IVT PKS 1000 Assembly instructions

Installer Guide
PKS 1000
6 720 641 553-08.1I
Passive Cooling station
Art. no.: 6720642838; Version 2010/03

Contents
6 720 642 838 (2010/03)
2
Contents
1 Explanation of symbols and safety information 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . 3
2 Included in the delivery . . . . . . . . . . . . . . . . . . . 4
3 Accessories for cooling station . . . . . . . . . . . . . 5
3.1 Installation example . . . . . . . . . . . . . . . . . 6
4 Passive cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Passive cooling 1 . . . . . . . . . . . . . . . . . . . . 7
4.2 Passive cooling 2 . . . . . . . . . . . . . . . . . . . . 7
5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Technical information . . . . . . . . . . . . . . . . . . . . 10
6.1 Component parts . . . . . . . . . . . . . . . . . . 10
6.2 Designations in system solutions . . . . . . 11
6.3 System solutions . . . . . . . . . . . . . . . . . . . 13
6.4 Technical Data . . . . . . . . . . . . . . . . . . . . . 16
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Handling circuit boards . . . . . . . . . . . . . . 18
7.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Removing the front panel . . . . . . . . . . . . 19
7.5 Connection . . . . . . . . . . . . . . . . . . . . . . . 19
7.6 Filling the heating system . . . . . . . . . . . . 21
7.7 Volume flow via the heating system . . . . 21
7.8 Circulation pump, heating system . . . . . . 21
8 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.1 Wiring diagram PKS 1000 . . . . . . . . . . . . 22
8.2 Wiring diagram XB2 . . . . . . . . . . . . . . . . . 23
8.3 Wiring diagram 3-way valve . . . . . . . . . . . 24
8.4 Wiring diagram electrical distributor for
heating/cooling . . . . . . . . . . . . . . . . . . . . 25
9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1 Menu overview . . . . . . . . . . . . . . . . . . . . . 27
9.2 Circuit 1 Cooling . . . . . . . . . . . . . . . . . . . 28
9.3 Circuit 2, 3... . . . . . . . . . . . . . . . . . . . . . . 30
9.4 Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.5 External control . . . . . . . . . . . . . . . . . . . . 31
9.6 Installer \ Outputs . . . . . . . . . . . . . . . . . . 31
9.7 Installer \ Circulation pumps . . . . . . . . . . 31
10 Factory values . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11 Commissioning protocol PKS 1000 . . . . . . . . . 33

Explanation of symbols and safety information
6 720 642 838 (2010/03) 3
1 Explanation of symbols and safety information
1.1 Explanation of symbols
Warning symbols
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
•NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.
•CAUTION indicates possible injury.
•WARNING indicates possible severe injury.
•DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety precautions
General
BRead the guide carefully and keep it to hand for future
use.
Installation and commissioning
BInstallation and start-up may only be carried out by a
qualified installer.
BThe appliance must not be used by untrained parsons,
children or persons with a physical disability, unless
they are authorised to do so or are supervised by a
person who is responsible for their safety.
BSupervise children to make sure they do not play with
the appliance.
Service and maintenance
BOnly qualified personnel may carry out repairs.
Incorrect repairs can lead to serious risks to the user,
and a reduction in savings.
BOnly use original spare parts.
BService and maintenance must be carried out annually
by an authorised service representative.
Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.
Electrical hazards are identified by a
lightning symbol surrounded by a warning
triangle.
Notes contain important information in
cases where there is no risk of personal
injury or material losses and are identified
by the symbol shown on the left. They are
bordered by horizontal lines above and
below the text.
Symbol Meaning
Ba step in an action sequence
a reference to a related part in the docu-
ment or to other related documents
•a list entry
–a list entry (second level)
Tab. 1

Included in the delivery
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2 Included in the delivery
Fig. 1 Included in the delivery
1Passive cooling station
2Spacer foot
3Wall mounting
4Handbook
5CAN-BUS cable (3.5m)
6 720 641 553-09.1I
5
2
1
3
4

Accessories for cooling station
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3 Accessories for cooling station
The following accessories are available for control of the
passive cooling system:
•LK three-way change over valve (E11.Q12) Three-way
change over valve is connected to the XB2 card in the
cooling station. The three-way change over valve can
be used to by-pass the buffer tank to protect it against
cooling. Power supply 230 V.
•Room transducer for relative humidity and
temperature (E11.TM) (dew point sensor)
Sensor for registering room temperature and
humidity in a reference room. Sauters room
transducer for relative humidity and temperature is
connected to the XB2 card on the cooling station by a
4x2x0.8 mm2cable. Power supply 24 V via the
transformer in the cooling station.
•Electrical distributor for heating/cooling Sauters
electrical distributor for heating/cooling for
underfloor heating loops is connected to the XB2 card
on the cooling station. Room temperature controller,
room transducer for relative humidity and
temperature and actuators are connected to the
distributor. The heat pump's C/O signal (switch from
heating to cooling) is connected to the distributor.
Distributor power supply 230 V. The heat pump's C/O
signal can only be managed from Sauters cable bound
distributor ASV6F116. The remote control controller
from Sauter cannot transfer the signal onwards.
•Electrical room temperature controller for heating/
cooling 230 V. Sauters room temperature controllers
are connected to the distributor by 7x1.5mm2cable.
•Thermal drive for unit valves Sauters thermal drives
for unit valves are connected to the distributor. Power
supply 230 V.
•Dew point monitor and transducer Sauters dew point
monitor and transducer and room temperature sensor
are used for comprehensive dew point monitoring
and are connected to the floor distributor flow line by
a tension strap. Dew point monitor and transducers
are connected to the distributor by 7x1.5mm2cable.
•Dew point monitoring The electronic dew point
monitor (E31.RM1) AL-Re can be used to monitor the
dew point, as a complement to the two recommended
components from Sauter. Power supply 24 V via the
transformer in the cooling station. The dew point
monitor is connected to the XB-2 card of the cooling
station by a 2-core cable.
•Humidity sensor The Humidity sensors (TM1-TM5)
from AL-Re are sensors that are also used for dew
point monitoring and are connected to the electronic
dew point monitor. Maximum of five humidity sensors
can be connected.

Accessories for cooling station
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6
3.1 Installation example
Fig. 2 Installation example with heat pump, passive cooling station and underfloor loops.
1Heat pump
2Passive cooling station
3Electrical distributor for heating/cooling underfloor heating loop
4Control distributor
5Room transducer for relative humidity and temperature (dew point sensor)
6Electrical room temperature controller with individual control
7Electrical room temperature controller with individual control
8Underfloor heating loops
6 720 641 553-10.1I
1
8
4
3
5
7
6
2

Passive cooling
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4 Passive cooling
The passive cooling station is designed for operation
connected to liquid/water heat pumps 6-17 kW with
underfloor heating systems or fan convectors. The
cooling station consists of a heat exchanger, a
circulation pump, a mixing valve and a circuit board for
control of cooling operation. In cooling operation the
system works to maintain the room temperature despite
the increasing outdoor temperature for greater comfort.
With passive cooling, the compressor in the heat pump
is not used. Instead, the cooling is controlled by the
collector circuit flow. All heating circuits can be used for
cooling.
4.1 Passive cooling 1
Passive cooling in combination with a fan convector. The
temperature is controlled via a thermostat in the fan
convector. It follows therefore that the fan is deactivated
if the room temperature falls. The temperature can also
be regulated using room temperature sensors. In this
case, the mixing valve to the cooling circuit is closed but
the fan continues to run until the room temperature has
fallen to the specified value. The desired flow
temperature is set by the installer.
The system must be protected from condensation,
either by the flow line temperature being set sufficiently
high that no condensation occurs, or by supplementing
with condensation draining/insulation. It is also possible
to supplement the system with a room transducer for
relative humidity and temperature, which ensures that
the flow line temperature is held at a level so that the
condensation does not build up, and dew point monitor,
which shuts off the cooling function if condensation is
created nonetheless.
4.2 Passive cooling 2
Passive cooling in combination with underfloor heating
system. This solution uses the existing underfloor
heating system to cool the room. The system must be
protected from condensation, either by the installer
setting the flow line temperature sufficiently high that
the no condensation occurs. Alternatively, the room
transducer for relative humidity and temperature is
installed, which gives the controller the opportunity to
establish appropriate flow temperature, which does not
cause condensation. The system can also be
supplemented with a dew point monitor, which
interrupts cooling operation if condensation is created
nonetheless.

Dimensions
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5 Dimensions
Fig. 3 Pipe connections, measured in mm.
Fig. 4 Breadth and depth measurements in mm.
1Roof decal
2Type plate
Fig. 5 Height measurements in mm.
Fig. 6 Dimensions in mm
6 720 641 553-01.1I
28 28 3535
500500500500
373373373373
6 720 615 125-24.1I6 720 615 125-24.1I
122
1
61,5
±
5
433
6 720 641 553-11.1I
0
58,5
187,5
312,5
437,5
500
0
15
62
112
6 720 617 643-11.1I

Dimensions
6 720 642 838 (2010/03) 9
Fig. 7 Roof decal
1HTF (coll) in
2Heat transfer fluid (cooling) out
3Heat transfer fluid (cooling) in
4HTF (coll) out
13720
6 720 615125-14.1I
1234

Technical information
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6 Technical information
6.1 Component parts
Fig. 8 Component parts
124 V Transformer
2Terminal block (X1)
3Circuit board (XB2)
4Mixing valve
5Heat exchanger
6Circulation pump
24V
220V
6 720 615 125-26.1I
1
2
3
4
5
6

Technical information
6 720 642 838 (2010/03) 11
6.2 Designations in system solutions
E10
E10.T2 Outdoor sensor
Tab. 2 E10
E11
E11.C101 Expansion tank
E11.C111 Buffer tank
E11.F101 Safety valve
E11.G1 The heating system's pump
E11.P101 Pressure gauge
E11.Q12 3-way valve for buffer tank (Cooling)
E11.T1 Flow sensor
E11.T31 Flow sensor (Cooling)
E11.TM Room transducer for relative humidity
and temperature (Dew point sensor)
E11.TT Room sensor
Tab. 3 E11
E12
E12.G1 Heating/cooling circuit mixing valve
E12.Q11 Mixing valve
E12.T1 Flow sensor
E12.TM Room transducer for relative humidity
and temperature (Dew point sensor)
E12.T5 Room sensor
Tab. 4 E12
E13
E13.G1 Circulation pump
E13.G2 Fan-assisted radiator
E13.Q11 Mixing valve
E13.T1 Flow sensor
E13.TM Room transducer for relative humid-
ity and temperature (Dew point sen-
sor)
E13.TT Room sensor
Tab. 5 E13
E21
E21 Heat pump
E21.E1 Compressor
E21.E2 Electric add. heat internal/external 1
(does not apply to Greenline HC)
E21.F101 Safety valve
E21.G2 Heat carrier pump
E21.G3 Heat transfer fluid (coll.) pump/fan
E21.Q21 3-way valve
E21.T6 Hot gas sensor
E21.T8 Heat transfer fluid out
E21.T9 Heat transfer fluid in
E21.T10 HTF (coll) in
E21.T11 HTF (coll) out
E21.V101 Filter
Tab. 6 E21
E31
E31.C101 Expansion tank
E31.E32 Heat exchanger passive cooling
station
E31.F101 Safety valve
E31.G1 Cooling system pump
E31.G31 Circulation pump cooling sys-
tem.
E31.G32 Fan-assisted radiator
E31.P101 Pressure gauge
E31.Q21 Ball valve filling unit
Tab. 7 E31

Technical information
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12
E31.Q22 Ball valve filling unit
E31.Q23 Ball valve filling unit
E31.Q31 Primary cooling mixing valve
E31.R101 Non-return valve passive cool-
ing
E31.RM1 Dew point monitor
E31.RM1.TM1-2 Dew point monitor, humidity
sensor 1-2
E31.T31 Flow sensor
E31.TM Room transducer for relative
humidity and temperature
(Dew point sensor)
E31.TT Room sensor
E31.V101 Filter
E41
E41 Water heater
E41.F101 Safety valve
E41.T3 Sensor hot water heater/coil tank
E41.V41 Hot water
E41.W41 Cold water
Tab. 8 E41
E21.E2 (Electric add. heat) is not included in
Greenline HC. HC C6-C11
E31
Tab. 7 E31

Technical information
6 720 642 838 (2010/03) 13
6.3 System solutions
6.3.1 Based on Greenline HE E6...E17
Fig. 9 Non-shunted and shunted heating and cooling circuit with buffer tank and passive cooling station. Heating water
does not pass through the cooling station during heating operation.
Circuits E11 and E12 are used for both heating and
cooling. Both circuits have room sensors, E11.TT and
E12.TT, humidity sensors, E31.RM1.TM1 and
E31.RM1.TM2, and room transducer for relative
humidity and temperature E11.TM and E12.TM (dew
point sensor). The humidity sensors are connected to
the cooling station via a condenser switch, E31.RM1.
Room transducer for relative humidity and temperature
E11.TM (dew point sensor) is connected to the cooling
station. E12.TM is connected to the heat pump circuit
board for circuit 2 (XB1).
6 720 641 553-02.1I
The system solution also applies to
Greenline HC, with an integrated hot water
heater (E41).

Technical information
6 720 642 838 (2010/03)
14
6.3.2 Based on Greenline HE E6...E17
Fig. 10 Non-shunted and shunted heating and cooling circuit with buffer tank and passive cooling station. Heating water
passes through the cooling station during heating operation.
Circuit E11 and E12 is used both for heating and cooling.
Both circuits have room sensors, E11.TT and E12.TT,
humidity sensors, E31.RM1.TM1 and E31.RM1.TM2, and
room transducer for relative humidity and temperature
E11.TM and E12.TM (dew point sensor). The humidity
sensors are connected to the cooling station via a
condenser switch, E31.RM1.
Room transducer for relative humidity and temperature
E11.TM (dew point sensor) is connected to the cooling
station. E12.TM is connected to the heat pump circuit
board for circuit 2 (XB1).
6 720 641 553-03.1I
The system solution also applies to
Greenline HC, with an integrated hot water
heater (E41).

Technical information
6 720 642 838 (2010/03) 15
6.3.3 Based on Greenline HE E6...E17
Fig. 11 Non-shunted and shunted heating circuit, with buffer tank, cooling station, IVT mixing valve module 1000 and fan-
assisted radiator, shunted and unshunted cooling circuit.
Circuit E11 and E12 is used only for heating. Both
circuits have room sensors, E11.TT and E12.TT.
Circuit E31 and E13 is used only for cooling. Circuit E13
is shunted from circuit E31 via accessory IVT mixing
valve module 1000. Both circuits have room sensors,
E31.TT and E13.TT, humidity sensors, E31.RM1.TM1 and
E31.RM1.TM2, and room transducer for relative
humidity and temperature E31.TM and E13.TM (dew
point sensor).
The humidity sensors are connected to the cooling
station via a condenser switch, E31.RM1. Room
transducer for relative humidity and temperature
E31.TM (dew point sensor) is connected to the cooling
station E13.TM is connected to IVT mixing valve module
1000.
6 720 641 553-05.1I
The system solution also applies to
Greenline HC, with an integrated hot water
heater (E41).

Technical information
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16
6.4 Technical Data
6.4.1 PKS 1000
Unit
Operation passive cooling station
Cooling output B5/W201) kW 15,5
Cooling output B10/W201) kW 10,4
Cooling output B15/W201)
1) The output details are stated for Bx/W20, which means that temperature of incoming heat transfer fluid is x and the radiator water
return temperature is 20 °C
kW 5,2
Temperature reduction at B10/W20 and water flow 0.38 l/s °C 6,5
Heat transfer fluid
Nominal flow l/s 0,42
Permitted ext. pressure drop at heat transfer fluid nominal flow kPa 32
Max. pressure bar 4
Operating temperature °C -5 - +20
Antifreeze Ethanol / Propyl-
ene glycol
Highest concentration heat transfer fluid (-15 °C freezing point) % 29 / 35
Pipe connections mm 35
Cooling water
Temperature °C +15 - +40
Internal pressure drop at water flow 0,38 l/s kPa 2
Max. pressure bar 3
Pipe connections mm 28
Values for electrical connection
Electrical supply VAC/Hz 230V/1-50Hz
Electrical consumption kW 0,1
Factory setting circulation pump step 3 W 100
Enclosure class IP X1
General
Dimensions (height x depth x width) mm 500 x 373 x 433
Weight kg 32
Extra height pipe connections mm 62
Tab. 9

Installation
6 720 642 838 (2010/03) 17
7 Installation
7.1 CAN-BUS
The various circuit boards in the heat pump are joined by
a communications cable, CAN-BUS. CAN (Controller
Area Network) is a two-wire system for communication
between microprocessor based modules/circuit boards.
Suitable cable for external laying is cable ELAQBY/
LIYCY (TP) 2x2x0.5. The cable must be twisted pair and
screened. The screen must only be earthed at one end
and to the chassis.
Maximum cable length is 30 m.
CAN-BUS cable must not be laid alongside power supply
cables. Minimum distance 100 mm. They may be laid
alongside sensor cables.
The connection between the circuit boards is by four
wires, because the 12V-supply between the circuit
boards must also be connected. The circuit boards have
markings for both the 12V and CAN-BUS connections.
Switch Term is used to mark the start and end of a CAN-
BUS loop. Ensure that the correct circuit board is
terminated and that all other switches are in the
opposite position.
Fig. 12
GND Soil
CANL CAN low
CANH CAN high
+12V Connection 12V
EWP Heat pump
CAUTION: Interference.
BThe CAN-BUS cable must be screened
and laid separately from the power cable.
CAUTION: Do not mix up the 12V and CAN-
BUS connections!
The processors are destroyed if 12V is
connected to the CAN-BUS.
BCheck that the four cables are connected
to the contacts with the corresponding
marking on the circuit board.
6 720 614 967-31.2I
CAN-BUS CAN-BUS

Installation
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18
7.2 Handling circuit boards
Circuit boards with control electronics are sensitive to
discharges of static electricity (ESD – ElectroStatic
Discharge) when handled. To prevent damaging the
components, special care is therefore required when
handled.
Fig. 13
Damage is usually latent, and a circuit board can operate
impeccably during commissioning but show signs of
problems later. Charged objects may only be
problematic if they are in close proximity to the
electronics. Keep a distance of at least one metre from
expanded polystyrene, protective plastic and other
packaging, synthetic material (e.g. fleeces) and similar
before starting work.
A condition for good ESD protection is a ground-
connected bracelet when handling electronics. This
bracelet must be put on before opening the screened
metal bag/packaging or before exposing an installed
board. The bracelet must be worn until the circuit board
is enclosed in its screen packaging or closed electric
box. Replaced, returned circuit boards must be handled
in the same way.
Fig. 14
CAUTION: Never grasp a circuit board
without wearing a ground-connected
bracelet.
6 720 614 366-24.1I
6 720 614 366-25.1I

Installation
6 720 642 838 (2010/03) 19
7.3 Assembly
BPress the spacer feet into position on the lower part
of the back of the cooling station. Install the wall
mounting on the wall and hang the cooling station in
place.
Fig. 15 Installation
7.4 Removing the front panel
BPlace the cooling station so that the front panel can
be removed and the internal components accessed
without any difficulty. Remove the front panel by
unscrewing the two screws on the roof of the cooling
station, tilt the front panel outwards and take it off.
7.5 Connection
BThe following connections must be made on the
cooling station:
•Flow and return lines cooling water
•Flow and return lines heat transfer fluid
•Power supply
•CAN bus
BInsulate the heat transfer fluid side pipes to/from the
cooling station against condensation.
BMake the connections according to the selected
system solution and wiring diagram.
The flow pipes can be thermally insulated to ensure
optimum heating or cooling distribution.
7.5.1 Room sensor (accessory)
The room sensor is an accessory that must be used in
system solutions with cooling.
Installation location requirements:
•If possible, interior wall without drafts or heat
radiation.
•Unimpeded circulation of room air under the room
sensor (dotted area in image 16 must be kept clear).
Fig. 16 Recommended installation location for room
sensor.
7.5.2 Room transducer for relative humidity and
temperature (dew point sensor) (accessory)
BConnect the room transducer for humidity and
temperature using the same principle as for room
sensor (Chapter 7.5.1).
WARNING: Install the wall mounting on a
suitable wall using appropriate screws for
the wall material and weight of the cooling
station.
WARNING: The insulation on the heat
transfer fluid pipes must be full coverage.
6 720 615 125-27.1I
It must be possible to disable the cooling
station electrical connections safely.
BInstall a separate safety switch that cuts
all current to the cooling station.
It is only the room where the room sensor is
located that can influence regulation of the
temperature. (Chapter 9.2)
If a room sensor is used the dew point
monitor with humidity sensor must be
installed. (Chapter 9.5)
6 720 615 125-28.1I

Installation
6 720 642 838 (2010/03)
20
7.5.3 Condensation monitoring (accessory)
BInstall a humidity sensor (E31.RM1.TM1-5) near the
cooling station on the flow line pipe. When installing
with underfloor heating loops (Chapter 3.1) a
humidity sensor can also be positioned on the flow
line pipe of the electrical distributor for heating/
cooling. The humidity sensors are connected to the de
point monitor in the cooling station. The dew point
monitor is an accessory and is placed between the
transformer and terminal block (X1) (Image 17,
page 20).
Fig. 17
1Dew point monitor
If several humidity sensors are fitted, they should be at
locations in the cooling distribution system where
humidity is most likely to form.
7.5.4 Three-way change over valve (accessory)
System solution (Chapter 6.3.1Chapter 6.3.2)
requires a three-way change over valve (E11.Q12), so
that the buffer tank does not cool down.
Fig. 18
In cooling operation the switch is closed, port A is open
and the buffer tank is bypassed. (Image 19, page 20)
Fig. 19
In heating operation the switch is open, port B is open
and the buffer tank is used. (Image 20, page 20)
Fig. 20
The three-way change over valve has a Molex switch.
Only terminals 2, 6 and 3 are used. (Image 21, page
20)
Fig. 21
Condensation monitoring must be used for
system solutions with underfloor heating
(Image 9, page 13 and Image 10, page
14).
WARNING: The humidity sensor and the
pipe to which it is attached must not be
insulated.
6 720 615 125-29.1I
1
6 720 617 643-06.1I
6 720 641 553-06.1I
6 720 641 553-07.1I
6 720 617 643-10.2I
2
6
3
L
N
Y