the AquaSTOR ...

Page 47: ...struction Manual 5 Mount the heat exchanger on the support bracket and connect to the secondary isolation valve connection of the heat exchanger 6 Tighten the U bracket on the heat exchanger support 8 Connect the secondary inlet sub assembly secondary pump to the inlet connection of the heat exchanger ...

Page 48: ...on Manual 10 Install a fibre washer in to one end of the flexible hose 12 Insure the pump connection is tight 13 Install a fibre washer in the flexible hose and connect to the bottom connection on the AquaSTOR 11 Connect the flexible hose to the secondary pump 14 Insure the flexible hose connection is tight ...

Page 49: ...n Manual 15 Mount the first half of the insulation jacket aligning with the heat exchanger secondary connections 16 Mount the second half of the insulation jacket aligning with the heat exchanger primary connections 18 Ensure both top and bottom clips are fully seated 17 Snap on the insulation retaining clips ...

Page 50: ...e secondary pump terminal box cover 20 Attach the gland and wiring loom to the terminal box 21 Remove the protective terminal strip 22 Connect the secondary pump wiring Brown Live Blue Neutral Green Yellow Earth 23 Ensure that the wiring will not be trapped by the terminal cover 24 Re attach the secondary pump terminal box cover ...

Page 51: ...allation Operating Instruction Manual Flowcharts 18 18 1 Flowchart A60B 1 HRS Hevac Scope of Supply 2 3 4 A B B C D E 1 Primary Inlet 2 Primary Outlet 3 Cold Feed 4 Water Outlets Key Heat Exchanger A B C D E Isolating Valve Shunt Pump Flow Regulating Valve Secondary Buffer Vessel ...

Page 52: ...n Manual 18 2 Flowchart A62B 1 2 3 4 C B A D E E H G F HRS Hevac Scope of Supply Key 1 Primary Inlet 2 Primary Outlet 3 Cold Feed Heat Exchanger A B C D E F G H 2 Port Control Valve Control Panel Control Sensor Isolating Valve Secondary Shunt Pump 4 Water Outlets Flow Regulating Valve Secondary Buffer Vessel ...

Page 53: ... 3 Flowchart A63B 1 2 3 4 C B A D E H G F F I HRS Hevac Scope of Supply Key 1 Primary Inlet 2 Primary Outlet 3 Cold Feed Heat Exchanger A B C D E F G H I Primary Shunt Pump 3 Port Control Valve Control Panel Control Sensor Isolating Valve Secondary Shunt Pump 4 Water Outlets Flow Regulating Valve Secondary Buffer Vessel ...

Page 54: ...supply If the control box is connected to the main power supply ensure that the main switch is turned off and locked 2 Open the electric box of the charging pump 3 Yellow Green wire to Earth Blue wire to Neutral N Brown wire to Phase L 4 With a UPS32 80N pump To allow the pump to report Ipsothermic contact to the control box wire the two black wires to the heating protection plug mark 2 mark 4 To ...

Page 55: ...quaSave A6 Range Installation Operating Instruction Manual Special instructions for options 20 20 1 Special instructions for A62B The actuator has been factory calibrated No special setting is needed 20 1 1 Electrical wiring Wire terminal 20 1 2 Wiring diagram ...

Page 56: ...56 of 58 t 01923 232335 www hrshevac co uk HRS Hevac Ltd AquaSave A6 Range Installation Operating Instruction Manual Commissioning report 21 All parts are not applicable to the AquaSave ...

Page 57: ...t 01923 232335 www hrshevac co uk 57 of 58 HRS Hevac Ltd AquaSave A6 Range Installation Operating Instruction Manual Declaration of Conformity 22 ...

Page 58: ...sion factors Non compliance with the guidelines for installation configuration and maintenance Over pressures water hammer scaling noncompliant water quality Also excluded from the warranty Fitting costs refitting costs packaging transport and any accessories or equipment not manufactured by HRS Hevac which will only be covered by any warranties issued by said third party manufacturers Any damage ...

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