GF Hycleen Automation System User manual

GF Piping Systems
Hycleen Automation System
User Guide
Version 2.5

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Contents
1 About this document
1.1 Follow the instruction manual 5
1.2 Symbols used in this manual 5
2 System Overview
2.1 Sample system 7
2.2 Operating principle 8
3 Installation
3.1 Changing components in a configured system 9
3.2 Valves 10
3.3 Master 11
3.3.1 Mounting the master on the wall 11
3.3.2 Connecting the master to the valves via cables 12
3.4 Uni Controllers 16
3.4.1 Mounting Uni controllers 16
3.4.2 Cabling Uni controllers 17
3.5 Additional components 19
3.5.1 Extending the connecting cable 19
3.5.2 Mounting the Powerbox 19
3.5.3 Mounting external temperature sensors 21
3.5.4 Installing the run off monitoring system 23
3.5.5 Installing the flow sensor 23
3.5.6 Installing an uninterruptible power supply 24
3.5.7 Connecting the master relay 24/230 V 25
4 Working with the master
4.1 Commissioning 27
4.2 Home/main menu 29
4.3 Flush 30
4.3.1 General procedure 32
4.3.2 Title 32
4.3.3 Process 34
4.3.3.1 Trigger = Temperature 35
4.3.3.2 Trigger = Time 37
4.3.3.3 Trigger = Usage 39
4.3.4 Protocols 40
4.3.5 Advanced settings 41
4.4 Hydraulic balancing 42
4.4.1 General procedure 44
4.4.2 Title 45
4.4.3 Process 45
4.4.3.1 Type = Temperature 46
4.4.3.2 Type = Temperature static 49
4.4.3.3 Type = Flow 51
4.4.3.4 Type = Fixed 53
4.4.4 Protocol 53
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4.4.5 Advanced settings 54
4.5 Temperature 55
4.6 Flow 56
4.7 Actuator Automation 57
4.7.1 Trigger 58
4.8 Automatic Maintenance Process 61
4.9 Manual operation 62
4.9.1 Valve 63
4.9.2 Valves 64
4.9.3 Actuators 65
4.10 Settings 66
4.10.1 Country 66
4.10.2 Object 67
4.10.3 Valves 67
4.10.4 External sensors 69
4.10.5 Actuators 70
4.10.6 Reset 70
4.10.7 Backup 71
4.10.8 Alarms 72
4.10.9 Update 72
4.10.10 Export 73
4.10.11 Network 74
4.10.12 Bluetooth 76
4.10.13 Modules 77
4.11 Protocols 78
5 Troubleshooting
5.1 Notifications 81
5.2 Error messages 82
5.3 Error management 83
5.3.1 Problems 83
5.3.2 Questions 84
6 CE Declaration
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1 About this document
1 About this document
1.1 Follow the instruction manual
The instruction manual is part of the product and an important element within the safety
concept.
Read and observe instruction manual.
Always have instruction manual available by the product.
Give instruction manual to all subsequent users of the product.
1.2 Symbols used in this manual
Safety-relevant information is labeled in this document by the following symbols and signal
words:
Risk of injury!
Non-observance may lead to physical injury!
Remedy
Risk of material damage!
Non-observance may lead to material damage (loss of time, loss of data, machine defects,
etc.)!
Remedy
Descriptive text
Instructions for conduct
Reaction of the system
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2 System Overview
2 System Overview
2.1 Sample system
The sample system shows a water supply with 3 cold water pipes and 5 hot water circulations.
1 Valve LegioTherm K 9 Sensor cable
2 Cold water pipe 10 Flow sensor
3 Water heater 11 Return line (hot water)
4 Temperature sensor 12 Power supply and communication cable
5 Feed line (hot water) 13 Master
6 Uni controller 14 Uninterruptible power supply (UPS)
7 Valve LegioTherm 2T 15 External power supply
8 Run off monitoring system
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2 System Overview
2.2 Operating principle
The hot water and cold water circulations contain valves of the types LegioThermK and
LegioTherm2T. The latter serve hydraulic balancing (circulation system).
Both circulations can be flushed. The flush water runs into a drain.
The LegioTherm valves are equipped with a temperature sensor.
All valves are connected to the Master via power supply and communication cables serially
(i.e. not radial!), which also supplies them with power. The master controls the opening angle
of the valves according to its programming, taking into account the connected sensors, and cre-
ates log data in the form of protocols.
If required, the system can be enhanced by Hycleen Automation (Hycleen AS) Uni controllers.
This allows the integration of additional sensors (existing Hycleen AS sensors or external 4-
20mA sensors) as well as the control of actuators via an output (4-20mA or relay).
The system can control a maximum of 50 LegioTherm valves (LegioThermK and/or
LegioTherm2T). If Uni controllers are installed in the system, the following applies:
(Number of LegioTherm valves) + (2 x number of Uni controllers) ≤ 50.
After the valves are installed according to their operating instructions, they only must be con-
nected to Hycleen Automation power supply and communication cables. The power is
supplied by the master via these connecting cables. For cable lengths of more than 300 m an
additionalHycleen Automation Powerbox is required. Via its 2 cable connections, a master
with 2 power boxes can supply and control up to 1,000 m cable length.
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3 Installation
3 Installation
3.1 Changing components in a configured system
Applications are reset when changing the hardware components!
When changing hardware components in an already configured system (e.g. when instal-
ling an additional external sensor), all applications are reset to the factory settings. The
valve parameters remain unchanged.
Prior to the installation Export the system configuration as a PDF.
After completion of the installation open the PDF and enter the application parameters
into the Hycleen master.
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3 Installation
3.2 Valves
The insulation of the valves must be removed for cabling the valves.
To remove the insulation, carefully pull apart both parts (1, 2). Make sure that the tem-
perature sensor cable is not detached or damaged.
Put the insulation aside for later assembly.
After assembling each valve, remove the detachable part (3) of the label from the valve and
stick it in the installation plan. This part contains information about the valve type, serial number
and size etc., and serves the subsequent identification of the valve in the installation plan.
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3 Installation
3.3 Master
3.3.1 Mounting the master on the wall
The housing of the master is attached to the wall using 4 eyelets (1).
Drill 4 dowel holes with a diameter of 6 mm into the wall according to dimensional dra-
wing and insert the supplied dowels (2).
Use a Phillips screwdriver to screw on the master with the 4 screws provided (3).
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3 Installation
3.3.2 Connecting the master to the valves via cables
The connecting cables include 2 lines for the voltage supply and 2 signal lines. The two cable
ends are equipped with the same female plug-in connectors. They are secured to prevent rota-
tion and their M12 knurled screws ensure a reliable hold, even in harsh environments.
Non-approved components can cause malfunctions!
Components must not be modified and connecting cables or distributors for star topology
cabling must not be installed at any time!
Always connect master, valves and, where required, powerboxes in series, i.e. one
behind the other, to the components specified by the manufacturer!
Faulty assembly can cause malfunctions!
Carrying out cabling with the power supply switched on could cause damage to the elec-
tronic components!
Make sure that neither the master nor powerbox(es) are supplied with voltage while
cabling!
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3 Installation
Connecting the master
Connect one of the plugsof the connecting cable to the left M12 connection(1) of the
master and fasten the knurled screw. After that the M12 (2) connection can also be
used, for example, (1) for one side of the building, and (2) for the other side.
Close the open M12 connection on the last valve with a protection cap (8).
When switching on the master, the valves coming from the master are numbered auto-
matically, starting with the left line (1). The components of the right line (2) are then fur-
ther numbered directly afterwards.
Faulty assembly can cause malfunctions!
If no component is connected to the left connection (1), the master will ignore the
right connection (2) during the booting procedure after switching on.
When connecting the components, start with the left line (1)!
Connect the power supply cable to the connection(7) of the master.
For the connections Ethernet (3), USB-2B (4), 2 USB-2A (5) and master relay
24V/230V (6) see Additional components.
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3 Installation
Connecting a valve
Faulty assembly can cause malfunctions!
Carrying out cabling with the power supply switched on could cause damage to the
electronic components!
Make sure that the master is not supplied with power while cabling!
Connect the other plug(2) of the connecting cable to one of the two M12 plugs(3)
of the valve and fasten with a knurled screw. Both M12 plugs(3) of the valves are
equivalent.
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3 Installation
Where required: Connect sensor(s) to the valve
Faulty assembly can cause malfunctions!
Carrying out cabling with the power supply switched on could cause damage to the
electronic components!
Make sure that the master is not supplied with power while cabling!
Connect plug (5) of the sensor to the sensor connection (4). During the switching on pro-
cess of the master, the sensor is automatically detected.
Connecting additional valves
Connect one of the plugsof the next connecting cable to the second M12 plug(3) of
the valve and fasten with a knurled screw, etc.
Faulty assembly can cause malfunctions!
If the knurled screw is not tightened correctly, the connection can work loose
over time. This causes the system to malfunction!
Make sure that all knurled screws of the connecting cables are tigh-
tened!
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3 Installation
3.4 Uni Controllers
If Uni controllers are installed in the system, the following applies:
(Number of LegioTherm valves) + (2 x number of Uni controllers) ≤ 50.
Examples:
Installed LegioTherm valves additional Uni controllers possible
10 20
20 15
30 10
40 5
The Uni controller is fully mapped via the BACnet interface, in the REST API interface only the
4-20mA inputs of the Hycleen AS-sensors are processed.
3.4.1 Mounting Uni controllers
Uni controllers can be mounted flexibly according to the situation. For information beyond the
mounting, see the instruction manual of the Uni controller.
Fixing to the pipe or pipe insulation via cable connector
Slightly bend the 2 fins (1) upwards at the rebated joints.
Position the Uni controller on the pipe or pipe insulation and fix it with cable connectors.
Wall mounting
Drill 4 dowel holes with a diameter of 6 mm into the wall according to dimensional dra-
wing and insert the supplied dowels.
Screw the Uni controller to the bracket (2) via 4 screws.
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3 Installation
3.4.2 Cabling Uni controllers
Faulty assembly can cause malfunctions!
Carrying out cabling with the power supply switched on could cause damage to the elec-
tronic components!
Make sure that neither the master nor Powerbox(es) are supplied with voltage while
cabling!
The Uni controller offers the following connections:
(1)Relay output 24V/230V
(2)4-20mA IN/OUT
(3)2 M12 plug
(4)2 inputs 4-20mA(top:port 1, bottom:port 2) for the connection of two 4-20mA sen-
sors (external Hycleen AS sensors or sensors of other manufacturers).
Uni controllers are cabled via M12 plugs (3) similar to a Valve.
Connect Uni controllers to the master and the valves in series via cables.
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3 Installation
Relay output 24/230V and connection 4-20mA IN/OUT
These connections allow the control of actuators such as, e.g. electric actuators with or
without position feedback (5). Actuators connected here can be controlled via the app-
lication Actuator Automation.
Connect the cable relay24/230V(3) or 4-20mAIN/OUT(4) of the actuator to the respec-
tive connection (1) or(2).
Inputs 4-20 mA
The inputs 4-20mA (4) can be used to connect the Hycleen AS sensors temperature (5), flow
(6) and process monitoring (7).
Connect the cables of the sensor to one of the two inputs (4).
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3 Installation
3.5 Additional components
3.5.1 Extending the connecting cable
Use the connector (6) for connecting two connecting cables in series.
3.5.2 Mounting the Powerbox
In the case of cable lengths longer than 300m, switch a Powerbox between two connecting
cables. This way, the cable length can be extended by another 200 m to 500 m maximum. For
more information see the installation instructions of the Powerbox.
Faulty assembly can cause malfunctions!
Carrying out cabling with the power supply switched on could cause damage to the elec-
tronic components!
Make sure that the Powerbox is not supplied with power while cabling!
When cabling the Powerbox, observe the IN and OUT marks!
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3 Installation
Connect the plug of the first connecting cable from the master to one of the M12 plugIN
(3) of the Powerbox and fasten with a knurled screw.
Connect the plug of the second connecting cable to the next controller to the M12
plugOUT(4) of the Powerbox and fasten with a knurled screw.
Only insert the cold-device plug of the power cable into the connection (2) to begin the
startup of the system once all components have been correctly cabled.
The LED (1) of the Powerbox lights up green´when the master is switched on and star-
ted up.
Faulty assembly can cause malfunctions!
If the knurled screw is not tightened correctly, the connection can work loose over time. This
causes the system to malfunction!
Make sure that all knurled screws of the connecting cables are tightened!
Faulty assembly can cause malfunctions!
If powerboxes are installed, these components provide voltage even when the master is
switched off.
Make sure that all powerboxes are first switched off before switching off the master!
Make sure that all powerboxes are first switched on again before switching on the
master!
Faulty assembly can cause malfunctions!
The master must be switched off during the connection of new external sensors.
Switching off the master.
Connect the sensors with the master as described below.
Switch on the master again. This first initializes all connected powerboxes and then
launches the master software. The newly connected external sensors are now auto-
matically detected by the master.
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