Installation Manual Instrucciones de instalación y manual de usuario 1
Installation instructions and user manual V8 2
INDEX 1 GENERAL SAFETY WARNINGS... 4 2 OPERATING PRINCIPLE... 5 3 TECHNICAL FEATURES... 6 4 INSTALLATION... 8 5 USAGE RULES... 18 6 MAINTENANCE, REPAIR AND CLEANING... 20 8 TROUBLESHOOTING... 21 Installation instructions and user manual V8 3
1 GENERAL SAFETY WARNINGS To avoid any injury to the user as well as material damage, the following instructions shall be followed. Incorrect operation due to ignoring these instructions may cause damage and invalidate the warranty. The installation is the responsibility of the purchaser. Read the information supplied with the equipment carefully before installing and using it. The manufacturer declines any responsibility as regards damages deriving from an incorrect installation and a failure to follow the instructions detailed here. Ask a suitably qualified installer to install this equipment as incorrect installation may cause gas and water leaks, electrical discharges etc. Do not install the equipment in the following places as they may bring cause malfunctioning of the equipment: areas with corrosive gases, factories where the electrical voltage experiences wide fluctuations, places with strong electromagnetic waves, places with inflammable materials or gases, other special environments. The electrical connection has to be carried out in accordance with that specified in the manual. It is vital to install the safety group and check that it is working properly. Sufficient space shall be set aside for installation and maintenance including the connections of pipes and wiring. The equipment shall always remain in a horizontal position during transport, transfer and installation. The support surface shall be flat, bear the weight of the unit and be ready for the installation of the unit without increasing noise or vibrations. Maintenance repairs and tasks shall be carried out by a professional technical service. An incorrect maintenance task or repair may bring about gas and water leaks, electrical discharges etc. Warning! Legionella disaffection in the existing cylinder. It is important that the existing immersion heater in the existing cylinder has a programmable timer added to it so that the immersion heater will be set to come on weekly and keep the temperature of the hot water to 65 degrees for at least 15 minutes. The main water should to be soft water. Hard waters (CaCO3 content >200 ppm) may produce obstructions due to the lime deposits inside the system. For hard water it is recommended to use a descaler in the hydraulic circuit. It is vital to install an appropriate filter in the hydraulic circuit. in order to prevent the entry of solid particles in the system which could damage it Alternatively the existing boiler may be used to raise the water temperature to 65 degrees for a minimum period of 15 minutes on a weekly basis. HEALTH & SAFETY: Care should be taken when moving any appliance. Check the weight before any lifting. This is for the safety of the installer and customer. Ensure the appliances and in particular the box are installed in a safe location and the mounting structure is adequate to withstand the additional loads. Take care when moving equipment to ensure there is no damage to the equipment or existing structure and fittings. Installation instructions and user manual V8 4
2 OPERATING PRINCIPLE The Green e-pack I is an innovative solution to cover the demand for domestic hot water in properties and houses that already have a cylinder installed. The system is extremely easy to install, as it connects to the water tank s flow and return connections and provides hot water continuously. This is a compact unit which includes all the elements of the heat pump as well as the inner heat exchanger. The built-in fan uses the air from inside the living space and transmits it to the water that pumps to storage cylinder. When leaving the air can be conducted to the outside via ventilators thanks to its connection. Installation instructions and user manual V8 5
3 TECHNICAL FEATURES TECHNICAL FEATURES- THE GREEN E-PACK I Mean thermal capacity (only thermodynamic) (W) 2000 Min to Max Mean power consumed (thermodynamic) (W) Voltage / frequency 300 to 500 230 V / I ph / 50 Hz Atmospheric temperature range (ºC) 0 to 45 COP range 2.5-7 Refrigerant fluid R134a DHW temperature range with thermodynamics (ºC) 55 Dimensions (height x width x depth) (mm) 645mm x 425mm x 345mm Maximum working pressure (bar) 8 Cold water input connections (") /Hot water output connections (") 1/2-1/2 Power Fan (W) 45 Installation instructions and user manual V8 6
Fig. 1 DESCRIPTION SCHEMATIC GREEN E-PACK (upper view) A. Water outlet 1/2 B. Water inlet 1/2 C. Condensate drain pipe D. Temperature probe E. Electric connection Installation instructions and user manual V8 7
4 INSTALLATION Order of assembly The installation is carried out in accordance with the steps detailed below: 1. Green e-pack Fitting 2. Hydraulic connections 3. Exhaust air connection 4. Temperature Sensor 5. Electrical connections 6. Draining of the hydraulic circuit 7. Turning the system on 4.1. GREEN E-PACK FITTING Siting location Before proceeding with the installation of the unit check that the place where The Green e-pack will be placed has: Sufficient space for the electrical and hydraulic connections. This apparatus is designed for assembly in horizontal position and should not be installed in any other position. The equipment shall not be installed in an environment with potential exposure to corrosive gases, factories where the electrical voltage experiences major fluctuations, places with sources of electromagnetic waves, inflammable materials or gases or other special environments. Minimum volume required for the room is 21m3 allowing air recycling. It is not recommended the installation in places with risk of icing. The maximum distance between the Green e-pack and the existing water cylinder is 8 metres. Using an 18mm minimum pipe size and having no more than, 10 elbows, 2 T connectors and 4 valves. It is recommended that the minimum number of accessories is used (elbows etc) and that the Green e-pack is placed as close to the existing cylinder as possible in order to provide optimum system performance. It is recommended that the Green e-pack is fitted at least 20cm below the water level of the water cylinder. This is a precautionary measure to avoid air lock in the pump. On vented systems an AAV (Auto Air Valve) should be positioned to avoid risk of air in the pump. If installed above the cylinder an additional water pump may be installed between the cylinder outlet and Green e-pack inlet of not less power than the 45w pump installed in the Green e-pack. Installation instructions and user manual V8 8
This is to avoid gravity removing the water from the pump. The pump must be suitable for sanitary hot water. Additionally a second automatic air vent may be required to be between the cylinder outlet and Green e-pack inlet, close to the inlet. Sanitary hot water outlet is always recommended to be above the water feeding to the Green e- Pack Handling when moved The equipment must be transported and moved in an upright horizontal position and should never be turned over or put sideways. Should this happen then we recommend leaving the unit in the horizontal position for 24 hours before installing. We also advise to proceed with caution. During the unloading and movement of the unit the instructions in this manual shall be strictly followed with a view to ensuring the safety of the unit and people. Otherwise there may be a risk of injury or material damage. Incorrect installation or procedures may invalidate the warranty. During its handling care should be taken to ensure it shall not be submitted to sudden movements or blows, in order to avoid damage. Installation The installation should be carried out in accordance with the steps detailed below: 1/ Anchor the plate to a suitable solid wall with four M8 screws. A vibration pad may be required if fixing to an internal partition wall. 2/ Carefully, insert the Green e-pack into the plate through the gaps. Fig. 2 Green e-pack I Fitting 1/ 2/ Installation instructions and user manual V8 9
4.2. HYDRAULIC CONNECTIONS The Green e-pack has a mains water inlet and hot water outlet located on the bottom part of the box (see Fig1 ). The minimum pipe size of the hydraulic circuit is 18mm Ensure the pressure of the hydraulic circuit is at least 1kg (see Fig 8, pressure gauge) It is responsibility of the installer to put in T connections in the water inlet and water outlet connections of the cylinder / buffer tank. The installer should assemble the proper filter, pressure guage, draining element, expansion vessel and security group according to the scheme showed in fig 8, 9 and 10. It is recommended to fit the Green e-pack at least 20cm below the water level of the water cylinder. Sanitary hot water outlet should always be above the water feeding the Green e-pack. Flexihose pipes should not be used as they restrict the water flow. A non-return valve must be installed. In a vented system ensure that the water pressure is sufficient to open the valve otherwise air may be sucked into the system. In these circumstances a flap style valve may be suitable. The hydraulic system will vary dependant on the existing type of cylinder/buffer tank. The following figures show the steps for installing buffer tanks with two connections, and two or more connections: Do not fit the pipes to an existing coil in the cylinder, this will stop the Green e-pack reaching maximum temperature. Installation instructions and user manual V8 10
FLOW RATE VARIATION PLOTTED WITH DISTANCE Assuming no more than 10 elbows, 2 T connections and 4 valves Length (m) Q (m3/h) Q (l/s) 0.5 2.3 0.639 1 2.14 0.594 1.5 2.02 0.561 2 1.91 0.531 2.5 1.83 0.508 3 1.75 0.486 3.5 1.68 0.467 4 1.62 0.450 4.5 1.57 0.436 5 1.52 0.422 5.5 1.48 0.411 6 1.44 0.400 6.5 1.41 0.392 7 1.37 0.381 7.5 1.34 0.372 8 1.31 0.364 Fig 3. T connection on water pipe from cylinder leading to Green e-pack inlet Installation instructions and user manual V8 11
Figure 4. Installation in tanks with 2 connections Green e-pack It is recommended to fit Green e-pack below water level in the cylinder, 20 cm at least Installation instructions and user manual V8 12
. Figure 5 Installation in tanks with 2 or more connections It is recommended to fit Green e-pack below water level in the cylinder, 20 cm at least Installation instructions and user manual V8 13
It is recommended to fit Green e- Pack below water level in the cylinder, 20 cm at least Installation instructions and user manual V8 14
4.3. EXHAUST AIR CONNECTION In the top of the equipment is located the connection to the exhaust air, to connect with a 120 mm elbow and the exhaust duct, not exceed a pressure drop of 50 Pa. FIGURE 7 AIR DUCTS (Where appropiate) Accessory Maximum duct lenght - 6 m 1 elbow 90ºC 5 m 2 elbow 90ºC 4 m 3 elbow 90ºC 3 m 4.4. TEMPERATURE SENSOR Attach the supplied temperature sensor to the cylinder / accumulator tank. It is recommended to place it on the middle of the cylinder / tank. The wire can be extended on installation if required. It is recommended to follow the manufacturer's instructions, which indicate the location and method of installation of the probe 4.5. ELECTRICAL CONNECTIONS The equipment shall be connected to the electrical system when all the refrigerant connections have been made. The power supply is single phase: 230V / 50Hz with earth connection. The electrical schematic of the equipment has been shown in the following figure: Installation instructions and user manual V8 15
Fig. 8 WIRING DIAGRAM Installation instructions and user manual V8 16
4.6. DRAINING OF THE HYDRAULIC CIRCUIT Once the installation is complete the water cylinder should be checked to ensure that it is full of water and free from air. Open the valves and hot water taps in order to remove any air from the circuit. Wait until all air is drained. Close the valve No1 (Fig 8 and 9) and keep the taps open. Wait until all air is drained. Open the valve No1 (Fig 8 and 9) and close the tap. 4.7. TURNING THE SYSTEM ON The Green e-pack may be started once the steps described previously have been completed. To turn the Green e-pack on, connect to the electrical system The Green e-pack, once connected, shall operate automatically thanks to the digital controller which shall start up when the temperature falls below the prefixed value. Fig. 9 Control panel scheme Installation instructions and user manual V8 17
5 USAGE RULES 5.1. TEMPERATURE ADJUSTMENT The digital thermostat of the equipment marks the temperature of the water at any time. This thermostat is preset at 55ºC. - To view the set point temperature of the compressor, press the SET button. To modify the adjustment temperature leave the SET button pressed for 7 seconds, SP be displayed. Using the buttons with the arrow pointing upwards / downwards we can increase / reduce the set point temperature. Once set, press the set button again. The temperature range is from 20 to 55ºC. Press ESC to cancel. The compressor will raise the temperature to 55C when it will cease working. It will automatically cut in to raise the water temperature once it falls to 50C. WARNING: The programmed temperature for the compressor should never exceed 55ºC Fig.10 Digital thermostat scheme. OPERATING: DESCRIPTION SET BUTTON UP BUTTON DOWN BUTTON ACTION Keep pressed down for 7 seconds to change the operating temperature of the compressor Increases the temperature Decreases the temperature COMMENTS The temperature of the compressor is pre-set at 55 C Never exceed 55 C. Installation instructions and user manual V8 18
Once the temperature is set; press the SET key again To modify the temperature follow the instructions in diagram 11. Fig. 11 Operating the digital thermostat Installation instructions and user manual V8 19
6 MAINTENANCE, REPAIR AND CLEANING WARNING. Follow the general warnings and safety rules listed at the start of the text carefully, paying due attention to everything which is indicated. All maintenance operations and interventions shall be carried out by qualified staff. Check that any operating failure does not depend on other causes such as, for example, a temporary lack of water or electrical energy. The siting of the unit must be dry, clean and well-ventilated. Any inspection or work must be carried out by authorized installers checking: - The proper operation of the installation, the regulator and the safety devices. It is vital to empty the apparatus if it has to remain out-of-use for a prolonged time period. Where necessary, empty the apparatus as indicated below: - disconnect the apparatus from the electrical system; - turn off the stop cock of the domestic installation; - turn on the hot water tap (sink or bath); If the installation is in a hard water area limescale may be deposited inside the system. In this situation it is recommended that a descaler is included in the hydraulic circuit and periodic inspections made to ensure the cleanliness of the system. Installation instructions and user manual V8 20
8 TROUBLESHOOTING First of all, it is recommended to check the gas pressure of the system. Measure the evaporation pressure and ensure that the respective evaporating temperature is 10-15ºC below the ambient temperature. Problems Causes Solutions Lack of power Check the power supply Check that the power switch is on The screen doesn t show any information High Pressure switch is on Check the R134a load Check that the pressure switches function properly Screen error Check that the screen functions properly Incorrect gas load Check the R134a load The system starts and stops, the screen switches off Obstruction in the hydraulic circuit High Pressure switch is on Non condensable gases in the refrigeration circuit Verify the cleanness of the hydraulic circuit Check that the pressure switches function properly Lime deposits inside the hydraulic circuit: Change the filter of the hydraulic circuit and clean the whole system Check the proper working of the water pump, draining any air that is inside Check the R134a load Empty the refrigeration circuit E1 error appears on screen Temperature probe Check the temperature probe connection Check the continuity of the probe using a multimeter AE error appears on screen Low pressure switch is open Gas leak: Check for leaks in the refrigerating circuit Check water pump for air and drain accordingly Check the R134a load Installation instructions and user manual V8 21
Problems Causes Solutions The water is cold and the compressor is working Incorrect gas load Adjustment of the water temperature The temperature sensor is disconnected to the cylinder The hydraulic circuit is not isolated properly Check the R134a load Check the temperature adjustment on screen Check the right placement of the temperature sensor inside the cylinder Check the proper isolation of the hydraulic circuit and the cylinder The water temperature is slow to recover Refrigerant Leak or Load Poorly Insulated Tank Check for leaks. If pipe run over 8 metres extra refrigerant must be added Add insulation Installation instructions and user manual V8 22
Energy Panel S.L. Ctra. Lucena-Loja, km. 1,7 Teléfono: 957 50 95 37 Fax: 957 50 24 41 Apdo. de correos 184 14900 Lucena (Córdoba) ESPAÑA contacto@energypanel.es Installation instructions and user manual V8 23