HPWH 300 HPWH 300HE. Installation and Operating Instructions. Hot Water Heat Pump for Outdoor Installation. English FD 9501

Transcription

1 HPWH 300 HPWH 300HE Installation and Operating Instructions Hot Water Heat Pump for Outdoor Installation FD 9501

2 Table of contents 1 Please read immediately... EN Important notes... EN Intended use... EN Regulations / safety information... EN-2 2 Description... EN General... EN Refrigerant circuit (heat pump operating principle)... EN Safety and control devices... EN-3 3 Storage and transport... EN General... EN Fork lift (or lift truck) transport... EN Manual transport... EN-4 4 Installation... EN Installation location... EN Installation... EN-5 5 Assembly... EN Connecting the water pipes... EN Connecting the condensate hose... EN Electrical connection... EN-6 6 Commissioning... EN Domestic hot water system... EN Operating the domestic hot water heat pump... EN-6 7 Maintenance / repair... EN Water circuit / condensate drain... EN Air circuit supply... EN Corrosion protection anode... EN-8 8 Faults / troubleshooting (for the user)... EN-8 9 Decommissioning... EN-8 10 Environmental requirements... EN-8 11 Device information... EN-9 Appendix... A-I Dimensioned drawing... A-II Integration Diagram... A-III Circuit Diagrams... A-VI FD 9501 EN-1

3 1 Please read immediately 1.1 Important notes Work on the domestic hot water heat pump may only be performed by qualified personnel. Observe accident prevention regulations. The device cover cannot be used for carrying (the cover cannot withstand significant forces). If devices are installed in locations with a risk of frost and are no longer operated or will not be connected to the power for a long period (several hours), the water must be drained from the cylinder. If this is not done, frost may destroy the device. The domestic hot water heat pump must only be operated when filled with water! Disconnect the power supply before opening the domestic hot water heat pump; possible fan coasting must be considered! Malfunctioning protection anodes reduce the service life of the device! (Electrically insulated magnesium anode with selenium complying with DIN 4753 part 6) Work on the domestic hot water heat pump is to be performed by qualified personnel only! Observe accident prevention regulations! DANGER! Failure to operate the PTR Valve easing gear every six months may lead the water heater exploding. Continuous water leaking from the drain may indicate a problem with the water heater. Water may drip from both the pressure relief device and the condensate drain. These pipes must be left open to the atmosphere. 1.3 Regulations / safety information NOTE Read these installation and operating instructions before commissioning! The domestic hot water heat pump is used exclusively to heat water for domestic use and drinking water within the specified operating temperature limits! The heating of fluids other than domestic water is not permitted. The installation must take place in accordance with the Australian standard AS/NZS For domestic use in Australia and New Zealand a TEMPER- ING VALVE must be fitted by the installer. The following are not permitted: - Operating the pump with solvent-based, explosive or chloric exhaust air - The use of exhaust air containing grease, heavy dust or adherent aerosols - Connecting extractor hoods to the ventilation system A PTR Valve must be fitted It is not permissible to operate the device: - With an empty cylinder The refrigerating system meets the requirements of ISO :2014. The technician must ensure that the refrigerant is flushed adequately to allow maintenance and repair work to be carried out on refrigerant circuit components without risk. Refrigerant must be properly handled and disposed of; it must not be released into the environment! The refrigeration circuit is "hermetically sealed" and contains the fluorinated refrigerant R134a with a GWP value of 1430, incorporated in the Kyoto protocol. The refrigerant is CFCfree, non-ozone depleting and non-combustible. Always disconnect the power supply before carrying out any work on the domestic hot water heat pump. When connecting the domestic hot water heat pump to the power supply, the relevant IEC standards and the AS 3000 must be complied with. Also observe the technical connection requirements of the electrical utility companies. Work on the domestic hot water heat pump may only be performed by qualified personnel. Observe accident prevention regulations. 1.2 Intended use This device is only intended for use as specified by the manufacturer. Any other use beyond that intended by the manufacturer is prohibited. This requires the user to abide by the relevant project planning documents. Please refrain from tampering with or alter-ing the device. Persons, especially children, who are not capable of operating the device safely due to their physical, sensory or mental abilities or due to their inexperience or lack of knowledge, must not operate this device without supervision or instruction by the person in charge. Children must be supervised to ensure that they do not play with the device. EN FD

4 2 Description 2.1 General The domestic hot water heat pump is a ready-for-use heating device whose main components are a domestic hot water cylinder, the components of the refrigerant, air and water circuits and the control, regulation and monitoring devices required for automatic operation. The domestic hot water heat pump is supplied with electrical energy and uses the heat stored in the intake air for domestic hot water preparation. The domestic hot water heat pump with internal heat exchanger can be connected to additional heat generators such as boilers and solar energy systems. A vertical cladding tube (inner 12 mm) houses an external temperature sensor. The devices are equipped as standard with an electric heating element (1.5 kw). The temperature of the intake air (the heat source) provides the reference value for the energy consumption and the domestic hot water preparation heating-up time. Falling exhaust air temperatures reduce the heat pump output and increase the heating-up time. In order for the heat pump to be operated economically, the air intake temperature should not fall below 15 C. If the air intake temperature falls below 0 C ±1.5, the heat pump is switched off and the domestic hot water heating is heated by the standard heating element (1.5 kw). 2.2 Refrigerant circuit (heat pump operating principle) The refrigerant circuit is a closed system in which the R134a refrigerant is the energy source. The finned heat exchanger extracts heat from the drawn-in air at a low evaporation temperature, and transfers it to the refrigerant. The vaporous refrigerant is taken in by a compressor, where it is compressed to a higher pressure and temperature level before being transported to the liquefier, where the heat absorbed in the evaporator and part of the compressing energy is transferred to the water. Subsequently, the high condensation pressure is lowered to the evaporation pressure by a throttle mechanism (expansion valve), and the refrigerant can again extract heat from the intake air in the evaporator. 2.3 Safety and control devices The domestic hot water heat pump is equipped with the following safety devices: High pressure switch (HP) The high pressure switch protects the heat pump against unacceptably high operating pressure in the refrigerant circuit and switches the heat pump off in the event of a fault. The heat pump restarts automatically as soon as the pressure in the refrigerant circuit has dropped again. The electric heating element fulfils four functions: Supplementary heating The heat-up time is approximately halved by switching on the heating element (via the "Heating element" switch, see Cap. 6.2 on pag. 6) in addition to the heat pump. Frost protection If the air temperature falls below 0 C ±1.5, the electric heating element switches on automatically and (nominally) heats the water up to the domestic hot water setpoint temperature of 60 C. Emergency heating In the event of a heat pump fault, the domestic hot water supply is maintained by the heating element. Higher water temperature If the required domestic hot water temperature is higher than the temperature achievable by the heat pump (approx. 60 C), it can be raised to a max. of 85 C by means of the heating element. NOTE When the domestic hot water temperature reaches 60 C, the heat pump switches off and the domestic hot water is heated solely by the heating element. The factory setting for the heating element controller is 65 C. Safety temperature limiter for heating element (STL) The STL protects the domestic hot water system against unacceptable temperature increases. The heating element is disconnected all-pole if the set switching value (99 C) is exceeded. The heating element cannot be switched on again until the domestic hot water temperature has decreased to 90 C and the reset button (see illustration) on the STL is pressed (this must only be done by qualified personnel). The domestic hot water heat pump is also equipped with the following regulation and control devices: FD 9501 EN-3

5 Heating element temperature controller (TC) The heating element thermo controller regulates the domestic hot water temperature during heating element operation. The maximum controller temperature is factory set to 65 C (the controller and the STL are installed together in a casing). Temperature settings can be changed using suitable tools (see illustration). Changes to this setting may only be carried out by qualified personnel. In automatic operation (activated via air temperature sensor), the water is heated by the heating element until the setpoint has been reached (60 C). In contrast to heat pump only operation, a smaller amount of water is heated up to minimise the operating period of the heating element. In continuous manual operation, the domestic hot water is heated until the set maximum temperature of the heating element controller has been reached. Heat pump temperature controller Temperature control in the domestic hot water cylinder and the regulation for compressor operation is carried out by the control electronics. A temperature sensor (R3) records the water temperature in the cylinder and another sensor (R1) records the air intake temperature before the evaporator. A further temperature sensor (R10) prevents the evaporator from freezing. 3 Storage and transport 3.1 General The domestic hot water heat pump should always be stored and transported packaged in an upright position, without being filled with water. If handled carefully, the device can be transported over short distances with a maximum tilt angle of 45. Ambient temperatures between -20 and +60 C are permissible during transport and storage. 3.2 Fork lift (or lift truck) transport The domestic hot water heat pump must remain mounted on the pallet when being transported with a fork lift. The pump should be lifted slowly. Because of its high centre of mass, the domestic hot water heat pump must be secured against toppling. To prevent damage, the domestic hot water heat pump must be lowered onto a level surface. 3.3 Manual transport The pallet can be used underneath the device for manual transportation. A second or third carrying position can be created with the help of ropes or carrying slings (these may be wrapped around the cylinder casing and attached to the water pipe nipples). When transporting the heat pump in this manner (or with a hand truck), do not, under any circumstances, exceed the max. tilt angle of 45 (see illustration). If the heat pump can only be transported in a tilted position, the domestic hot water heat pump ("Heat Pump" switch) should not be operated for at least one hour after installation in its final location. The device cover cannot be used for carrying (the cover cannot withstand significant forces). EN FD

6 4 Installation 5 Assembly 4.1 Installation location Condensate drainage (with a siphon) must be provided. The condensate must be discharged without frost. The air taken in may not be excessively contaminated or contain large amounts of dust. The load-bearing capacity of the foundation must be sufficient (the weight of the domestic hot water heat pump is approx. 440 kg!). For fault-free operation and for any maintenance and repair work, minimum clearances of 0.6m are required on all sides of the device. If the BWP is installed in any kind of enclosure, the clearances set out in the figure must be maintained If devices are installed in locations with a risk of frost and are no longer operated or will not be connected to the power for a long period (several hours), the water must be drained from the cylinder. If this is not done, frost may destroy the device. 4.2 Installation Remove the three transport restraint screws (M12 - fixing the device to the pallet) from the bottom of the pallet. Remove the pallet and mount the three M12 supporting feet (in the plastic bag attached to the nipple of the cylinder pipe). Position the domestic hot water heat pump and align it vertically by adjusting the device feet. Then tighten the counter nuts on the device feet. 5.1 Connecting the water pipes The water connections (see Cap. 1 on pag. II) are located on the rear of the unit. Important information: Circulation pipe For energy efficiency reasons, a circulation pipe should not be used if this can be avoided. If a circulation pipe is installed in the domestic hot water distribution system, a valve or a similar device must be provided as shut-off facility to avoid unnecessary energy losses. Circulation is enabled according to use (time or requirement control). The nominal pipe widths for the on-site sanitary installation must be determined by taking into account the available water pressure and any pressure drops expected to occur in the pipework. Water installations must be executed according to the Australian standard AS , also observe local regulations for domestic water installations! The heat pump must be permanently connected to the water mains! Both rigid and flexible water pipes may be used. Install a 500 kpa pressure and temperature relief valve (PTRV)(see Cap. 2.3 on pag. IV) Observe the corrosion behaviour of the pipework materials used in order to avoid corrosion damage (see section "Commissioning"). Pipe nipples (on the cylinder) and water pipes must be protected from frost! The pipe nipples are protected from corrosion with a heat shrinkable tubing. In the connection thread area, the heat shrinkable tubing should only be removed as far as necessary. The transition or interface area should be protected (e.g. with silicon) to provide corrosion protection. A safety valve (PTR valve) must be mounted on-site by the installer. This valve must not be lockable and must not have a shutoff device. NOTE Domestic hot water, cold water, circulation connections: These pipe nipples contain plastic inserts, the purpose of which is to protect against corrosion (in particular to the pipe nipple flange surfaces). These plastic inserts remain in their positions after installation. NOTE When installing the on-site pipework, ensure that the pipes are not contaminated (flush pipes before connecting the domestic hot water heat pump if necessary)! NOTE The PTR Valve must be installed as per the Hydraulic Drawing on page A-IV. Both the PTR Valve and Pressure Reduction Valve must comply with AS FD 9501 EN-5

7 5.2 Connecting the condensate hose The condensate hose is routed out through the sheet metal covering. It should be routed in such a way that the condensate produced (during heat pump operation) can flow away freely - ensure frost-free drainage. There is a pressureless seal valve at the end of the condensate hose, which must be relocated accordingly if the condensate hose is shortened (the valve can be easily removed and re-inserted). 5.3 Electrical connection The domestic hot water heat pump is wired ready for use; power is supplied via the mains power connection, which is plugged into an earthed wall socket (~230 V, 50 Hz). This socket must remain accessible after installation. The installation (electical work) and commissioning, as well as the maintenance of this equipment, must only be carried out by an authorised qualified contractor in accordance with these instructions. Mains power connection replacement The electrical connecting terminal (X2) is located on the partition in the device. Cable type: H07RN-F3G 1.5 mm² Routing in accordance with the original mains power connection via cable entry on the rear wall. Sheath stripping length 85 mm Shorten L/N wires to 55 mm Strip wires 7 mm, fit with cable ferrules and connect to X2: L/ N/PE 6 Commissioning 6.1 Domestic hot water system The domestic hot water heat pump must only be operated when filled with water! Domestic hot water system requirements The following materials can be used in the consumer's domestic hot water system: Copper Stainless steel Brass Plastic Depending on the materials used in the domestic hot water system (customer installation), material incompatibility may lead to corrosion damage. This especially applies to zinc-plated materials and materials containing aluminium. If there is a risk of water contamination during operation, it may be necessary to install a filter. Commissioning the domestic hot water system All installations for the water circuit and air circuit, as well as all electrical installations, must have been carried out correctly and fully completed. Fill the domestic hot water circuit via an external connection. Purge the domestic hot water circuit (open domestic hot water taps at the highest extraction points until there are no more traces of air). Check the entire domestic hot water system for leaks. Establish the power supply. 6.2 Operating the domestic hot water heat pump If the supply cord is damaged, it must be replaced by a special cord or assembly available for the manufacturer or its service agent. Apart from the switch for the electric heating element, there are no other controls on the device. The domestic hot water temperature is preset to 60 C and is regulated automatically. EN FD

8 "Heating Element" switch If there is an increase in hot water consumption or if a higher hot water temperature (60±2 C) is desired, the heating element switch can be used to switch the integrated 1.5 kw radiator on. If the "Heating Element" switch is in the "On" position (switch lit), approx. the upper third of the cylinder will be heated up to the maximum temperature of the heating element controller (factory setting 65 C); at domestic hot water temperatures > 60 C, domestic hot water preparation is carried out using the heating element only. Note Heating element controller The heating element controller is a second control unit for controlling the operating range of the electric heating element, which is completely independent of the domestic hot water controller. The factory set switch-off temperature of 65 C can be changed by a technician (see Cap. 2.3 on pag. 3) Sensor pipe for external temperature sensors A vertical sensor pipe 12mm (opening in the bottom plate sealed with a leading-in tube) for an external temperature sensor is fitted in the rear of the domestic hot water heat pump. 7 Maintenance / repair Disconnect the power supply before opening the domestic hot water heat pump; possible fan coasting must be considered! General The domestic hot water heat pump is virtually maintenance free. Furthermore, a one-off visual inspection for possible leaks in the water system and clogging of the condensate drain must be carried out a few days after commissioning. The refrigeration circuit of the heat pump does not require maintenance. Only use a damp cloth with a little soap solution to clean the domestic hot water heat pump. The installation (water and electical work) and commissioning, as well as the maintenance of this equipment, must only be caried out by an authorised qualified contractor in accordance with these instructions. NOTE Ensure water does not come into contact with the operator controls. Unplug the mains plug and switch off the power supply before beginning any cleaning work. Installation position of the external temperature sensor (device cover removed in illustration) 7.1 Water circuit / condensate drain The water circuit check is limited to filters that may have been installed on site and possible leakages. Dirty water filters should be cleaned and, if necessary, replaced. The seal valve in the end of the condensate hose must only be checked for contamination, and cleaned if necessary. 7.2 Air circuit supply Maintenance work is limited to cleaning the evaporator on a regular basis and as required. NOTE Risk of injury caused by sharp-edged fins. Fins must not be deformed or damaged! If air filters are used, they should be regularly checked for contamination and be cleaned and replaced if required. NOTE The PTR Valve must be discharged every six months to check for correct operation FD 9501 EN-7

9 7.3 Corrosion protection anode The corrosion protection anode installed in the domestic hot water cylinder should be electrically checked on a regular basis (at least every two years after commissioning) and be replaced as necessary. Electrical checking is carried out by means of a suitable ammeter, without draining the cylinder. Procedure: 1) Unplug the PE cable from the protection anode tab. 2) Connect the ammeter (0 to 50 ma) between the PE cable and the tab. 3) Evaluation of wear on the protection anode: Measured value > 1 ma protection anode is in working order. Measured value < 1 ma protection anode must be tested and/or replaced. If electrical testing does not provide any clear results, a visual inspection of the protection anode by a technician is recommended. Should replacement of the protection anode [by a technician] be necessary, the cylinder must be drained via the drainage valve provided (to be fitted during installation - see Appendix). Malfunctioning protection anodes reduce the service life of the device! (Electrically insulated magnesium anode with selenium complying with DIN 4753 part 6) 8 Faults / troubleshooting (for the user) Work on the domestic hot water heat pump is to be performed by qualified personnel only! Observe accident prevention regulations! The heat pump will not operate! Check the following: Voltage is applied to the device the intake air or ambient temperature is 0 C The heat pump has not been switched off by the temperature controller the hot water temperature has reached (or exceeds) 60 C Condensate cannot drain properly (there is water under the device) Check the following: The seal valve in the end of the condensate hose is contaminated or clogged, and clean if necessary; the valve can be easily removed and replaced. The air supply / air outlet is significantly reduced. If the above suggestions cannot help you eliminate these faults, please contact your technician or after-sales service partner. 9 Decommissioning Tasks to be carried out: Disconnect the domestic hot water heat pump from the power supply. Completely shut off the water circuit (domestic hot water, cold water and circulation pipe) and drain the domestic hot water cylinder through the drain valve. 10 Environmental requirements During maintenance or decommissioning of the domestic hot water heat pump, all environmental requirements regarding recovery, recycling and disposal of materials and components must be observed in compliance with DIN EN378. EN FD

10 11 Device information 1 Type and order code HPWH 300 HPWH 300HE 2 Design 2.1 Defrosting yes yes 2.2 Nominal cylinder volume litre Transfer area of the internal heat exchanger m Sensor pipe ø internal for external sensors mm Installation location Outside Outside 2.6 Cylinder material Enamelled steel complying with DIN 4753 Enamelled steel complying with DIN Cylinder insulation PU with sheet metal covering PU with sheet metal covering 2.8 Nominal cylinder pressure kpa (bar) 700 (7) 700 (7) 3 Operating limits 3.1 Heat source operating limit 1 C 0 to 45 0 to Domestic hot water in heat pump operation C 60 ± 1.0 K 60 ± 1.0 K 4 Sound 4.1 Sound power level db(a) Dimension/weight and filling quantities 5.1 Dimensions height (max.) x cross-section (max.) mm 1680 x x Weight (empty) kg Refrigerant R 134a/ filling weight kg Electrical connection 6.1 Degree of protection IP 24 IP Connection voltage 1/N/PE~230 V, 50 Hz 1/N/PE~230 V, 50 Hz 6.3 Fuse max. A C16 C Heat pump power consumption cos A Supplementary electrical heating power consumption A Power consumption max. A Heat pump nominal power consumption at 60 C 2 W Supplementary electrical heating power consumption W Total power consumption max. W Hydraulic connection 7.1 Circulation pipe connection external thread R 3/4 R 3/4" 7.2 Domestic hot water outlet connection external thread R1 R1" 7.3 Cold water inlet connection external thread R1 R1" 7.4 Internal heat exchanger connection external thread - R1" 8 Performance values 8.1 Heat-up time from 15 C to 60 C 2 h Mean heat output at 45 C COP according to EN cycle XL Useful domestic hot water quantity Litres Stand-by energy consumption at 55 C / 24 h W At temperatures below 0 C ± 1 C, the heating element is automatically switched on and the heat pump module off. 2. Heating up of the nominal volume from 15 C to 60 C at an air intake temperature of 20 C and a relative humidity of 70 % 3. Heating up of the nominal volume from 15 C to 45 C at an air intake temperature of 20 C and a relative humidity of 70 % A H5 850 kpa PTR Valve must be fitted A PSL 50 Valve (500 kpa) must be fitted FD 9501 EN-9

11 EN FD

12 Appendix 1 Dimensioned drawing... A-II 2 Integration Diagram... A-III 2.1 Process circuit diagram... A-III 2.2 Legend... A-III 2.3 Hydraulic integration diagram... A-IV 2.4 Legend... A-IV 2.5 Heat Exchanger Integration Diagram for Thermal Solar Installation... A-V 3 Circuit Diagrams... A-VI 3.1 Load... A-VI 3.2 Control... A-VII 3.3 Legend... A-VIII Appendix FD 9501 A-I

13 1 Dimensioned drawing A-II FD

14 2 Integration Diagram 2.1 Process circuit diagram Appendix 2.2 Legend Compressor Evaporator Hot water cylinder with Liquifier High-pressure switch Check valve Air inlet temperature sensor (R1) Filter dryer Expansion valve Cylinder temperature sensor Heating element Safety temperature limiter for heating element Service valve Four-way valve Defrost end sensor R10 Additional heat exchanger only for HPWH 300HE FD 9501 A-III

15 2.3 Hydraulic integration diagram Appendix 2.4 Legend 1 Shutoff valve 2 Pressure reducing valve 3 Test valve 4 Return flow inhibitor 5 Pressure gauge connecting stubs 6 Drain valve 7 Safety temperature pressure valve (PTR valve) There must be no shut-off device between the cylinder and the safety valve (PTR valve). The bleeding line/drain line of the valve must not be blocked 8 Circulation pump 9 Outlet * No connections for second heat generator required (i.e. no heating water flow and no heating water return flow) for hot-water heat pumps without internal heat exchanger The PTR discharge pipe is to be installed in a continuously downward direction in a frost free environment. The discharge pipe shall not be blocked. A pressure reducing valve set at 500 kpa must be fitted to the cold water inlet. A-IV FD

16 2.5 Heat Exchanger Integration Diagram for Thermal Solar Installation Appendix FD 9501 A-V

17 3 Circuit Diagrams 3.1 Last / Load Appendix A-VI FD

18 3.2 Control Appendix FD 9501 A-VII

19 3.3 Legend A2 B5 C1 C2 C5 E1 External bridge block Thermostat E1 Condenser compressor Condenser fan Suppressor capacitor Electric heater F1 Control fuse (230 V / 4 A) F2 High-pressure switch F3 Thermal contact, compressor F17 Safety temperature limiter E1 H1 Electric heater indicator lamp J1 Digital inputs / outputs (U=230 V) J3 Analogue inputs (screw terminals) K1 K2 K4 M1 M2 N1 R1 R3 R10 S1 Compressor load relay Starting relay for M1 Load relay for E1 Compressor Ventilator Control PCB Air intake temperature sensor Cylinder temperature sensor Defrost end sensor Electric heating "ON/STANDBY" switch Appendix X1 X2 X4 Y Mains plug Terminal strip 230 V Fan terminal strip Four-way valve Wired by the customer A-VIII FD

20 Appendix FD 9501 A-IX

21 Glen Dimplex Australia Pty Ltd 1/21 Lionel Road Mount Waverley, VIC ph: fax: Subject to alterations and errors.