KOREX AIR-SEP AS-T 20 Series User manual

AIR-SEPPressure Maintenance
with touchscreen color display
User manual
AIR-SEPType AS-T 20 and 48
AIR-SEPType AS-T 100 up to 2400
Version 1.02 (GB)
www.korexbenelux.com

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
2 KOREX Benelux B.V.
Table of contents
1 General and Information ........................................................................................................................................ 4
1.1 Liability and Warranty .................................................................................................................................... 4
1.2 Symbols Used ................................................................................................................................................. 4
1.3 Intended Purpose .......................................................................................................................................... 4
1.4 Unacceptable Operating Conditions.................................................................................................................. 5
1.5 Warranty Preconditions ................................................................................................................................. 5
2 Equipment Explanation and Scope of Supply ...................................................................................................... 5
2.1 Function Description ...................................................................................................................................... 6
2.2 Principle Diagram, Types AS-T 20 and 48 .................................................................................................... 7
2.2.1 Principle Diagram, Types AS-T 100 to 2400 ................................................................................................. 8
2.3 Scope of Supply ............................................................................................................................................ 9
2.4 Accessories for Types AS-T 20 and 48 (recommended) ............................................................................... 9
2.4.1 Accessories for Types AS-T 100 to 2400 (recommended) ............................................................................ 9
2.5 Accessories (optional) ................................................................................................................................... 9
2.6 Accessories for Cooling and Refrigeration Systems ................................................................................... 10
3 Technical Data ...................................................................................................................................................... 10
4 Installation ............................................................................................................................................................. 11
4.1 Conditions ................................................................................................................................................... 11
4.2 Installation Site ............................................................................................................................................ 11
4.3 Hydraulic Connection .................................................................................................................................. 12
4.3.1 Hydraulic Connection Accessories...................................................................................................... 12
4.4 Electrical Connection ................................................................................................................................... 12
4.4.1 Electric Drawing ............................................................................................................................... 13
4.4.2 Terminal Board with Smart Control Controller ................................................................................ 14
5 Initial Commissioning .......................................................................................................................................... 14
5.1 System Requirements ................................................................................................................................. 14
5.2 Commissioning ............................................................................................................................................ 15
5.3 Testing ........................................................................................................................................................ 17
5.4 Information about Commissioning ............................................................................................................... 17

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Table of contents
6 Navigation of the "AIR-SEPSmart-Control" ..................................................................................................... 17
6.1 Operation ..................................................................................................................................................... 17
6.2 Welcome Screen .......................................................................................................................................... 17
6.3 Homepage ................................................................................................................................................... 18
6.4 Menu "Automatic Mode".................................................................................................................................. 18
6.4.1 Service Menu "Settings" ............................................................................................................................... 19
6.5 Menu "Information" ....................................................................................................................................... 21
6.5.1 Menu "Inputs" (Sensors) ................................................................................................................... 21
6.5.2 Menu "Outputs" ................................................................................................................................. 22
6.5.3 Menu "Reports / Failures" ................................................................................................................. 23
6.6 Factory Customer Service Menu "INTERNAL Settings / Parameters" ......................................................... 24
7 Component Parts .................................................................................................................................................. 25
7.1 Pressure Transmitter ................................................................................................................................... 25
7.2 Water Gauge Glass with Level Switch ......................................................................................................... 25
7.3 Suction Valve ............................................................................................................................................... 25
7.4 Overflow Valve ............................................................................................................................................. 26
7.5 Water Magnetic Valve with Pulse Output ..................................................................................................... 27
7.6 Cleaning Opening ........................................................................................................................................ 27
8 Faults / Maintenance / Cleaning ........................................................................................................................... 28
8.1 Fault Finding ................................................................................................................................................ 28
8.2 Desludging of the Expansion Tank ............................................................................................................... 28
8.3 System Separator for Fresh Water .............................................................................................................. 29
8.4 Servicing ...................................................................................................................................................... 30
8.5 Service Request ........................................................................................................................................... 30
8.6 Cleaning the Dirt Trap in the Overflow Valve ............................................................................................... 30
9 Appendices ............................................................................................................................................................ 31
9.1 Commissioning and Service Records .......................................................................................................... 31
9.3 Plant Logbook................................................................................................................................................. 32
9.4 Dimension and Connection Diagram, Types AS-T 20 and 48 ................................................................ 33/34
9.4.1 Connection Diagram for 2 sources, Types AS-T 20 and 48 ......................................................................... 36
9.4.2 Dimension and Connection Diagram, Types AS-T 100 to 2400 .................................................................. 37
9.4.3 Connection Diagram for 2 sources, Types AS-T 100 to 2400 ...................................................................... 38

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
4 KOREX Benelux B.V.
1. General and Information
In this user manual, the installation and the operation of the KOREX AIR-SEP®pressure maintenance stations are described.
It describes the equipment in its basic configuration with the necessary accessories and with optional accessories. Information
about the optional accessories can be found in Accessories (optional) | Chapter 2.5.
KOREX shall accept no liability whatsoever for claims arising from the non-observance of this user manual. The national
legislation and regulations of the respective country of installation must be complied with (accident prevention, environmental
protection, safe and professional working, etc.)
1.1 Liability and Warranty
The equipment is constructed in accordance with the state-of-the-art technology and the recognized safety-related regulations.
Nevertheless, when using the equipment risks to the life and limb of the personnel and / or third parties as well as damage to
the equipment or to other material assets can occur. There must be no alterations made to the equipment.
The liability of the manufacturer shall be excluded when these can be traced back to one or more causes:
▪Use not in accordance with the intended purpose of the equipment.
▪Incorrect and / or improper commissioning, operation, maintenance, servicing, repair and installation of the
equipment.
▪Non-observance of the safety instructions in this user manual.
▪Operation of the equipment with defective or incorrectly fitted safety devices / protective equipment.
▪The late carrying out of scheduled maintenance and inspection work.
▪The use of non-approved spare and accessory parts.
1.2 Symbols Used
WARNING! DANGER! CAUTION! ATTENTION!
The non-observance of these safety instructions can lead to personal injury and / or material damage!
WARNING!
The non-observance of these safety instructions can lead to electric shock which can result in serious
personal injury or death.
WARNING!
The surfaces of the product can become so hot that contact with them can lead to personal injury in the form
of burns.
1.3 Intended Purpose
The AIR-SEP®unit is a pressure maintenance station for heating, cooling and refrigeration systems. It serves the purpose of
maintaining water pressure, the resupplying with water and the degassing of the water in a system. Operation must only take
place in corrosion-resistant closed systems with the following waters:
▪Not corrosive
▪Not chemically aggressive
▪Not toxic
The ingress of atmospheric oxygen through permeation into the entire heating and cooling system, top-up water, etc. during
operation must be reliably minimized.

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1.4 Unacceptable Operating Conditions
The equipment is not suitable for the following conditions:
▪In mobile system operation
▪For outdoor use
▪For use with mineral oils, with flammable media, with distilled water and with Temper
(for use with Temper, please inquire about our AIR-SEPunits in special designs! ).
INFORMATION!
Changes to the hydraulics or interfering with the wiring are not permitted.
1.5 Warranty Preconditions
▪Professional installation and commissioning of the equipment
▪Water-side connections must only be made using stainless steel pipelines
▪Carbon steel pipes must not be used
▪The integration must take place by means of “Accessory 2” or “Accessory 3” from KOREX
▪A DVGW-certified system separator BA must, without fail, be connected upstream in the fresh water feed line
(included in “Accessory 1 –Fresh Water Connection”)
▪The filling of the system must take place in accordance with VDI 2035 and must be documented
▪A plant logbook must be kept
2. Equipment Explanation
The AIR-SEP®unit is a pump-controlled pressure maintenance station. It performs the functions of the pressure maintenance,
the expansion, the degassing and the resupply in closed heating, cooling and refrigeration systems. All functions are
integrated in just ONE unit whereby the installation is made significantly easier. In addition, there is a space saving of up to
60% when compared with conventional solutions.
The AIR-SEP®unit offers the following securities:
Optimization of all the processes for pressure maintenance, degassing and resupply
▪No direct intake of air through the control of the pressure maintenance with automatic resupply
▪No circulation problems caused by free bubbles in the circuit water
▪Reduction of corrosion damage through the removal of oxygen from the fill and resupply water.

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
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2.1 Function Description
The AIR-SEPunit is a pressure maintenance station for heating, cooling and refrigeration systems. It performs the functions
of the pressure maintenance, expansion, degassing and resupply with water and / or water-glycol mixtures. The unit
consists of at least one valves and control section (A2) - including a touch screen with a colour display (8) - and a degassing
and expansion tank (A1).
2.1.1 Pressure Maintenance
The pressure monitoring in the plant system takes place via the pressure sensor (19). AIR-SEPthereby ensures that the
system pressure is optimally maintained at all times.
If the water cools, the pressure in the plant system falls. On undershooting the set pressure, the pressure maintenance pump
(10) is switched on and feeds the already degassed water from the expansion tank (A1) back into the system via the pressure
maintenance connection (3). The pressure in the plant system increases. On reaching the desired system pressure, the pump
- controlled by the pressure sensor - is switched off again.
2.1.2 Expansion
The pressure in the plant system is increased by increases in temperature. On exceeding the set pressure, the overflow valve
(11) is opened and allows water to flow out of the system via the expansion line (4) and into the expansion tank (A1) which is
closed to the atmosphere. The pressure in the system falls to the set value setting and the overflow valve (11) is closed again.
The expanded water is collected in the expansion tank (A1) and used again later for pressure maintenance. The entire
hydraulic pipework, including the valves and control section (A2), is mounted on the expansion tank (A1). Optionally, several
expansion tanks –also with a second valves and control section - can be connected.
2.1.3 Degassing
For the degassing of the system water, two hydraulic connections “ON (4)”and “OFF (3)”are needed. The “ON”line feeds the
gas-rich water to the AIR-SEPunit. The “OFF”line is a return line to the system for the degassed water. During the
degassing, the pump (10) and the overflow valve (11) are in operation. Thereby, a gas-rich partial flow of the system water is
fed via the pressure-less expansion tank. Here, the free and dissolved gases are separated from the water by the atmospheric
pressure and reliably purged via the degassing valve with an air non-return lock (14). The overflow valve (11) guarantees the
hydraulic balancing though the control of the valve stroke. The repetitive processes degas the system efficiently and invasive
air is repeatedly separated out. The degassing takes place in the operating modes: resupply, expansion and in the interval and
fast degassing.
2.1.4 Resupply
If the minimum water level in the expansion tank is fallen below, the resupply valve is opened (18) for so long until the desired
water supply, monitored by the level switch on the water gauge glass (12), has been reached again. In doing so, the refill
quantities, frequency or capacities of softening or deionization are checked and monitored.
2.1.5 Cleaning
In the settling area of the degassing and expansion tank (A1), salts, minerals and suspended particles are deposited. In
addition, the optional magnetite filter (AS-MF) fixes all the magnetic particles in the tank. The sludge and magnetite can be
permanently removed from the system via the cleaning opening (13). This serves for the protection of all the components in
your system circuit (such as, for example, efficiency pumps, valves, packing glands, etc.) and guarantees the continuous safe
operation of the plant.

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2.2 Principle Diagram AIR-SEP- Types AS-T 20 and AS-T 48
A1
Degassing and expansion tank
16
Suction valve
(stainless steel 1.4301 or PE on Type AS-T 20/x-K)
18
Water magnetic valve with pulse output
A2
Valves and control section (technical level)
19
Pressure transmitter
20*
Heat insulation (not available for AS-T 20/x-K!)
1
Resupply connection ¾" ext. thread
2
Safety overflow DN50
2a
Funnel waste trap, customer
3
OFF1”= pressure maintenance
AS-MF
Magnetite filter (AIR-SEPaccessory)
4
EIN 1”= Expansion
5
Emptying
AIR-SEPAccessory 1 –Fresh Water Connection
6
Supply voltage 230 VAC / 50 Hz
1a
Ball valve ½”
(3-wire via terminal box, 10A fuse)
1b
Dirt trap ½”
7
Potential-free alarm signal (max. 230 VAC/1A)
1c
Water volume meter
8
AIR-SEPSmartControl (with touch screen colour display)
1d
System separator Type BA
9
Switch ON / OFF
1e
Flexible hose ¾" x 1m
10
Rotary pump (pressure maintenance)
AIR-SEPAccessory 2 –System Connection DN15
11
Overflow valve
2b
Ball valve ½"
12
Water gauge glass with level switch (replaceable)
2c
Ball valve ½" with safety cap
13*
Cleaning opening (see AIR-SEPAccessory 4 )
2d
Flexible hose ½" x 1m (2x)
14
Degassing valve with an air non-return lock
AIR-SEPAccessory 4 –Cleaning Opening
15
Safety valve (internal)
13*
Cleaning opening (not available for AS-T 20/x-K!)
2b 2c
2d 2d
Accessory 2
13*
Accessory 4
2a 2 14 15 11
Accessory 1
1a 1b 1c 1d 1e 1 18
8
•9
19
3 4
A2
A1
5
AS-MF
10
16 12
20*
6
7

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2.2.1 Principle Diagram AIR-SEP- Types AS-T 100 to 2400
A1
Degassing and expansion tank (stainless steel 1.4301)
17
Angle ball valve with screw connection
A2
Valves and control section (technical level)
18
Water magnetic valve with pulse output
19
Pressure transmitter
1
Resupply connection ¾”ext. thread
20
Cladding at a distance as heat insulation
2
Safety overflow DN50
2a
Funnel waste trap, customer
3
OFF 1”= pressure maintenance
4
ON 1”= expansion
AS-MF
Magnetite filter (AIR-SEPaccessory)
5
Emptying
6
Supply voltage 230 VAC / 50 Hz
AIR-SEPAccessory 1 –Fresh Water Connection
(3-wire via terminal box, 10A fuse)
1a
Ball valve ½”
7
Potential-free alarm signal (max. 230 VAC/1A)
1b
Dirt trap ½”
8
AIR-SEPSmartControl (with touch screen colour display)
1c
Water volume meter
9
Switch ON / OFF
1d
System separator Type BA
10
Rotary pump (pressure maintenance)
1e
Flexible hose ¾”x 1m
11
Overflow valve
AIR-SEPAccessory 3 –System Connection DN25
12
Water gauge glass with level switch (replaceable)
3a
Ball valve 1”with safety cap
13
Cleaning opening (AIR-SEPAccessory 4)
3b
Ball valve 1”
14
Degassing valve with an air non-return lock
3c
Flexible hose 1”x 1m (2x)
15
Safety valve (internal)
AIR-SEPAccessory 4 –Cleaning Opening
16
Suction valve
13
Cleaning opening
Accessory 1
1a 1b 1c 1d 1e 1 18
3b 3a
3c 3c
Accessory 3
Accessory 4
13
A1
A2
5
8
2a 2 14 15 11
10 3 4
6
7
•9
16 12
17
AS-MF
19
20

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2.3 Scope of Supply
The scope of the delivery is described on the delivery note and the contents are displayed on the packaging. Immediately on
receipt, check the delivery for completeness and damage. Report transport damage immediately.
2.4 Accessories for Types AS-T 20 and 48 (recommended)
For optimum and time saving connection, we recommend the use of the following AIR-SEP®accessories:
ACCESSORY
ARTICLE DESIGNATION
PART NO.:
Accessory 1
Fresh water connection in accordance with DIN 1988 and DIN EN 1717 with a
DVGW certified system separator Type BA and water volume meter
Z1
Accessory 2
System connection DN15 (2 flexible hoses, ball valve and capped ball valve)
Z2
Accessory 4
Cleaning opening for the manual cleaning of the tank (not available for Type AS-T 20/x-K!)
Z4
2.4.1 Accessories for Types AS-T 100 to 2400 (recommended)
For optimum and time saving connection, we recommend the use of the following AIR-SEP®accessories:
ACCESSORY
ARTICLE DESIGNATION
PART NO.:
Accessory 1
Fresh water connection in accordance with DIN 1988 and DIN EN 1717 with a
DVGW certified system separator Type BA and water volume meter
Z1
Accessory 3
System connection DN25 (2 flexible hoses, ball valve and capped ball valve)
Z3
Accessory 4
Cleaning opening for the manual cleaning of the tank
Z4
2.5 Accessories (optional)
With optional accessories, the AIR-SEP®can be extended and thereby the range of functions can also be usefully extended:
ACCESSORY
ARTICLE DESIGNATION
PART NO.:
Accessory 1A
Fresh water connection, as "Accessory 1”but with contact water volume meter
Z1A
Accessory 1M
Fresh water connection, as "Accessory 1”but with M-Bus water volume meter
Z1M
Accessory 1E
Fresh water connection with a stainless steel non-return valve and water volume
meter (with existing system and without request)
Z1E
AIR-SEP®ION
AIR-SEP®ION –compact softening fitting in accordance with VDI 2035 Sheet 1
ION
AIR-SEP®VE
AIR-SEP®VE –compact complete demineralization fitting in accordance with DIN EN 12828
VE
Replacement
Cartridge
Replacement cartridge for the AIR-SEP®ION (for exchange, 2 replacement cartridges are needed)
IONEK
Replacement
Cartridge
Replacement cartridge for the AIR-SEP®VE (for exchange, 2 replacement cartridges are needed)
VEEK
Magnetite Filter
NEW! Magnetite filter (for fitting on the tank bottom)
AS-MF
Accessory 23*
Communication of two pressure maintenance stations each with a pressure maintenance pump for
alternating operation (master / slave)
Z23
Accessory 40*
Upper level for the water storage of each pressure maintenance station
Z40
Accessory 41*
Pressure minimal with multi-pump systems for the running up of all pumps for quicker pressure maintenance
Z41
AIR-SEP®Interface
NEW! AIR-SEPSmartControl Interface - interface to the AIR-SEPcontroller
▪Remote access to the AIR-SEPpressure maintenance stations
▪Visualization
▪Changing of parameters and data logging
▪Send error messages by e -mail
▪Possibility of connection to MODBUS/TCP
Interfaces: CAN-Bus, DL-Bus, SD card slot and Ethernet (RJ45)
AS-SCI
Commissioning
Commissioning by the KOREX Customer Service (each unit)
473
* Not available for the Types AS-T 20 and 48!

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2.6 Accessories for Cooling and Refrigeration Systems
With the following accessories for cooling and refrigeration systems, the AIR-SEP®can be usefully extended and optimized
ACCESSORY
ARTICLE DESIGNATION
PART NO.:
Accessory 5
Insulation with vapour barrier,
necessary with media temperatures below +14°C, max. suitable to +6°C
Z5
Accessory 51*
Insulation with vapour barrier in special design,
necessary with media temperatures below +6°C, max. suitable to -10°C
(< -10°C additional customer-supplied insulation is needed)
Z51
Accessory 5A*
Heating sleeve for the overflow valve, necessary with media temperatures below 0°C
Z5A
PE Tanks-
PE storage tanks for the storage of glycol-water mixtures,
for fully automatic resupply with 200 litres and a glycol lifting pump
Z13
PE Tanks
PE storage tanks for the storage of glycol-water mixtures,
for fully automatic resupply with 1000 litres and a glycol lifting pump
Z14X
PE Tanks
PE storage tanks for the storage of glycol-water mixtures,
for fully automatic resupply with 2000 litres and a glycol lifting pump
Z15
Commissioning
Commissioning by the KOREX Customer Service (each unit)
473
* Not available for the Types AS-T 20 and 48!
3 Technical Data
AIR-SEPUnit Type AS-T …
(see the dimension and connection
diagram)
20/2-K
20/4-K
20/2
20/4
48/4
100/4
/6
/8
150/4
/6
/8
200/4
/6
/8
400/4
/6
/8
600/4
/6
/8
1200/4
/6
/8
1600/4
/6
/8
2400/4
/6
/8
Expansion volumes
l
20
48
100
150
200
400
600
1,200
1,600
2,400
Static height, max.
mWS
11
25
25
25
40
60
Pressure maintenance, max.
barg
1.6
3.0
3.0
3.0
4.5
6.5
Operating temperature, max.
°C
55
100
System contents, max.
l
900
2,150
4,500
6,750
9,000
18,000
27,000
54,000
81,000
108,000
Height
mm
750
1260
1170
1460
1760
1570
1450
1880
2380
2400
Width
mm
445
560
790
1020
1350
Depth
mm
495
560
790
1020
1350
Weight
kg
20
21
40
65
77
86
95
104
129
180
330
Resupply pressure
barg
4.0
Refill quantity
l/min
5.0
Connection, "expansion" line
R 1/2
R 1
Connection, "pressure maintenance" line
R 1/2
R 1
Installation mounting
floor, wall
floor
Certification mark
CE
Operating voltage
VAC/Hz
1x 220-240 / 50
Current consumption
A
2.9
2.9
3.8
4.4
Power consumption
kW
0.6
0.6
0.7
0.8
Fuse, electrical cabinet
A
10, medium delay

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4 Installation
Danger –Electric Shock!
▪Life-threatening injuries through electric shock
-Systems in which the unit is installed must be disconnected from the power supply,
-Ensure that the system cannot be switched on again by other people
-Installation work on the electrical connections of the unit must be carried out by a skilled electrician only and
in accordance with electrical engineering regulations.
Caution –Risk of Injury!
▪In the event of defective installation or maintenance work on the connections, burns and other injuries can be caused
by hot water or steam under pressure suddenly spurting out.
-Ensure professional installation
-Ensure that the system is pressure-less before carrying out maintenance work on the connections
Caution –Risk of Burn Injuries!
▪Skin burn injuries can be caused in heating systems through too hot surfaces.
-Wait until these have cooled down or wear safety gloves
-The operating company must place appropriate warning signs in the vicinity of the unit
Caution –Risk of Injury through Falls and Collisions!
▪Bruises through falling or collision with system components during installation
-Wear your personal protective equipment
(safety helmet, protective clothing, protective gloves, safety shoes).
Advice:
Confirm the correct and proper installation and commissioning as in the installation, commissioning and maintenance
description. This is a prerequisite for any warranty claims.
Have the initial commissioning and the annual servicing carried out by the Korex Works Customer Service!
4.1 Conditions
4.1.1 Checking the Delivery Condition
The unit is carefully checked and packed before being shipped. Damage during transport cannot be ruled out.
Advice!
On receipt, check the delivery for completeness and damage. Document any transport damage. Contact the haulier
to claim for any damage.
4.2 Installation Site
Preparation for the installation of the equipment:
▪No access for unauthorized people
-Frost-free, well ventilated room (room temperature 0°C to 45°C)
▪Level and sufficiently load-bearing floor
-Ensure the sufficient load-bearing capacity of the floor when filling the containers.
-Ensure that the pressure maintenance station and expansion vessels are placed on one level
▪Filling and drainage facility.
-Provide a filling connection DN15 in accordance with DIN1988 T4
-Provide an optional cold water mixture
-Provide a drain for the waste water.
▪Electrical connection: 230VAV / 50HZ, 10A with an upstream connected FI circuit breaker: Tripping current 0.03A.
▪Use only approved transport and lifting equipment.

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4.3 Hydraulic Connections
Connections for the heating, water and waste water integration
Types AS-T 100 to 2400 Types AS-T 20 and 48
1 Connection for resupply ¾" external thread
(by means of optional “Accessory 1 –Fresh Water Connection”)
2 Safety overflow DN50, connection via funnel waste trap(!)
3 OFF = pressure maintenance connection (1”or 1/2”ext. thread)
4 ON = expansion connection (1”or 1/2”external thread)
4.3.1 Hydraulic Connection Accessories
AIR-SEP“Accessory 1 - Fresh Water Connection”AIR-SEP“Accessory 3 - Connection System DN25”
4.4 Electrical Connections
The AIR-SEPunit is delivered fully wired. Two cable lines are routed to the outside:
6. Supply voltage, 230VAC / 50Hz, 3x 0.75mm² flexible
7. Alarm cable (potential free), max. 230V / 1A, 3x 0.75mm² flexible
The cable for the supply voltage must be connected in a customer-supplied terminal box. The fusing takes place in the
customer-provided electrical cabinet with 10A, slow.
The alarm cable is potential free and is complete with a normally open and normally closed contact. In normal operation, [1]
and [3] are closed! In the event of a fault, power cut or with the unit switched off, the relay switches off. The contacts [1] and
[3] open and [2] and [3] are closed (see 4.4.1 Electric Drawing).
1 2 3 4 6+7 3 4 2 6+7 1
(via optional Accessory 2 or 3)
AIR-SEP"Accessory 2 - Connection System DN15"

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4.4.1 Electric Drawing

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
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4.4.2 Terminal Plate and AIR-SEPSmart-Control Controller
Each AIR-SEPSmartControl controller has a plate, located between the low voltage and the 230V terminals, showing the
terminal designations. All internal connections have already been made in the factory!
View with the fitted Designation Plate AIR-SEPSmartControl Controller with Display
5 Initial Commissioning
5.1 System Requirements
(for the legends see “2.2 Principle Diagram”on pages 7/8)
1. The AIR-SEPunit is set pressure-dependent in accordance with your specifications and basically needs no
correction! (for the pre-settings see the label on the electrical cabinet)
2. The hydraulic connections must be made in accordance with 4.3 (Hydraulic Connections).
3. The pipe network –with closed valves to the AIR-SEP(3a + 3b and 2b + 2c) - must be charged with at least 1.8
barg pressure.
4. The supply voltage must be connected in accordance with 4.4 (Electrical Connections).
5. The safety overflow (2) and the waste water connection of the system separator (1d) must be connected to the sewer
network via a funnel waste trap (2a).
6. The AIR-SEPunit must be prefilled with mains water via the filling and draining valve (5) so far until the float in the
water gauge glass (12) is approx. 10cm above the black level switch
(or up to the marker when present).
Fill height at initial
commissioning

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5.2 Commissioning
1. Open the technical level. First remove the magnetic frame from the display. Then remove the 4 knurled screws from
the front cover (or only the one at the front and loosen the 2 at the sides), gently pull the cover away from the front
and lift it off.
2. Open the shut-off (1a) of the resupply connection.
Advice!
When using AIR-SEPsoftening or demineralization cartridges, also use this user manual and follow the
instructions!
3. Open the system connections: Ball valve and ball valve with safety cap (3a + 3b and 2b + 2c).
4. Switch on the main fuse on the electrical cabinet.
Advice! The switch on the AIR-SEPmust be switched off (up position)!
5. The AIR-SEP controller starts. Wait until the LED lights up constant green.
6. Tap –using the stylus or finger –the flag with the language of your choice. You are taken to the homepage.
7. Tap the top right-hand button . You are taken to the “Automatic Mode”page. Then tap the centre gear wheel button
to open the “Settings”page. Enter the Password “Asdf”and confirm your entry by tapping the green tick.
8. As the AIR-SEPunit has been prefilled, to start with there is sufficient water in the vessel
(Lower Level = “NU”= “OFF”). If the “NU”= “ON”the unit has not been filled enough (see 5.1 Section 6)!
Advice!
The pressure maintenance pump is blocked with the active "Lower Level" (NU = ON)!
9. To check the resupply, tap the “Start resupply”button. The magnetic valve opens for a max. 60 seconds and top-up
water flows into the AIR-SEP. In doing so, the “filling rate”must be between 4-7 l/min. The meter reading is
increased by the resupplied volume of water.
The resupply can be stopped early by tapping the “Stop resupply”button.

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10. Briefly open (3-5 seconds) the ball valve (10a) to vent the pressure maintenance pump (10). The pressure in the
system falls simultaneously. Close the ball valve again.
The system pressure can be read off from the display (“Pressure … / current:”).
11. Then tap the “Start pump”button. The pressure maintenance pump now runs for a max. 60 seconds and the system
pressure increases. It is possible - depending on the pressure situation - that the overflow valve is simultaneously
active.
By tapping on “Stop pump”the pump operation is stopped.
Advice!
In the event of no or only a small pressure increase, repeat Points 10 and 11 until
the “Pressure current”is the same as the “Pressure set”.
12. The pressure maintenance pump is now ready for operation.
13. By tapping the buttons + you return to the homepage.
14. Now switch on the AIR-SEPunit. To do so, press the switch below the display.
The green LED on the switch indicates the operational readiness. The display indicator of the control changes to
"ON" The AIR-SEPnow works in Standard Mode: Pressure maintenance with interval degassing.
15. If the system pressure is within the desired pressure maintenance, after approx. 1 minute the first degassing interval
begins
Indicator water magnetic valve (OFF / ON)
Indicator pressure maintenance pump (OFF / ON)
Indicator current pressure (system pressure)
Indicator control (OFF / ON)
Indicator set pressure / switch-on point
Indicator Lower Level (OFF / ON)
10 10a 11 11a 9 10 10a 9

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5.3 Testing (Types AS-T 100 to 2400)
1. Pull on the ring (11a) of the overflow valve (11).
2. The system pressure sinks and in doing so must fall below the pressure maintenance (p -0.2 barg).
3. The pressure maintenance pump starts and on the display the indicator changes to "ON".
4. Release the ring (11a) again. The indicated value "SYSTEM Pressure" rises again.
5. Once the system pressure has been reached again, the pump stops and the indicator of the pump on the display
changes to "OFF".
5.4 Information about Commissioning
Through water extraction, during commissioning the lower level can be reached. On the display the indicator changes to "ON",
the pressure maintenance pump switches “OFF”(dry running protection!) and the resupply is activated ("ON"). In the process,
fresh water is fed into the degassing and expansion tank (A1) via the magnetic valve (18). The float in the water gauge glass
(12) rises. The “Lower Level”is overflown, the indicator changes to "OFF", the magnetic valve (18) remains open ("ON") as
the AIR-SEPunit is still feeding water volume X (depending on unit type) as a resupply volume. The litre-precise recording
takes place via the pulse output of the magnetic valve (18).
6 Navigation of the "AIR-SEPSmartControl"
6.1 Operation
The “AIR-SEPSmartControl”controller is operated via a 4.3”touch screen display. For easier of handling, an operating
stylus is available, inserted at the side of the front cover of the electrical cabinet. The control surfaces can be tapped with this
stylus and the display view can be further scrolled by sliding (if available).
6.2 Welcome Screen
The LED status lamp (bottom left) can indicate various conditions. After the hardware initialization, the controller waits for
approx. 30 seconds in order to receive all the necessary information for the functions (sensor values, etc.). The controller start
takes place after the following sequence:
Red –Orange –Green flashing–Green continuous light
After the start the welcome screen is shown:
Tap –with the stylus or a finger –the flag of the language of your choice. You are taken to the homepage.

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6.3 Homepage
After tapping you reach the homepage:
Here you receive an overview of all the important information:
▪The AIR-SEPpressure maintenance station is displayed schematically.
▪The switching states of the fresh water magnetic valve and of the pressure maintenance pump (OFF / ON) are
shown.
▪The status of the level sensor is displayed (OFF / ON).
▪The information whether the control is switched OFF or ON is shown.
▪In addition, the system pressure is displayed in the centre.
▪The desired pressure maintenance with its switching hysteresis is likewise displayed.
▪The navigation menu is located on the right:
"Automatic Mode"
Status "pressure maintenance with interval degassing"
Status "fast degassing”with the start button
"Maintenance" button (password protected)
"Setting" button for the system parameters (password protected)
"INFO"
Information about "inputs", "outputs" and "messages"
“INTERNAL”
Parameterization by the KOREX Works Customer Service (password protected)
?
"QUESTION MARK"
Return to the welcome screen (language selection, type and manufacturer's number)
is via the question mark symbol in the top left corner
6.4 Menu "Automatic Mode"

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Pressure maintenance with interval degassing: OFF
The main switch (in the middle under the display), and thus also the pressure maintenance together with interval degassing, is
switched off.
Pressure maintenance with interval degassing: ON
The main switch, and thus also the pressure maintenance together with interval degassing, is switched on. The timer starts
approx. 1 minute after the switching on of the pressure maintenance.
Run time Time specification during which the degassing, and thus the pressure maintenance
pump, is active.
Interval Time specification of the intervals at which the fast degassing starts.
Fast degassing: OFF
The fast degassing is not active.
Fast degassing: ON
The fast degassing is active and stops automatically at the end of the run time.
Run time Time specification of the run time of the fast degassing.
Remaining Shows the remaining time with active fast degassing.
Inactive Shows the remaining time during which the fast degassing is paused
(optional programming).
"Start fast degassing" button
The fast degassing is started by pressing the button.
"Stop fast degassing" button”
Appears after the fast degassing has been started. The fast degassing is stopped by this button before the full run time has
elapsed.
MAINTENANCE (password protected)
Restart of the maintenance intervals following professional maintenance
(KOREX customer service or authorized heating system or plant manufacturers).
SETTINGS (password protected)
Input of system parameters and the carrying out of the initial commissioning (heating
system or plant manufacturers).
Password: “Asdf”
HOMEPAGE
Return to the homepage.
6.4.1 Service Menu "Settings"
The Settings menu is intended exclusively for the plant manufacturer and is, therefore, password protected!
DH = Pressure Maintenance SE = Fast Degassing P1 = Pump P2 = Pump 2 (when installed) NU = Lower Level
NO = Upper Level (when installed) MV = Magnetic Valve UD = [not occupied]

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Pressure set / current
Input of the desired pressure maintenance in barg. The pressure maintenance must be at least 0.5 barg above the static
height of the system. To change the data, tap on the respective parameter (for example, "2.0 barg").
Safety valve
Here the response pressure of the customer-installed safety valve can be entered. The response pressure of the safety valve
should be at least 3.0 barg and must be at least. +1.0 barg above the pressure maintenance.
Run time of the fast degassing
Here, the run time of the fast degassing can be changed. The start of the fast degassing is started via the "Automatic Mode"
menu.
Maximum resupply volume (p.a.)
Through the input of a volume of water, the maximum amount per year of supplementary water can be limited.
With the use of upstream softening or demineralization (AIR-SEPION or AIR-SEPVE) the capacity can be monitored here.
With the use of the AIR-SEPVE fitting, the value must be changed from 5 l/min to 4 l/min.
Resupply monitoring
Here, it can be decided whether the resupply frequency and resupply volume should be monitored.
Resupply disablement
With capacity monitoring (for example, with the use of the AIR-SEPVE fitting) the resupply is disabled.
The pressure maintenance pump is stopped / started via the "Start pump" / Stop pump" button (even with the control switched
off!!!). Through this the pump can be vented during the initial commissioning (see Initial Commissioning | Chapter 5).
An "Auto-Stop" timer automatically switches off the output after 1 minute.
The magnetic valve is opened / closed via the "Start resupply”/ "Stop resupply" button (even with the control switched off!!!).
Here it can be checked whether the resupply is functioning.
The filling rate is displayed in l/min and should be between 4-7 l/min.
An "Auto-Stop" timer automatically switches off the output after 1 minute.
Meter reading
Here can be read off, how much water has already been resupplied.
"Delete meter reading"
By clicking here, the meter reading is set to "0". The new monitoring of the maximum resupply volume is started.