REMKO HPS 500 User manual

REMKO
STORAGE TANK SYSTEMS
Buffer tank for hot water
HPS 500, MPS 800, MPS 1000
Operation · Technology
Edition GB-F08

3
Contents
Carefully read this operating manual prior
to commissioning/using the units!
This operating manual is a translation of the German original.
This operating manual is an integral part of the unit
and must always be kept in the vicinity of the installation
location or on the unit itself.
Subject to modifications; no liability accepted for errors or
misprints!
Safety notes 4
Environmental protection and recycling 5
Guarantee 5
Intended use 5
Operation 5
Description 6
Shutdown 6
Care and maintenance 7
Installation instructions for qualified personnel 7-8
Installation 8-9
Fitting the insulation 10-12
Connection examples 13-14
Commissioning 15
Unit dimensions and technical data 16-19

4
REMKO HPS 500, MPS 800, MPS 1000
Carefully read the operating manual
before placing the unit in service for
the first time. It provides useful tips,
notes and hazard warnings to prevent
injury and material damage. Failure to
follow the directions in this manual can
endanger persons, the environment and
the equipment itself and will void any
claims for liability.
■ Keep this manual in the vicinity of the
units.
■ Only qualified personnel may set up
and install the units and components.
■ Set-up, connection, and operation of
the units and their components must
be carried out in accordance with
the operating conditions as specified
in this manual, and comply with all
applicable local regulations.
■ Modification of the units and
components supplied by REMKO
is not permitted and can cause
malfunctions.
■ Units and components may not be
operated in areas where there is
an increased risk of damage. Observe
the minimum clearances.
Safety notes
■ The electrical power supply is to be
adapted to the requirements of the
units.
■ The operational safety of units and
components is only assured if they are
fully assembled and used as intended.
Safety devices may not be modified
or bypassed.
■ Do not operate units or components
if there are obvious defects or signs of
damage.
■ The units and components must be
kept at an adequate distance from
flammable, explosive, combustible,
abrasive and dirty areas or
atmospheres.
■ Installation, repair and maintenance
work may only be carried out
by authorised specialists. Visual
inspections and cleaning can be
performed by the operator as long
as the unit is disconnected from the
power.
■ Take appropriate precautions when
performing installation, repair or
maintenance work or cleaning the
unit to make sure the unit does not
pose a danger to persons.

5
Guarantee
The guarantee conditions are listed in the
"General terms and conditions".
Please contact your direct contractual
partner about this first instance.
Environmental
protection and
recycling
Disposing of packaging
All products are packed for transport
in environmentally friendly materials.
Make a valuable contribution to reducing
waste and sustaining raw materials.
Only dispose of packaging at approved
collection points.
Disposing of
the components
The manufacturing process for the units
is subject to continuous quality control.
Only high-grade materials are processed,
the majority of which are recyclable. Help
protect the environment
by only disposing of the components in
accordance with local regulations and
in an environmentally safe manner, e.g.
through authorised disposal and recycling
specialists or at collection points.
Intended use
The buffer tanks are employed for the
storage of hot water in all types of hot
water central heating systems (solid
fuel/oil-fired boilers, heat pumps, solar
plant, gas/electric instantaneous water
heaters) within enclosed spaces and for
the storage of cold water for cooling
processes or heat recovery purposes.
Any different or additional use is
a non-intended use. The manufacturer/
supplier assumes no liability for damages
arising from non-intended use. The user
bears the sole risk in such cases.
Intended use also includes working
in accordance with the operating and
installation instructions and complying
with the maintenance requirements.
Operation
Manual operation is not necessary.

6
REMKO HPS 500, MPS 800, MPS 1000
Shutdown
Temporary shutdown
1. Disconnect the electrical connection
at all poles.
2. Drain the storage tank in areas where
it is at risk from frost and before the
onset of winter.
3. Then drain all pipes leading to the
heating units and to the unit itself,
as well as all water carrying fittings
and pipes (also heating cycle = heat
exchanger) to the frost-proof part
of the installation provided by the
customer.
!CAUTION
When emptying the storage tank,
hot water may escape!
!CAUTION
When putting the storage tank
back into service, ensure that it is
filled with water and that water
which is free of bubbles is escaping
from the valves!
Permanent shutdown
Ensure that units and components are
disposed of in accordance with local
regulations, e.g. through authorised
disposal and recycling specialists or at
collection points.
REMKO GmbH & Co. KG or your
contractual partner will be pleased to
provide a list of certified firms in your
area.
Description
The buffer tanks are used to store hot
water in all types of hot water central
heating systems (combustible burners for
solid fuel, oil-fired boilers, heat pumps,
solar plants, gas/electric instantaneous
water heaters) within enclosed spaces.
The storage tank volume can be
adapted to your particular needs by
connecting several buffer tanks to form
batteries. The buffer tanks may be used
universally, either as parallel buffer
tanks (hydraulic compensators) or series
buffers.
The insulation of the HPS 500 and
MPS 800/1000 hot water tanks consists
of high-efficiency double-lining thermal
insulation.
All buffer tanks are produced from
high-quality steel in accordance with
DIN EN 10025/10111, and are provided
with rust protection on the outside.
Immersion heater elements can be
screwed into the built-in 6/4" socket in
the buffer tanks.
A D240 blank flange cover is included to
retrofit a fine-tube heat exchanger.
The buffer tanks have 9 (11 for the
MPS 800/1000) 6/4" IG connection
threads as well as inflow restrictors.
A conductive rail is installed in
the storage tank to enable probe/
thermometer immersion sleeves to be
used.

7
Care and maintenance
Care
■ Clean the units with a damp cloth
(by adding a liquid household
cleaner, for instance).
Do not use any caustic, abrasive or
solvent-based cleaning products.
Maintenance
■ We recommend that you take out
a maintenance contract with an
annual service from an appropriate
specialist firm.
This will guarantee that your
equipment always operates reliably!
NOTE
■ Regularly check that the safety valve
is functioning.
The expansion water amount at
maximum heat represents approx. 3.5 %
of the storage tank capacity.
When the safety valve test knob is lifted
or in the “Test” position, the water must
flow unhindered out of the safety valve
body into the drainage funnel.
!CAUTION
This can cause the cold water
supply and parts of the storage
tank connection fitting to become
hot!
If the storage tank is not heated or if
hot water is removed, no water should
be dripping from the safety valve. If this
does occur, either the pressure in the
water pipe is greater than the permitted
value or the safety valve is defective. If
the pressure in the water pipe is higher
than permitted, a pressure relief valve
must be used.
Installation instructions
for qualified personnel
General instructions prior to installation
■ Ensure that the area in which the
unit is to be operated is free of frost
and easily accessible for required
maintenance, repairs and even
for the possible replacement of
the unit (e.g. avoid overly narrow
thoroughfares and doorways).
■ When installing the buffer tank in
unusual locations, such as in lofts,
residential units with floors that
are sensitive to water, storerooms,
etc., take account of the possibility
of leaking water and ensure that
a facility is in place to catch the
water, including appropriate drainage
methods.
■ The unit may only be positioned and
operated on level surfaces.

8
REMKO HPS 500, MPS 800, MPS 1000
The buffer tank is not suitable for
preparation for domestic water!
CAUTION
Installation should only be
performed by authorised
specialists.
The hot water must be prepared
in compliance with the latest
applicable standards.
NOTE
Installation
General notes
■ Do not continually top up the water
level in the buffer tank. This will
prevent corrosion damage to the
storage tank.
■ Observe DIN-VDI 2035 on system
filling.
■ You must bleed the buffer tank.
■ When planning the unit's installation
surface and selecting the installation
location, note the total weight of
the buffer tank, including the weight
of the water (the nominal capacity)
in order to ensure that the statics
of the load-bearing surface are not
exceeded.
■ Ensure proper clearance from firing
systems.
■ Make sure that units with enclosures,
which are installed in small, tight
spaces or in suspended ceilings
have the connection block (water
and electric connections and heater
installation) still freely accessible and
that there us no build-up of heat.
■ Leave at least 500 mm of space
free to remove the fine-tube heat
exchanger.
■ Check the contents of the packaging
for completeness and check the
unit for visible transport damage.
Immediately notify your contract
partner of any deficiencies.
■ The unit must be assembled on site.
■ For all connecting sockets, ensure
that the thread is fully engaged.

9
!CAUTION
However, under no circumstances
may the supply and return flow be
blocked, as otherwise the water in
the heat exchanger will not have
room to expand and there is a risk
of damage to the heat exchanger!
Central heating connection
Before being put into service, the heat
distribution system must be flushed in
order to remove any soiling (e.g. scale)
from the heating cycle. You have
the option to connect another heat
generator (e.g. a solar-thermal system)
using a fine-tube heat exchanger (special
accessory) in a closed system.
■ Use one of the 1 1/2" sockets
to install an auxiliary heater (see
chapter: Connection examples).
On the MPS 1000, either
a combustible burner for solid fuel
or one or two immersion heater
elements can be fitted.
■ Please note that the auxiliary heater
must not be used as a permanent
heating system.
■ Please note that the inflow restrictor
must first be bent back with a pipe
or similar.
■ You must bleed the buffer tank.
Buffer tank with auxiliary heater
(immersion heater elements)
Installation should only be
performed by authorised specialists.
NOTE
Electric booster heaters (immersion
heater elements) must be equipped
with a safety temperature limiter
which stops heating the buffer tank
at a temperature of max. 110 °C. The
choice of connection components
(connecting pipes, circulation, safety
valve combination, etc.) must be such
that, in the event of a malfunction of
the temperature control, the connection
components will withstand temperatures
of 110 °C, avoiding possible damage.

10
REMKO HPS 500, MPS 800, MPS 1000
To install the insulation, proceed as
follows:
1. Open the packaging and pull
the perforated insulation section
onto the connections with the
matting pointing inwards. In order
to prevent danger to those under
your supervision (e.g. children
suffocating), all packaging must be
disposed of immediately or cut up.
Fitting the insulation
2. Hook the unperforated insulation
section onto the hooked closure strip
on the insulation section that you
attached previously.
3. Hook the supplied cover assembly
strips over the hooked closure strip.
This will prevent the hooked closure
opening during further installation.
4. After fitting the cover assembly strip,
the insulation can be closed using the
second hooked closure strip.
If the insulation consists of three
sections, repeat the previous two
steps.

11
5. Insert the round section of insulation
on top of the storage tank and fix it
in place by pressing down lightly.
In order to achieve optimum heat
insulation, there must not be an air
gap between the round section and
the insulation.
!CAUTION
6. Correctly position and attach the
insulation cover using the hooked
strip openings on the top of the
insulation.
7. Fit the supplied collars to the
connections.

12
REMKO HPS 500, MPS 800, MPS 1000
2. Slide the completed collar centrally
on to the socket/pipe.
Fitting the collars
1. Remove the packaging for the collars
as delivered.
The insulation must not be bent or
pushed in, as this risks damage (stress
whitening). Any stress whitening which
occurs through improper handling can
be carefully removed or minimised using
a hot-air blower.
Depending on the heating capacity of
the hot-air blower, it may be necessary
to maintain a minimum distance
between the insulation and the
blower. Naked flames are prohibited.
!CAUTION
During operation, the tank
temperature must not consistently
exceed 110 °C.
NOTE
When fitting the collars, please
carry out the following steps:

13
HPS 500 connection example
A
B
C
2
14
3
HPS
D
Legend
A: Outdoor unit
B: WFK indoor unit
C: External probe
D: HPS 500 storage tank example
1: Cooling cycle
2: Mixed heating cycle
3: Hot water
4: Cold water
This hydraulic circuit diagram is only to be used as a planning aid, and does not
replace an installation drawing!
Hydraulic systems provided by the customer must be designed and planned by
a specialist installer!

14
REMKO HPS 500, MPS 800, MPS 1000
MPS 800/MPS 1000 connection example
AB
C
2
14
35
D
E F
Legend
A: Outdoor unit
B: WFK indoor unit
C: External probe
D: MPS 800 or MPS 1000 storage tank
E: Boiler/wall heating device
F: Solar
1: Hot water
2: Cold water
3: Unmixed heating cycle
4: Mixed heating cycle 1
5: Mixed heating cycle 2
This hydraulic circuit diagram is only to be used as a planning aid, and does not
replace an installation drawing!
Hydraulic systems provided by the customer must be designed and planned
by a specialist installer!

15
Commissioning
1. Check all connections, even those
which were sealed ex works
(flange), for leak-tightness.
2
. Then check all pipes for any leaks
and fix them if necessary.
3
. Test the safety module and valves to
ensure they are functioning.
Commissioning should only be
performed and documented by
specially trained personnel.
(DIN-VDI 2035)
NOTE
Flange installation port
Depending on the design of your
system, fine-tube heat exchangers may
be attached to the boiler flanges.
■ First tighten the nuts by hand.
■ Then tighten the nuts, in the
sequence specified below, to
a torque of 20 Nm to max. 25 Nm.
Fitting the flange installation port
Flange ring
Seal
Supporting disc
Flange plate
During the heating process, all expansion
water generated in the storage tank
must be captured by an appropriate
expansion vessel.

16
REMKO HPS 500, MPS 800, MPS 1000
Unit dimensions and technical data
We reserve the right to modify the dimensions and design as part of the ongoing technical
development process.
Unit type
Nominal
contents
[l]
Max.
operating
temperature
[°C]
Operating
pressure
[bar]
Test
pressure
[bar]
Tilt height
[mm]
Weight
[kg]
HPS 500 500 95 3 4.5 1670 113
Unit type Dimensions in mm
a b c d e f g (Ø) h i
HPS 500 220 620 1010 1390 1250 1640 650 340 1725
HPS 500
Flange
12xM12.1 bolts
6/4"
6/4"
6/4"
6/4"
6/4"
6/4"
6/4"
6/4"
6/4"
a
b
c
d
Øg
exterior
h
ef
i
6/4" 6/4"
1/2"
40° 40°
240

17
Unit type
Nominal
contents
[l]
Max.
operating
temperature
[°C]
Operating
pressure
[bar]
Test
pressure
[bar]
Tilt height
[mm]
Weight
[kg]
MPS 800 800 95 3 4.5 1750 157
We reserve the right to modify the dimensions and design as part of the ongoing technical
development process.
MPS 800
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
ø 790
1/2“ F
1/2“ F
1/2“ F
1/2“ F
ø 240
6/4“ F
260
500
630
1030
1230
1430
1694
Sensor strips
40°
60°
40°
60°
Tilt height without insulation: 1750 mm
Diameter with insulation: 990 mm
Height with insulation: 1735 mm

18
REMKO HPS 500, MPS 800, MPS 1000
Unit type
Nominal
contents
[l]
Max.
operating
temperature
[°C]
Operating
pressure
[bar]
Test
pressure
[bar]
Tilt height
[mm]
Weight
[kg]
MPS 1000 1,000 95 3 4.5 2090 176
We reserve the right to modify the dimensions and design as part of the ongoing technical
development process.
MPS 1000
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
6/4“ F
ø 790
1/2“ F
1/2“ F
1/2“ F
1/2“ F
ø 240
6/4“ F
310
580
745
1250
1470
1710
2050
Sensor strips
40°
60°
40°
60°
Tilt height without insulation: 2090 mm
Diameter with insulation: 990 mm
Height with insulation: 2135 mm

19
Designation Value
Mass per unit area kg/m21.7
Insulation thickness mm 100
Thermal conductivity λ
(calculated) W/mK 0.038
Standby energy consumption For specification, see rel. product folder
(in accordance with EN 60379)
Thermal resistance °C Max. continuous load 110 °C (inside)
Fire class B2 in accordance with DIN 4102
Number of parts 2 (or 3), divided outside of the connection
levels
Environmental compatibility Min. 70 % recycled material in the raw materials, even the matting itself
is recyclable
Toxicologically harmless Yes
CFC and HCFC-free Yes
Other properties Good sound insulation, kind to the skin
and hypoallergenic
Technical data for the insulation
We reserve the right to modify the dimensions and design as part of the ongoing technical
development process.

REMKO INTERNATIONAL
... and also right in your neighbourhood!
Take advantage of our experience and advice
REMKO GmbH & Co. KG
Air conditioning and heating technology
Im Seelenkamp 12 D-32791 Lage
Postfach 1827 D-32777 Lage
Telephone [phone]
Fax [phone]
E-mail [email protected]
Website www.remko.de
We reserve the right to make technical changes and provide no warranty as to the accuracy of this data!