Installation and Operating Manual

Transcription

1 Installation and Operating Manual Heat Pump for Cooling of Domestic Water with Airduct Connection KWP FD84

2 TABLE OF CONTENTS. Regulations / Safety Notices 3 2. Description 4 2. Refrigeration Cycle Water Circuit Safety and Control Devices 5 3. Storage / Transport 6 3. General Requirements 6 4. Installation 6 4. Installation Site Installation 7 5. Mounting 7 5. Connection of Water Piping Electrical Connection 8 6. Commissioning 8 6. Domestic Water Circuit Operation of the Heat Pump for Cooling of Domestic Water 9 7. Maintenance / Service 0 7. Water Circuit Air Circuit Sacrificial Anode 8. Malfunctions / Troubleshooting 2 9. Decommissioning 2 0. Environmental Requirements 2 Page. APPENDIX. Refrigeration Cycle with Legend 3.2 Hydraulic Plumbing Diagram 4.3 Circuit Diagram 5.4 Technical Data 6 (HPCDW = abbreviation used in the following for Heat Pump for Cooling of Domestic Water) 2

3 . Regulations / Safety Notices ( This installation and operating manual must be read prior to starting up the unit! ) ¾# The heat pump for cooling of domestic water (short: HPCDW) is designed exclusively for the cooling (in part also for the heating) of domestic or potable water within the specified operating temperature limits! The cooling (or heating) of liquids other than drinking water is not permissible. The technical regulations for the drinking water installation (DIN 988) must be adhered to. ¾# The air supplied to the unit should not exceed a temperature of +45 C. The energy-efficient operation of the heat pump decreases as the air temperature increases. ¾# The following is not permitted: - operation using exhaust air posing an explosion hazard or containing solvents - use of exhaust waste air laden with grease, dust or sticking aerosols - connection of exhauster hoods to the ventilation system ¾# The unit must not be installed: - outdoors - in rooms with a danger of freezing - in wet rooms (e.g. bathrooms) - in room with an explosion hazard due to gases, vapours or dust ¾# The operation of the unit is not permitted: - with empty storage tank - during the construction phase ¾ ¾ In the design and construction of the HPCDW all relevant EC directives were complied with. (See also EC Declaration of Conformity.) The qualified expert must ensure that prior to the commencement of any maintenance/repair activities on refrigerant-carrying parts, the refrigerant has been removed to such an extent as necessary for the safe performance of this work. The refrigerant must be handled and disposed of in accordance with applicable regulations and must not be released into the atmosphere! (Refrigerant R34a is CFC-free, non-flammable and has no ozone-depleting properties.) ¾# When working on the HPCDW, the unit must always be disconnected from the power source. ¾# The electrical connection of the HPCDW must be performed according to and conforming with all relevant VDE, EN and IEC standards. Beyond that, the technical connection requirements of the local utility company have to be observed. Caution! Any work on the cooling/domestic water heat pump may only be performed by qualified persons! All relevant accident prevention regulations have to be observed! 3

4 2. Description The HPCDW is a domestic water cooling unit ready for connection and essentially consists of a domestic water tank, the components of the refrigeration, air and water circuits as well as all control, regulating and monitoring devices required for automatic operation. In accordance with the heat pump's principle of operation, unwanted heat is extracted from the domestic water and then transferred to the discharged outlet air. The unit is equipped as standard with an electric immersion heater (.5 kw) which enables domestic water to be heated (up to a temperature of max. 85 C) (heating function). 2. Refrigeration Cycle (Heat Pump Principle of Function) The refrigeration cycle is a closed system in which the refrigerant R34a circulates as an energy carrier. In a tubular evaporator wrapped around the domestic water tank, heat is extracted from the domestic water at a low evaporation temperature and transferred to the refrigerant. The vaporous refrigerant is drawn in by an electrically driven compressor and compressed to a higher pressure/temperature level and then passed to the condenser (fintype heat exchanger), where the heat that is absorbed in the tubular evaporator and part of the heat of the compressor motor is transferred to the drawn-in exhaust air. Subsequently, the high condensing pressure is reduced by means of a throttling device (expansion valve) to the level of the evaporating pressure, and the refrigerant can again absorb heat from the domestic water tank via the tubular evaporator. 2.2 Water Circuit The water circuits of the HPCDW are to be field-installed (by the customer). The water connections (Fig. ) are located at the rear of the unit. Ø Ø60 Domestic Brauchwasserzulauf water supply external R" Außengewinde thread R Domestic water outlet tap external Brauchwasserentnahme thread R R" Außengewinde Fig. : Water connections

5 2.3 Safety and Control Devices The HPCDW is equipped with the following safety features: 2.3. High-pressure pressostat (HD) The high-pressure pressostat protects the heat pump from excessive operating pressures in the refrigeration cycle. In the case of a malfunction, the pressostat switches off the heat pump; the heat pump is restarted automatically as soon as the pressure in the refrigeration cycle has dropped to an acceptable level Safety temperature limiter for immersion heater (STL) The STB protects the hot water installation from excessive temperature increases. When the preset switching value (99 C) is exceeded, the immersion heater is switched off. The immersion heater cannot be restarted unless the hot water temperature has fallen to 90 C and the reset button (Fig. 2) on the STB has subsequently been pressed (may be performed by qualified personnel only!). Reset button B3 F2 Partition STB Fig 2: Resetting STL Panel Temperature controller for immersion heater (TC) The temperature controller for the immersion heater controls the temperature of the water for domestic use during the immersion heater mode of operation. The maximum temperature of this controller has been factory-set to 65 C (the controller is installed with the STL in a common casing). The temperature setting can be changed with the aid of a suitable tool (see Fig. 2). Changing this setting may be performed by qualified persons only! In the immersion heater mode, which can only be turned on manually, the domestic water is heated up to the preset maximum temperature of the immersion heater Temperature controller of HPCDW Temperature control in the domestic water storage tank and the control of the compressor operation is taken over by the temperature controller. The latter senses the water temperature by means of a sensor and regulates it as a function of the preset setpoint. The desired temperature level (setpoint) can be adjusted via the dial on the operating panel. 5

6 3. Storage and Transport 3. General Requirements As a rule, the CWP is to be stored or transported in its shipping box in upright position and without water charge. For a transport over short distances, and provided due care is exercised, an inclination angle of up to 45 is permitted. Both during transport and storage, ambient temperatures of -20 to +60 C are permissible. 3.. Transport using a forklift (or lift truck) When transported by a fork lift, the HPCDW must remain mounted on the pallet. The lifting rate should be kept to a minimum. Due to its top-heaviness, the HPCDW must be secured against tipping over. To prevent any damage, be sure to place the HPCDW on a level floor Manual transport For the manual transport, the wooden pallet can be used for the bottom part. Using ropes or carrying straps (which can be placed around the jacket of the storage tank and secured to the water tube nipples), a second or third handling configuration is possible. With this type of handling (applies to the transport by hand truck as well), care must be taken that the max. permissible inclination angle of 45 is not exceeded (see Figure). If transport in an inclined position cannot be avoided, the HPCDW ("heat pump" switch) should be taken into operation one hour after it has been moved into final position at the earliest. Caution! Do not lift the unit by its cover (the cover is not designed to withstand the weight of the unit!) Fig. 3: Transport of the unit Installation 4. Installation Site CAUTION! ¾# The HPCDW must be sited in a dry and freeze-proof room, the room air temperature and/or the air taken in by the HPCDW must be within a temperature range of 20 C to 45 C (required for heat pump operation). ¾# In addition, the unit must not be installed in rooms where there is an explosion hazard due to gases, vapours or dust. ¾# The air drawn in must be not excessively contaminated or heavily laden with dust. ¾# The floor surface must have adequate load bearing capability (the estimated HPCDW weight is 400 kg when fully loaded!). For trouble-free operation as well as for the performance of maintenance and repair work, provide clearance of at least 0.6 m all around the unit, furthermore, a minimum ceiling height of approx m is required for operation without airducts or airduct elbows ( "free-blowing installation ) (see Fig. 4). The connection to the HPCDW is effected (optionally) by means of airducts (NW 60) which must not exceed a total length of 0 m. 6

7 If the ceiling is lower and no airducts are used, an air ducting elbow (90 NW 60) must be used on the outlet air side (to ensure effective operation). When an air ducting elbow is used, care must be taken that it is slipped onto the flange collar of the discharge side in such a way that the discharge opening of the air ducting elbow is as far away from the intake opening of the unit as possible. Moreover, the minimum clearances shown in Figure 4 have to be complied with. The air connection fittings, i.e. "intake pipe" and "discharge pipe", of the HPCDW are identified by adhesive labels. ca. approx. 2,5 m 2.5 (ohne m (without Luftschläuche airducts und and Luftführungsbogen) air ducting elbow) approx. ca. 2,0 2.0 m m discharged ausgeblasene air Luft,2 * m angesaugte drawn-in air Luft 0,6 m * the minimum distance of the discharge opening of the air ducting elbow to the wall is.2 m The minimum ceiling height for "free blowing installation" is approx. 2.5 m Fig. 4: Installation requirements 4.2 Installation ¾ From the underside of the pallet, remove the three M2 bolts securing the pallet to the unit as a shipping safety measure. ¾ Remove the pallet and mount the three levelling feet (M2 bolts contained in the polybag, secured to the storage tank pipe nipple). ¾ Move the HPCDW into final position and adjust the unit so that it is perfectly perpendicular by adjusting the levelling feet! Subsequently, tighten the check nuts provided on the levelling feet. 5. Mounting 5. Connection of Water Piping The nominal pipe widths of the field-installed sanitary installations must be determined on the basis of the available water pressure and the expected pressure losses within the piping system. The water-side installation has to be executed in compliance with DIN 988 (see appendix in the case of excessive water pipe pressure, a pressure relief valve is to be provided, among other things!) The water pipes may be of the rigid or flexible type. To prevent corrosion damage, make sure that the materials used in the piping system are compatible (see section Commissioning). Caution! When installing the pipework on the customer's site, any contamination of the piping system must be avoided (pipes may have to be flushed prior to the connection of the HPCDW)! 7

8 5.2 Electrical Connection The HPCDW is pre-wired, ready for connection, the power is supplied via the mains cable connected to a socket with earthing contact (GB: "Home Office socket") (~230 V, 50 or 60 Hz). This socket must be accessible also after the installation has been completed. 6. Commissioning 6. Domestic Water Circuit Caution! The HPCDW may only be operated with the unit filled with water! 6.. Water circuit requirements On the consumer side, the following materials may be incorporated into the water circuit:  copper  stainless steel  brass  plastic Depending on the materials used in the hot water circuit (installation to be provided by the customer), corrosion damage may occur due to material incompatibilities. This must be taken into account, in particular where galvanised materials and those containing aluminium are used. A filter may have to be provided if there is a danger of the water being contaminated during operation Commissioning of the domestic water system All installations at the water and air circuits as well as all electrical installations must have been properly executed and completed. Fill water circuit via external connection. The domestic water tank must be filled from below, i.e. via the domestic water outlet tap (see Fig. and hydraulic plumbing diagram in the appendix)! (during operation, the top-up water enters the domestic water tank from the top). Bleed the domestic water circuit (open water taps at the topmost points of use until no more air escapes, or open air bleed cocks in the water circuit to be provided by the customer). Perform a leak test of the entire domestic water circuit. Connect the unit to the power supply. Turn on the "heat pump" switch (Fig. 5). The desired domestic water temperature is continuously adjustable (6-25 C) by means of a temperature selector dial (Fig. 5). An appropriate time period (cooling period) must be allowed for until the selected temperature level is reached. 8

9 6.2 Operation of the HPCDW 6.2. Operating panel Temperature display The sensor of the thermostat (analog remote thermometer with trend display) senses the domestic water temperature at the middle part of the water tank. The display is located on the operating panel. Temperature display blue 20 C red 35 C 70 C In the I switch position, the immersion heater is switched ON, in switch pos. the immersion heater is switched OFF "Immersion heater" switch Switch position O Æheat pump is OFF, in switch position the heat pump is in operation. "Heat pump" switch Fig. 5: Operating panel Temperature display Temperature dial for domestic water (setpoint transmitter) left stop Æ lowest cooling temperature (6 C) right stop Æ low cooling temperature (25 C) "Domestic water temperature" dial 9

10 6.2.2 Domestic water temperature controller (dial) The desired domestic water temperature level can be adjusted using the selector dial (an adjustment accurate to within one degree is not possible) 'Heat pump' switch If the 'heat pump' switch is placed in position (On), the heat pump is ready for operation. When the domestic water temperature inside the tank rises above the preset setpoint, the heat pump cooling function is activated until the desired domestic water temperature is reached. Note If the 'heat pump' switch is placed in position (heat pump mode), it is not possible to activate the immersion heater (selecting the 'immersion heater' switch position will have no effect) 'Immersion heater' switch The integrated.5 kw heating element can be activated by means of the 'immersion heater' switch when there is a demand for hot water or a preset hot water temperature level is to be reached. When the 'immersion heater' switch is in position " I ", the tank content is heated up to the maximum temperature of the immersion heater controller (factory setting 65 C). In switch position the immersion heater is switched off. Note If the 'immersion heater' switch is in position " I " (heating mode), the heat pump cooling function is deactivated until the 'heat pump' switch is placed in position. Note Immersion heater controller The factory-set switch-off temperature of 65 C can be changed by a qualified expert (see item 2.3) 7. Maintenance / Service CAUTION! Prior to opening the HPCDW, the unit must be disconnected from the power supply; be careful of fan that may still be rotating! General ¾#The heat pump for cooling of domestic water is nearly maintenance-free. A few days following the commissioning procedure, a visual check for possible leaks in the water system is to be performed once. ¾#No maintenance activities need to be performed on the refrigeration cycle of the heat pump. ¾#For cleaning the HPCDW, simply use a damp cloth and some soapy water. Caution! Do not allow water to come in contact with the operating controls. Prior to commencing the cleaning procedure, withdraw the mains plug or disconnect the unit from the power supply. 0

11 7. Water Circuit The inspection of the water circuit is limited to any filters that may have been field-installed, and the performance of leak tests. Dirty water filters have to be cleaned and replaced, if necessary. 7.2 Air Circuit The maintenance activities are limited to cleaning the fin-type heat exchanger (only) as required. Caution! Hazard of injury from sharp-edged fins. Fins must not be distorted or damaged! If air filters are used, these must be regularly checked for contamination and to be cleaned or replaced, if necessary. 7.3 Sacrificial Anode The sacrificial anode installed in the domestic water tank for corrosion protection purposes, must be checked electrically on a regular basis, at least every two years after commissioning, and be replaced, if necessary. The electrical check is to be conducted by means of a suitable ammeter without draining the water in the tank. Procedure: n o p Withdraw PE wire from tab of sacrificial anode. Connect ammeter ( ma) between PE conductor and tab. Evaluation of wear of sacrificial anode: Measured value > ma sacrificial anode is okay. Measured value < ma sacrificial anode must be checked or replaced. If an unambiguous electrical check is not possible, it is recommended that a visual inspection by an expert be performed. (For a replacement of the sacrificial anode that may be necessary [to be performed by an expert], the water must be drained from the tank via the drain valve (to be provided upon installation see appendix). Caution: Protective anodes that are impaired in their function will reduce the life of the unit! The sacrificial anode is screwed into the storage tank below the immersion heater (covered with a plastic cap) Fig. 6: sacrificial anode

12 8. Malfunctions / Troubleshooting ( only for the user ) Caution! Arbeiten an der Kühl-Brauchwasser Wärmepumpe dürfen nur von sachkundigen Personen ausgeführt werden! Unfallverhütungsvorschriften sind zu beachten! Heat pump fails to run! Please check whether Ö the plug is plugged in Ö the control switch is in the OFF position Ö voltage is present at the socket Ö the heat pump has been switched off by the temperature controller Ö the domestic water temperature has already reached (or is less than) 8 C Heat pump switches off prematurely (setpoint temperature has not been reached yet) Please check whether Ö Ö airducts are kinked or their openings are closed, or air filters that may be provided are severely contaminated (clogged) the temperature of the intake air lies above the permissible limit value (45 C) If the malfunction cannot be corrected based on the above questions, please consult your installer or customer service. 9. Decommissioning Activities to be performed: Disconnect HPCDW from the power source. Completely shut off water circuit (supply and drain sides) and drain hot water storage tank. 0. Environmental Requirements Environment-relevant requirements regarding the recovery, reuse and disposal of service fuels and components in accordance with DIN EN 378 must be adhered to when repairing or decommissioning the HPCDW. 2

13 . Refrigeration Cycle with Legend 3 4 PA-CO-H TI 9 8 TI -CO-H -C I -L TI-CO-H 5 6 TC 2 7 TI -CO - L -C I - H freie free immersion Tauchhülse sleeve 3 6 Compressor 8 Safety temperature limiter 5 Non-return valve 2 Pressostat HP 9 Temp. controller immers. heater 6 Insulation 3 Evaporator 0 Temperature display 4 Hot water tank Filter drier 5 Immersion heater 2 Expansion valve 6 Corrosion protection anode 3 Condenser 7 Temperature controller HP 4 Fan 3

14 .2 Hydraulic Plumbing Diagram Wasserzulauf water supply water Wasseranschluß connection acc. nach to DIN domestic Brauchwasserentnahme water outlet tap filling Befüllung 8 Shut-off valve 6 Draining and filling valve 2 Pressure reducing valve 7 Diaphragm safety valve 3 Test valve (to be mounted above tank edge) 4 Check valve 8 Drain 5 Manometer connection 4

15 .3 Circuit Diagram Wärmepumpe Heat X3 L N PE Ventilator Fan Compressor Verdichter B T > C 2 4 el. Elektro Immersion - Heizstab heater S2 2 X K3 4 K L/N/PE 230VAC 50Hz ( C ) Legende S 2 B3/ F2 +65 C TR T > STB +99 C 2 B Operating Betriebsthermostat thermostat, WPheat pump B3 Regulating Regelthermostat-El.Heizung thermostat, el. heating C Starting Anlaufkondensator-Verdichter capacitor, compressor C2 Operating Betriebskondensator-Ventilator capacitor, fan E El. El.Heizstab immersion heater F HP HD-Pressostat pressostat F2 Safety Sicherheitsbegrenzer-Thermostat limiter thermostat, el. heating F3 Klixon, El.Heizung compressor K2 F3 Starting Klixon-Verdichter relay, compressor K2 K3 All-or-nothing Anlaufrelais-Verdichter relay, HP pressostat K3 M Compressor Schaltrelais HD-Pressostat M Verdichter M2 Fan M2 Ventilator S "ON/OFF" switch, heat pump S Schalter "EIN/AUS" Wärmepumpe S2 S2 "ON/Off" switch, el. heating Schalter "EIN/AUS" El.Heizung X X Mains Netzstecker plug X3 X3 Terminal Klemmleiste strip, intern internal M2 M X3-3 schwarz black F3 C P M grün/gelb green/yello A M C2 C L PE N 0 (bn) K2 (bl) 4 F 2bar P > 2 E 2 22 X3-2 X3- K3 A A2

16 .4 Technical Data Heat pump for cooling of domestic water KWP 300 Type compact unit Nominal tank capacity ( litres) 300 Tank material enamelled steel acc. to DIN 4753 Nominal tank pressure ( bar ) 0 Dimensions ( height x width x depth [without tube connections] ) ( cm ) 69 x 66 x 66 Weight ( kg ) approx. 0 Electrical connection ( plug-in device cable length approx. 2.7 m ) 230V ~ 50 or 60 Hz Fusing ( A ) 6 Refrigerant R 34a, charge weight ( kg ).0 Performance data Temperature, operating range (air) ( C) 20 to 45 Water temperature, selectable (heat pump mode) ( C ) 6 to 25 Heat-up time from 25 C to 65 C (electr. immersion heater) ( h ) 9.2 Power consumption, electric heating ( watt ) 500 Average power consumption ) at 45 C (at 60 Hz) ( watt ) 850 Average cooling capacity ) at 45 C (at 60 Hz) ( watt ) 450 Cooling-down time from 45 C to 20 C ) ( h ) 6.5 Air flow rate: ( m 3 / h ) 585 External pressure ( Pa ) 0 Maximum airduct connection length (total) ( m ) 0 Airduct connection, diameter ( mm ) 60 Connection domestic water outlet external thread R Connection domestic water supply external thread R ) The cooling process of the nominal tank content from 45 C to 20 C at an air intake temperature of 35 C

17 KKW Kulmbacher Klimageräte-Werk GmbH Subject to technical changes Department Dimplex Fax (0 92 2) Am Goldenen Feld 8 D Kulmbach 7