HRS AQUASAVE A6 Series Instruction Manual

A60B
A62B
A63B
No Controls
2 Port Control
3 Port Control
10-12 Caxton Way, Watford.
WD18 8JY t. 01923 232335
Head Office
[email protected] 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 6Bar Range
A63B
Operating & Instruction Manual

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
AquaSave A60B Dimensional Details
Primary Inlet1
2Primary Outlet
3 Secondary Flow
4 Secondary Return
5 Cold Feed
6 Instrument Connections (3-off)
7
Gauge Connections
8
Immersion Heater(s) - See Table
10 Inspection Opening (DN250)
9
Safety Valve Connection(s) - Subject to Duty
11
50mm Mineral Wool Insulation c/w Al. Stucco Cladding
A
1111
C
DB
8
5
6
6
61
2
6
6
1010
6
39 377
9
9
7
8
8
4
4
A B C D 1 2 3 4 5 6 7a 7b 8
600
1910 880 1105 1" 2"
1/2" 1/2" 3/8" 2" 260
800 1965 965 1205 1" 2" 1/2" 1/2" 3/8" 2" 295
1000 1945 1050 1305 1" 2" 1/2" 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
1111
C
DB
8
5
6
6
1
2
6
6
1010
6
39 377
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 1910 910 1265 1" 2" 1/2" 1/2" 3/8" 2" 280
800 1965 965 1365 1" 2" 1/2" 1/2" 3/8" 2" 315
1000 1945 1050 1465 1" 2" 1/2" 1/2" 3/8" 2" 355
1250 2020 1135 1565 1"
1"
1"
1"
1"
1"
1"
1"
1"2"
2"
2"
2"
2" 1/2" 1/2" 3/8" 2" 385
1500 2020 1220 1665
700
800
900
1000
1100 1" 1" 1"2" 2" 1/2" 1/2" 3/8" 2" 420
2000 2275 1305 1765 1200 1" 1" 1"2" 2" 1/2" 1/2" 3/8" 2" 560
Connections (Screwed BSP F)Dimensions
Volume
(Litres)
Weight
(kg)
A
1111
C
DB
8
5
6
6
1
2
6
6
1010
6
39 377
9
9
7
8
8
4
4
A63BA62B
A60B

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Contents
Product overview.................................................................................................................. 51
1.1 Working pressure and temperature ...........................................................................................................6
1.2 Packing format ...........................................................................................................................................6
Options..................................................................................................................................72
2.1 A60B No Controls ................................................................7
2B26A2.2 Port Control Valve
3 Port Control Valve
.........................................................................7
2.3 A63B ................................................................................................ .................................................8
Installation............................................................................................................................. 93
3.1 Siting ..........................................................................................................................................................9
3.2 Hydraulic connections ...............................................................................................................................9
3.3 Basic assembly instructions .......................................................................................................................9
3.4 Commissioning ....................................................................................................................................... 10
Setting the DHW flow rate .................................................................................................. 114
Electrical connections........................................................................................................ 125
5.1 A60B ................................................................................................ ............................................................... 12
5.2 A62B & A63B ................................................................................................................................................................... 12
5.3 Electrical power ratings table ................................................................................................................. 12
5.4 Current limiting fuses.............................................................................................................................. 12
Electrical installation of control box, A62B & A63 only ................................................... 136
6.1 Controller components ........................................................................................................................... 13
6.2 Electrical wiring diagram, A62B ................................................................ ..................................................................... 14
6.3 Electrical wiring diagram, A63B ................................................................ ..................................................................... 15
User instruction operator control panel Micro 3000......................................................... 167
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.................................................................................................................... 198
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 ...................................................................................................................................... 20
8.4 Making a quick temperature change ...................................................................................................... 21
Technician menu ................................................................................................................ 229
9.1 Login....................................................................................................................................................... 22
9.2 The technician Main menu ..................................................................................................................... 22
9.3 Configuration menu ................................................................................................................................ 23
9.4 S1 Menu Secondary Outlet .................................................................................................................... 24
9.5 Thermal Treatment Menu ....................................................................................................................... 24
9.6 Safety Function....................................................................................................................................... 25
9.7 Eco-Booster Function ............................................................................................................................. 25
9.8 Fouling function ...................................................................................................................................... 26
9.9 230V Triac menu .................................................................................................................................... 26
9.10 Autotest menu ........................................................................................................................................ 27
9.11 Clear alarm menu................................................................................................................................... 28
Service Menu ................................................................................................................. 2910
10.1 Change password for technician level ................................................................................................... 29
10.2 Login installer ......................................................................................................................................... 29
10.3 Menu Continue ....................................................................................................................................... 30
10.4 Operating hours...................................................................................................................................... 31
10.5 Trending parameters menu .................................................................................................................... 32
10.6 Display the trend buffer .......................................................................................................................... 33
................................................................................................
................................................................

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Installation, Operating & Instruction Manual
10.7 Point Data............................................................................................................................................... 33
Alarm menu ................................................................................................................... 3411
Parameters’ list ................................................................................................................... 3512
Factory reset ....................................................................................................................... 3613
Modbus................................................................................................................................ 3714
14.1 Modbus communication ......................................................................................................................... 37
14.2 Connecting multiple Micro 3000 control boxes ...................................................................................... 37
14.3 Change Modbus parameters.................................................................................................................. 38
14.4 Modbus slave communication parameters............................................................................................. 39
Trouble shooting ................................................................................................................4015
Maintenance and repairs .................................................................................................... 4116
16.1 Antibacterial treatment of the AquaSTOR ............................................................................................ 42
16.2 Clean the copper brazed plate heat exchangers .................................................................................. 43
16.3 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 ............................. ................................. 4617
17.1 Attaching the heat exchanger insulation ................ ................................................................................ 49
17.2 Wiring the seconary shunt pump ........... ................................................................................................ 50
Flowcharts........................................................................................................................... 5118
18.1 Flowchart A60B ................................................................ ........................................................................................ 51
18.2 Flowchart A62B ...................................................................................................................................... 52
18.3 Flowchart A63B ............................................. ................................................................ ....................................................... 53
Wiring the charging pump.................................................................................................. 5419
Special instructions for options ........................................................................................ 5520
20.1 Special instructions for A62B ................................................................ .................................................................. 55
20.1.1 Electrical wiring ................................................................................................................................. 55
20.1.2 Wiring diagram .................................................................................................................................. 55
Commissioning report........................................................................................................ 5621
Declaration of Conformity .................................................................................................. 5722
Warranty .............................................................................................................................. 5823
23.1 Spare parts ............................................................................................................................................. 58
23.2 How to contact HRS Hevac .................................................................................................................... 58

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Product overview1
The basic version of the HRS Hevac AquaSave DHW heater, indirect (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
666
55
44
3
3
22
11

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

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Options2
There are three different control systems available as option.
2.1 A60B - No Controls
Supplied with only the secondary charging circuit.
Primary flow connection
Primary return connection
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 Assembly of the
charging kit to the AquaSTOR
Actuator
Control valve
Control box mounted on its
support

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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

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Installation3
3.1 Siting
The AquaSave hot water heater shall be installed in a dry place where room temperature is below 40°C,
and ideally in ventilated premises.
AquaSave is placed preferably on a sub-base footing.
3.2 Hydraulic connections
Connect the charging kit (exchanger + control valve + charging pump) to the storage tank using the interlink kit.
Make arrangements for fitting the insulation onto the tank before connecting up the piping.
The indirect AquaSave module can run without a recirculation system fitted.
To avoid creating a galvanic coupling, check 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 top section and a draw-off in the bottom section.
NOTE: The valve is a compulsory fixture that has to be pre-loaded at the storage tank operating pressure.
NOTE: The safety valve on the charging kit only protects the secondary system – it will neither protect nor
surge-feed the installation and the volume stored, in correspondence with local rules.
The safety valve shall have the same diameter as the cold water inlet fixture
Top section connection Exchanger support + accessories

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Bottom section connection, shut-off valve inserted between the conduit hose and the cold water 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 pressure.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Setting the DHW flow rate4
The secondary DHW flow rate is set with the tank full and the primary circuit at nominal operating temperature
and at the available exchanger power capacity required for the generator.
1. Fully open up the control valve on the primary side.
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 48 56 63 76
10 > 60°C 8.5 11.5 14 17 20 23 26 28 35 43 50 57 68
5 > 70°C 6 9 11 13 15 17 20 22 27 33 38 44 53
The recirculation flow rate has to be 60% maximum of the secondary flow rate.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Electrical connections5
All devices shall be connected up in compliance with the governing standards.
All work on control box and other electrical components must be done by qualified people.
The main electrical box should be equipped with short-circuits protection
5.1 A60B
The charging pump has to be powered constantly.
5.2 A62B & A63B
For more information about the Operator Control box, see chapter 6 Electrical installation of control box, option,
and forward.
Power the control box via a single-phase 230 V + ground.
Electrical system components pre-cabled according to the hardware ordered.
5.3 Electrical power ratings table
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
1) The electrical consumption of the control box and the actuator is 10W, 0.3A.
Figures are rounded up to the nearest value.
2) Has no control box
5.4 Current limiting fuses
Power cards are equipped with fuses, labelled FU1 to FU5 on the printed circuit.
Fuse FU1 FU2 FU3 FU4 FU5
Protection PUMP 1 N/A PUMP N/A PCB
Size (mm) 6.3x32 6.3x32 6.3x32 6.3x32 6.3x32
Calibre 2.5A 2.5A 250mA
Voltage 250V 250V 250V 250V 250V
Safety fuses are supplied inside the control box.
A60B
80 - 200 kW
A60B
>200 kW
A62B
80 - 200 kW
A62B
>200 kW
A63B
80 - 200 kW
A63B
>200 kW

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
Electrical installation of control box, A62B & A63B 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

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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.

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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.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
User instruction operator control panel Micro 30007
Button Function
Rotary button, wheel, for scrolling through the menus. Access sub-menus and change
settings by pressing 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 data transmission
Active data reception
Alarm indicator
The Control box is switched on.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
7.2 Home screen
When starting up the Micro 3000 controller this menu displays on them screen. The menu is called the Home
screen.
1 Date / hour 4 Access level:
Locked=restricted /
Key= total (3333)
2 DHW Temperature 5 Command symbols
3DHWSetpoint
NOTE: if there is an ongoing alarm when starting up the controller AquaSave, an alarm text will be
displayed on the screen. Press the House button to enter the Home screen.
7.3 Command symbols
Auto
Datapoint is in automatic operation and can be switched into manual operation.
Manual
Datapoint in manual 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 etc.) can be added to a list e.g. datapoint can be put to a list of
trended datapoints.
Deleted
Item can be deleted
Enable/disable
Checked: item is enabled
Unchecked: item is disabled
7.4 Password and login
The controller has password protection, allowing accesses to different menus.
End user level- requires no login. Marked with a locker in the upper right corner.
Technician level- access to all menus requires login. Marked with a key in the upper right corner.

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7.5 Setting the time and date
1. Turn the wheel anticlockwise to highlight the line with time and
date at the top of the screen. Press the wheel to enter the
Date/Time menu.
2. Press the wheel to change the first variable, the year.
3. When the year flashes, increase or reduce the set value by
rotating the wheel.
Once the right value is displayed, press the wheel to confirm the
setting. Next parameter 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 define the dates for changes if they are altered.
The default settings for summertime is:
Last Sunday in March to last Sunday in October.
7.8 Saving changes
Once a value has been changed and confirmed by pressing the wheel, the corresponding change will be
immediately updated. Press the or to return to the home screen.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
End user mode8
The following changes can be done in end user mode:
Settings which are identical/different for each day of the week at defined times
Normal temperature(s)
Lower temperature(s)
Special period of defined duration during the current year
Waiver with change of setting at a specific time.
One time temperature change at a specific time.
8.1 Set the hot water temperature
Please set a hot water production temperature in line with current national legislation and recommendations
(UTD, Standards EN, ISO etc.)
All countries have different rules for how hot or cold tap water should be.
HRS Hevac recommends the hot water temperature is at least 55°C and a hot water recirculation not less than
50°C.
At a temperature below 50°C there is a risk of bacterial growth.
Note that at temperatures above 60°C 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 Menu, to activate a thermal treatment (1 sensor
mode).
Multi_P to be found in 9.9 230V Triac menu, to activate the 230V power output on the controller
The time program has two different temperature modes - week program or weekend-program.
For each day of the week, define which time program to use.
By default has the weekend-program the same settings as the week- program.
It is even possible to customize the temperature programs with special dates (holidays periods or free days).
Each time program can have a number of different times set per day, each time can have a different
temperature. The set temperature is then in effect until the next time occurs. If only one temperature is set, the
program will run with the set temperature.

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HRS Hevac Ltd AquaSave A6 Range
Installation, Operating & Instruction Manual
8.3 Changing time and temperature in a time program
By default the DHW set point SP_T_Sec_Outlet, set to 60°C by default, at any time, all the days of the week.
Add extra temperature set points at different times of the day.
These changes will be reported to all days with the time program week, excluding the time program; weekend.
1. Use the wheel and mark the clock logo. Press the wheel.
2. Mark the day you want to change.Press the wheel.
Now you can choose to:
a) Change a time or temperature.
Mark the line and press the wheel. Change the value by turning the
wheel.
Confirm 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 that can be selected in the Time program.
Exception days override the weekly schedule.
In the Main screen menu, mark ‘Spcl.Days’ and press the wheel.
Choose between:
Annual - holiday periods where you have to specify beginning date,
end date and DHW set point. This mode is applicable to schools,
offices and so on.
Bank Holiday - special days during the year where set points can be
different ex: Christmas, New Year.
Daily programs - particular days where you want to change the
temperature set point.
.