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

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
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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.

AIR-SEPPressure Maintenance with AIR-SEPSmartControl
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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.