Kemper KHS MASTER User manual

Installation and operating instructions
KEMPER KHS Mini System Control
KEMPER KHS Mini System Control MASTER Figure 686 02 005
KHS Mini System Control SLAVE Figure 686 02 006

Manual KHS Mini System Control MASTER
TABLE OF CONTENTS
1. GENERAL INSTRUCTIONS: ................................................................................................................1
2. AREA OF APPLICATION....................................................................................................................2
2.1 Operating modes for the water exchange ....................................................................... 2
2.2 KHS MASTER/SLAVE technology ....................................................................................... 2
2.3 Water exchange groups.....................................................................................................2
3. SAFETY.............................................................................................................................................3
3.1 Safety Instructions ..............................................................................................................3
3.2 Hazards if the safety instructions are not complied with ............................................... 3
3.3 Unauthorized alteration and spare part fabrication....................................................... 3
3.4 Unauthorised modes of operation.................................................................................... 3
4. TECHNICAL DATA ............................................................................................................................4
5. CAN BUS SYSTEM OVERVIEW..........................................................................................................5
5.1 Layout variants ................................................................................................................... 5
5.2 Terminal resistance ............................................................................................................ 6
5.3 Connection of terminal resistor ........................................................................................ 6
6. ASSEMBLY........................................................................................................................................7
6.1. Wall mounting.................................................................................................................... 7
6.2 Electrical installation KHS Mini System Control ............................................................... 8
6.2.1Terminal description -MASTER- and -SLAVE-.....................................................................................8
6.2.2Detailed illustration of the terminals for cable entry ......................................................................9
6.2.2.1Power supply connection ....................................................................................................................9
6.2.2.2Connection of KHS Isolating valve with servo-drive (Figure 686 00) ...................................................9
6.2.2.3Connection of KHS Isolating valve with spring reset servo-drive (Figure 686 01)...................10
6.2.2.4CAN bus connection ...........................................................................................................................10
6.2.2.5Connection of external switch .........................................................................................................11
6.2.2.6Connection of KHS-CONTROL-PLUS flow measurement valve (Figure 638 4G).......................12
6.2.2.7Connection of KHS Temperature sensor Pt 1000 (Figure 628 0G) ..............................................13
6.2.2.8Connection of KHS drain with overflow monitor (Figure 688 00) .............................................13
6.2.2.9Connection of water sensor (Figure 620 00) ...................................................................................14
6.2.2.10Connection of floating alarm relay ..............................................................................................14
7. COMMISSIONING ................................................................................................................... 15

Manual KHS Mini System Control MASTER
8. CONFIGURATION ................................................................................................................... 16
8.1.1 Basic menu operation and functions ........................................................................................17
8.1.2 General plan...................................................................................................................................18
8.1.4 Main menu .....................................................................................................................................20
8.1.4.1 System settings..............................................................................................................................21
8.1.4.2 CAN BUS setup ..............................................................................................................................24
8.1.4.3 Device settings ..............................................................................................................................25
8.1.4.4 Operating modes .........................................................................................................................28
8.1.4.5 Journal ............................................................................................................................................33
8.1.4.6 Switching programs.....................................................................................................................34
8.1.4.7 Valve manual mode .....................................................................................................................35
8.1.4.8 Error handling...............................................................................................................................36
8.1.5 Using the USB interface ..............................................................................................................37
8.2 Configuration PC-software...............................................................................................38
9. DESCRIPTION OF MALFUNCTIONS AND MALFUNCTION REPAIR .......................................... 39
10. DIMENSIONS, ATTACHMENT DIMENSIONS ........................................................................... 41
11. ACCESSORIES ......................................................................................................................... 42
12. WIRING INSTRUCTIONS FOR COMPONENTS WITH ELECTRICAL CONNECTION..................... 42
13. APPENDIX .............................................................................................................................. 43
13.1 Valve technology..............................................................................................................43
13.2 Overview for the system commissioning of the KHS Mini System Control ..................43

Manual KHS Mini System Control MASTER 1
1. General instructions:
Assemble and commission the KEMPER KTS Mini System Control only after reading these
assembly and operating instructions. It informs you in detail about the assembly,
commissioning, operating principles and operation of the Kemper KHS Mini System
Control. If you cannot find the information and instructions you need in these operating
instructions, ask the manufacturer, Gebr. Kemper (please refer to last page for the
address). Keep the mounting and operating instructions with the device or file it with the
other technical documentation in the system documentation.
Symbols used
The symbols used in the text are explained below.
List of symbols
Note:
Useful information
Warning notice:
Danger electric shock
Attention:
Imminent danger
Maintenance:
Maintenance/Repair

Manual KHS Mini System Control MASTER 2
2. Area of application
The KEMPER KHS Mini System Control can be used for monitoring and water exchange in
drinking water systems. The water exchanges can be generated and documented as
flushing logs with the -MASTER- control. The dedicated water exchanges prevent
stagnation in the drinking water with the aim of maintaining the drinking water hygiene
in the drinking water systems. The KHS Mini System Control -MASTER- can be
parameterised by a PC-software or by the internal menu.
NOTICE:
If two or more valves are simultaneously opened in a drinking water
system, under certain circumstances pressure fluctuations or a large
pressure drop can occur in the system. For that reason, make sure
beforehand that the required flow pressure is continuously guaranteed
at all tapping points. It is recommended to not make simultaneous
water exchanges.
2.1 Operating modes for the water exchange
Time controlled water exchange
Temperature controlled water exchange
Volume controlled water exchange
2.2 KHS MASTER/SLAVE technology
The -MASTER/SLAVE- technology can be used to trigger flushing measures for
maintaining the drinking water hygiene for the drinking water system. The corresponding
operating modes can be individually configured for each individual water-exchange
group. Positioning the individual -MASTER- or -SLAVE- controls directly on the water
exchange groups ensures short wiring distances for interconnection.
2.3 Water exchange groups
Shown in Ill. 2.1 as an example is a KHS
Mini System Control -SLAVE- (2) in
connection with a water exchange group
which comprises a KHS Isolating valve (4),
Temperature sensor (1), Volume flow sensor
(3) and a KHS Drain (5). The components of
the water exchange group are only listed as
examples here. The operating mode
depends on the components. In the example
illustrated, the -SLAVE-(2) controls the
specified water exchange groups. It is
connected with the -MASTER- through a
CAN bus cable.
(5)
Note:
Maintenance cut-offs are re-
commended in front of the
Volume flow sensor (3).
Ill. 2.1 Illustration of a water exchange
group
(1)
(2)
(3)
(4)

Manual KHS Mini System Control MASTER 3
3. Safety
The descriptions and instructions in
these operating instructions concern
the KHS Mini System Control
-MASTER- and KHS Mini System
Control -SLAVE-.
3.1 Safety Instructions
Before commissioning, make sure the connections have been made properly and
professionally and that the system is properly protected. Comply with the pertinent
regulations (EN, VDE, etc.) and the regulations of the local energy utility.
3.2 Hazards if the safety instructions are not complied with
Non-compliance with the safety instructions can result in both hazards to people and
hazards to the environment and the system. Non-compliance with the safety instructions
leads to the loss of rights to any compensation claims. In some cases, non-compliance
can, for example, result in the following hazards:
Failure of important functions in the device
Hazards to people through electrical and mechanical effects
3.3 Unauthorized alteration and spare part fabrication
Alternations and modifications to the device are only permissible after agreement with
the manufacturer. Original spare parts and manufacturer authorised accessories serve
the purpose of safety. The use of any other parts may annul the liability for any resultant
consequences.
Attention:
Use only original/approved spare parts otherwise no warranty claims
will be recognized.
3.4 Unauthorised modes of operation
The reliability of the supplied unit is only ensured when used as intended. Never exceed
the limits stated in this documentation under any circumstances.
Note:
If the operating instructions are not followed, the manufacturer of this
controller does not assume any responsibility. These operating
instructions contain basic instructions that must be complied with
during set-up, commissioning and maintenance. Therefore, the
plumber/mechanic and the responsible specialists/operators must read
these operating instructions before assembly and commissioning.
Comply not only with the general safety instructions listed in this main
point; also follow the specific safety instructions listed under the other
main points.
Warning notice:
During assembly and
maintenance, make sure that
the control is not switched on.
Only skilled professional
personnel are permitted to
operate electrical systems (as
per DIN EN 50110-1). Danger
of fatal electric shock.

Manual KHS Mini System Control MASTER 4
4. Technical Data
Technical Data
Power supply 230 V AC 50/60Hz
Display Graphic display with background lighting
Operation with 4 buttons: Up | Down | Enter | Esc
Relay flush valve switching capacity 230 V, 2 A
Floating alarm relay, max. 230 V, 2 A
16 memory locations for the operating modes:
Time controlled water exchange
Temperature controlled water exchange
Volume controlled water exchange
Routine-time, routine-duration and routine-volume
For connecting:
1 ea. KHS Isolating valve-plus or KHS Isolating valve
1 ea. KHS Temperature sensor Pt 1000
1 ea. KHS Control Plus volume flow measurement valve
1 ea. KHS overflow monitor
Acoustic alarm signal in case of faults (disengageable)
Alarm acknowledgement on -MASTER-
System is expandable: 1 -MASTER- with max. 62 - SLAVEs- via CAN bus
Bus system connection per direction: CAN installation cable, max. 1000m
total length, overall 2000m possible
Serial interface for the PC-link by the customer for configuration and for
reading out the flush log
Can save 50,000 journal entries
External switch | Switchover:
Program 1 (e.g. school-holidays program)
Program 2 (e.g. school program)
Maintenance mode (system is blocked)
Menu driven operation in German, English or Dutch
Internal consumption 10 VA
Manual operation of the valves on device
Ambient temperature range from 0 °C to 50 °C
Protection class IP 54
Surface mounted housing for wall installation
USB interface for updating the firmware, reading out the journal and data
logging and for downloading and uploading the configuration file
Network link through network cable (accessory)

Manual KHS Mini System Control MASTER 5
CAN bus
A
CAN bus
B
CAN bus
A
5. CAN bus system overview
The basic version of the -MASTER- control system includes as the smallest solution a
flushing valve for water exchanging measures. This -MASTER- System Control is
required for triggering the flushing valve and for signal evaluation.
Up to a maximum of 31 -SLAVE- controls per CAN-BUS connection of the -MASTER-
can be controlled per CAN bus connection. Furthermore, the -MASTER- System
Control, using two integrated CAN bus connections, can trigger up to 62 -SLAVE-
controls and one directly-connected KHS water exchange group.
That means up to 63 KHS water exchange groups can be connected and operated.
The accumulated total length of one CAN bus connection can amount to a
maximum of 1000 m (total length is thus 2000m).
5.1 Layout variants
Note:
The controllers must be connected in series, as can be seen in Example
1. During this, the -MASTER- System Control can be connected within
the series (Variant 2) or as a final subscriber (Variant 1). Branches or
start connections, as can be seen in Example 2, are not possible.
Furthermore, shorter cable distances are recommended.
Example 1: Layout variant, KHS-Mini System Control -MASTER-
Variant 1
Variant 2
Ill. 5.1 Illustration of a layout variant, KHS Mini System Control -MASTER- system control

Manual KHS Mini System Control MASTER 6
CAN bus
A
CAN bus
A
CAN bus
B
CAN bus
A
Example 2: Incorrect layout
Ill. 5.2 View of an impermissible layout variant, KHS Mini System Control -Master-
5.2 Terminal resistance
Variant 1
Note:
The 120 Ω terminal
resistance must be installed
only in the last control
component (-SLAVE-) of a
CAN bus cable line. The
-MASTER- control does not
require a terminal
resistance.
Variant 2
Ill. 5.3 Illustration of a CAN bus line with terminal resistor
5.3 Connection of terminal resistor
Attention:
All KHS Mini controls
-SLAVE- are supplied with a
120 Ω terminal resistor.
For non-terminal -SLAVE-
controls, the resistor must be
removed!
120 Ω
Note:
Incorrect layout
Ill. 5.4 Illustration of the terminal resistor
connection

Manual KHS Mini System Control MASTER 7
6. Assembly
Warning notice:
Allow only certified electricians to assemble and install electrical
equipment. Danger of fatal electric shock.
Very strong magnetic fields can impair the functioning. Interferences can be prevented
by following the installation rules below:
Do not mount the controller and the sensors near inductive loads (motors,
transformers, contactors, etc.).
Feed through a separate mains voltage circuit (if necessary, with an a.c. mains
filter).
Inductive loads must be equipped with safeguards to reduce overvoltages
(varistors, RC-filter).
Attention:
When using the controller together with other devices in one system,
check to see if that causes interference signals to be emitted.
6.1. Wall mounting
The KHS Mini System Control is intended for wall installation. The housing has 4 each ø
4mm mounting holes in a clearance of w = 188mm and h = 88mm. Additional
dimensions are listed in Chapter 10. To mount, open the cover and screw the device
tightly to the wall. After mounting the housing, make the required electrical connections.
Ill. 6.1 Illustration of the mounting holes for wall installation

Manual KHS Mini System Control MASTER 8
6.2 Electrical installation KHS Mini System Control
The following chapter explains the electrical installation. The electrical connections are
made through screwless-type terminals.
6.2.1 Terminal description -MASTER- and -SLAVE-
Ill. 6.2 Cut-out view of the -MASTER- and -SLAVE- controller board with terminals
Illustration: Control board with terminals
1. Flushing valve switching output 230 ________________________
2. Flushing valve voltage output 230 V (only on 68604) ___________
3. Flushing valve N _______________________________________
4. Power supply - LI 230V__________________________________
5. Power supply –N ______________________________________
6. External input 230 V (Function only with -MASTER-) ___________
7. Grounded conductor PE _________________________________
8. CAN-Bus HIGH 1 ______________________________________
9. CAN-Bus LOW 1_______________________________________
10. CAN-Bus GND 1 ______________________________________
11. CAN-Bus HIGH 2 _____________________________________
12. CAN-Bus LOW 2______________________________________
13. CAN-Bus GND 2 ______________________________________
14 Flow measurement valve - Voltage output 5V ________________
15 Flow measurement valve - Flow input ______________________
16 Flow measurement valve - no function _____________________
17. Flow measurement valve GND ___________________________
18. Pt 1000 Input 1 _______________________________________
19. Pt 1000 Input 2 _______________________________________
20. Pt 1000 Input 3 _______________________________________
21. Pt 1000 Input 4 _______________________________________
22. Drain floating switch (strands interchangeable) ______________
23. Drain floating switch (strands interchangeable)
[Terminals 22 and 23 can also be used to connect
the water sensor]
PC-interface
__________________________
(only for –MASTER-:
jack plug, no clamp)
24. Alarm relay voltage input external ________________________
25. External monitor voltage error ___________________________
26. External monitor voltage operation ________________________

Manual KHS Mini System Control MASTER 9
6.2.2 Detailed illustration of the terminals for cable entry
Note:
The following illustrations apply to the KHS Mini System Control
-MASTER- and the KHS Mini System Control -SLAVE-. Please note the
preceding warning notices.
6.2.2.1 Power supply connection
Power supply: 230 V +/- 15% AC 50/60Hz
Connection: Terminals, L, N, PE
Line fuse max. 16A
BN = brown = L
BU = blue = N
GR = green = PE
Ill. 6.3: Schematic representation of the power supply connection
6.2.2.2 Connection of KHS Isolating valve with servo-drive
(Figure 686 04 / 696 04)
BN = brown = 1
BK = black = 2
BU = blue = 3
Ill. 6.4: Schematic representation of the connection of the KHS Isolating valve
BN
BK

Manual KHS Mini System Control MASTER 10
6.2.2.3 Connection of KHS Isolating valve with spring reset servo-drive
(Figure 686 05 / 686 15 / 696 05)
BN = brown = 1
BU = blue = 3
Ill. 6.5: Schematic representation of the connection of the KHS Isolating valve with
spring reset servo-drive
6.2.2.4 CAN bus connection
Attention:
Follow the notices and instructions in
Chapter 5. The twisted pair of the CAN
bus cable should be separated and the
shielding removed only as far as
necessary to assign the maximum
terminals (recommendation: max. 4cm).
The shielding must be properly bundled
with a heat shrink tube or insulating tape
to prevent contact of the individual wires
of the shielding to the other potentials.
Ill. 6.6: Schematic diagram of the twisted pair

Manual KHS Mini System Control MASTER 11
Ill. 6.7: Exemplary illustration of a CAN bus installation from a -MASTER- and three
-SLAVE- controls
6.2.2.5 Connection of external switch
Attention:
The external connection can only be
used with the KHS Mini System Control
-MASTER-.
Power supply: 230V +/- 15% AC 50/60Hz
Line fuse max. 16A
BK = black = L
Ill. 6.8: Schematic diagram of connection of external switch
Note:
Through the trigger on Terminal 6 you have a facility to switch the
KHS Mini System Control program with external switching processes
through a 230V input. The program switching of the external
connection is discussed in Chapter 8.
230V
L (external voltage)
Switch
CAN bus H and L = 1
Twisted-Pair
H: Strand 1
L: Strand 2
Put on GND cable
shielding
The terminal groups 8/9/10 and
11/12/13 are of equal value. For
instance the wire end a can also be
connected to Terminals 11/12/13 and
the wired end b to Terminals
8/9/10.

Manual KHS Mini System Control MASTER 12
6.2.2.6 Connection of KHS-CONTROL-PLUS flow measurement valve
(Figure 638 4G / 138 4G)
Connection of KHS-CONTROL-PLUS volume flow measurement valve
BR = +5V DC = 14
BU = Flow = 15
BK = GND = 17
Ill. 6.9: Schematic diagram of connection of KHS-CONTROL-PLUS flow
measurement valve
Connection of KHS-CONTROL-PLUS temperature sensor
Attention:
The KHS-CONTROL-PLUS has an
internal Pt 1000, enabling an
additional temperature measurement.
If no temperature measurement is
needed or a Pt 1000 connected,
insulate and protect the strands from
contact with the board.
GY = grey (green/yellow) = 19
W = white = 20
Ill. 6.10: Schematic diagram of connection of KHS-CONTROL-PLUS volume flow sensor
Note
Attention:
To perform the temperature
measurement through the KHS-
CONTROL-PLUS, the jumper on the
board must be changed from 4-wire to
2-wire, see Photo 6.11.
Important comment:
During this measurement, the
temperature measurement is falsified
through the line resistance. For 10m
line-length with 0.34mm² cross-
section, the measurement falsification
can amount to approx. + 0.5°C.
Ill. 6.11: Schematic diagram of connection of KHS-CONTROL-PLUS temperature sensor
14 15 17

Manual KHS Mini System Control MASTER 13
Connection of KHS-CONTROL-PLUS cable-plug connector
Ill. 6.12: Schematic diagram of the preparation of the sensor top to make cable-
plug connection of the KHS-CONTROL-PLUS
6.2.2.7 Connection of KHS Temperature sensor Pt 1000 (Figure 628 0G)
RD = red = 18
RD = red = 19
W = white = 20
W = white = 21
Ill. 6.13: Schematic diagram of connection of KHS Temperature Measurement
Valve Pt 1000
6.2.2.8 Connection of KHS drain with overflow monitor (Figure 688 00)
Note:
In the as delivered state, a bridge
strand is plugged between Terminals
22 and 23. It must be removed before
connecting the KHS drain.
W = white = 22
BN = brown = 23
Ill. 6.14: Schematic diagram of connection of the KHS drain with overflow monitor
1. Cut off top of cap 2. Route cable through 3. Screw cable to sensor 4. Put on the
cap

Manual KHS Mini System Control MASTER 14
6.2.2.9 Connection of water sensor (Figure 620 00)
Note:
It is possible to link up to 25 water
sensors in parallel in the detection
circuit.
Max. cable length water sensor:
< 50m with standard cable
Max. cable length water sensor:
> 50m to 500m as shielded cable,
2x 0.75 mm², (e.g. UL-LIYCY)
W = white = 22
BN = brown = 23
Ill. 6.15: Exemplary diagram of the water sensor connection
6.2.2.10 Connection of floating alarm relay
Monitoring example: Errors and mains
voltage failures are reported with
external voltage to the warning lamp, the
warning horn or to the BMS.
Ill. 6.16: Exemplary diagram of the alarm relay
Warning light
Alarm horn
e.g input BMS or
alarm relay
External voltage max.
230V, 2A or 24V input

Manual KHS Mini System Control MASTER 15
7. Commissioning
After finishing the wall installation and the electrical installation in accordance with
Chapter 5, apply the mains voltage of 230V.
Warning notice:
Allow only certified electricians to assemble and install electrical
equipment. Danger of fatal electric shock.
ATTENTION!
Note:
To simplify the control system and to guarantee flawless installation,
fill in the overview of the system commissioning of the KHS Mini
System Control (see supply pressure, Chapter 13.2) before making the
settings. It is mandatory to fill in the supply pressure to be able to take
advantage of the optional factory support.

Manual KHS Mini System Control MASTER 16
8. Configuration
The KHS Mini System Control -MASTER- can be configured through the internal menu
driven operation or through a web server. Furthermore, the saved configurations can be
uploaded through a USB interface to the KHS Mini System Control -MASTER-.
The sample project shown below shows the basic controller types of the KHS Mini System
Control -MASTER-. The individual configuration facilities of the KHS Mini System Control
-MASTER- is elucidated using exemplary configurations of the sample project in the
following chapters (Ill 8.1 and 8.2).
After all units, as described in Chapter 6, have been mounted and electrically connected,
the actual configuration of the individual KHS Mini System Controls starts.
The sample project has one KHS Mini System Control -MASTER- and two KHS Mini
System Controls -SLAVE-. The system controls shown in Illustration 8.1 are intended to
secure the cold-water line against stagnation and leaks in a fictitious building.
Ill. 8.1 Sample project
MASTER
SLAVE 1.1
SLAVE 1.2
Water sensor 1-4; Cellar
Valve
cellar
Volume flow sensor 1;
Cellar
Valve C1;
Cellar
Valve C2;
Cellar,
GF
Consumers
Sensor cable
230V cable
CAN bus cable
Cellar
Drain + overflow
monitor 1-2; Cellar

Manual KHS Mini System Control MASTER 17
8.1 Manual configuration
Basic settings, configurations and changes can be made onsite by using the integrated
menus. In the following chapter, the menu interfaces and their functions are clarified. To
explain the settings and functions, the sample project is configured as a reference
building.
8.1.1 Basic menu operation and functions
The KHS Mini System Control is set and operated through various menus, which appear
in the -MASTER- display. Access to the menus is enabled through the control panel on
the -MASTER- with the four control buttons.
"ESC" button: Exit the menu / switch between
overview and main menu
"↑" button: Scroll back
"OK" button: Confirm button
"↓" button: Scroll forward
III. 8.2 -MASTER- buttons
The menus are structured "scrolling", i.e., pushing the "↓-button" on the last menu item
jumps back to the first menu item. Likewise, pressing the "↑-button" changes from the
first to the last menu item.
Note:
If no entry is made for three minutes, the control reverts from the
setting mode to the general plan.
Window types
Menu operation is divided into two sections. The following windows are available:
"General plan"
"Main menu".
The functions of the windows are listed in Table 8.1.
The "General plan" window is used only for visualising the current states.
In the "Main menu" window, preset parameters can be viewed, changed and
saved. The "Main menu" window can be protected against changes caused by
interference through password protection.
Tab. 8.1 Chart of window types
Window types
General plan
Main menu
Viewing possible without password
Functions:
Detailed overview
Control state display
View network
Device settings
Flushing processes
Error statuses
Viewing impossible without password
Function:
Setting the control parameters
CAN BUS setup
Select the operating modes
Journal
Program selection