INSTALLATION MANUAL 1. Introduction 1.1 Product description 1.2 General Notes 1.3 Parts List 1.4 Receipt and Handling of goods 1.5 Health and Safety 1.6 Assessing of System Suitability 1.7 Technical Survey 1.8 System description 1.9 Hydraulic functionality 2. Bunsen Air Technical Data 3. Heat Pump Unit Installation 3.1 Installation Location of the heat pump unit 3.2 Mounting the Heat Pump Unit 3.3 Fixing the triangular mounting brackets 3.4 Fix the Bunsen Air onto the mounting brackets 4. Solar panel installation 4.1 External Panel location 4.2 Solar panel minimum pitch 4.3 Solar panel Orientation 4.4 External Solar Panel Connections 4.5 Solar Panel Fixing Points 4.6 Vertical Wall Installation 4.7 Pitched Roof Installation 5. Refrigerant pipe work and installation 5.1 Installation of refrigerant pipes 5.2 Pipework lengths must be equal 5.3 Pipework lengths and refrigerant pre-charge 5.4 Insulation of refrigerant pipework 5.5 System pressure testing 5.6 System Vacuuming 5.7 System Refrigerant Charging 5.8 Process for adding extra charge 6. Hydraulic installation 6.1 Hydraulic Functionality 6.2 Dip Pipe Assessment and installation 6.3 Hydraulic connections 6.4 Unvented Cylinder Installations 6.5 Vented Cylinder Installations 6.6 Refill system and purge water 1
6.7 Plumbing commissioning/purging 7. Temperature Sensor Installation 8. Electrical installation 9. Test and commissioning 10. Controller Functions 11. Maintenance 12. Trouble Shooting 13. Warranty 1.0 INTRODUCTION 1.1 Product Description The Bunsen Air unit is Solar Assisted Heat Pump designed to transfer energy from the free natural elements into hot water for domestic properties. The unit will retro-fit to existing cylinders, or newly introduced cylinders, and turn that cylinder into a heat store for renewable water heating. The system is made up of one heat pump unit, the Bunsen Air, and 2 solar collector panels which are mounted externally to the property. The system is designed to heat the hot water up to 55 C at all times, and up to 60 C once a week for anti-legionella. The unit is set to a default (can be adjusted) temperature of 55 C, when the temperature of the cylinder drops by 5 C the system will automatically switch on to raise the temperature back to the required set temperature. There are 2 time zone settings which can be activated to fix operation times each day if required. In addition there is an Energy Saving mode which will allow 3 time periods to be set up with 3 different target temperatures for use with a time zone setting or under automatic mode. The Bunsen Air will work in all temperatures (tested to -8 C), all weathers and day and night to generate energy in the form of hot weather. The Bunsen Air Solar Assisted Heat Pump has all the benefits of standard heat pump technology, based on low level power usage running for longer periods to generate low energy renewable heating of hot water. In addition to the standard heat pump technology is the use of the Solar Collectors, which as well as absorbing ambient air over its large surface area, benefits from thermal energy in the wind and rain, and especially solar gain from irradiation to generate significant additional levels of performance. 1.2 General Notes This manual is a guide to the installation and maintenance of the Bunsen Air. Please read this manual fully before commencing on any installation. Please read the manual of any other products you are using in conjunction with the Bunsen Air system to be sure of compatibility. Please note that Solamics, as the manufacturer, decline any responsibilities as regards damages deriving from an incorrect installation and a failure to follow the instructions detailed in the document. Any damage caused or 2
malfunction of systems which do not comply with this manual, any deviation from this manual will invalidate the guarantee. It is advisable to keep a copy of both this installation manual (and any other components provided) in an accessible place for any future reference. 1.3 Parts List L-shaped Brackets long x 3 Phillips Hex Head Screws x 8 Flange Nuts x 8 Phillips Self-tapping Screws x 10 Light Duty Finned Anchors x 10 Fused Spur 13A x 1 22mm Elbow x 1 22mm Equal Tee x 1 10-16mm Reducer x 1 9.52mm*250mm Brass x 1 22mm/10mm*35mm Adapter x 1 3/4 Non-return Valve x 1 Brass Fittings x 2 Lever Valves x 2 Fittings x 2 Brass Compression Ring x 2 Brass Inline Y Filter x 1 3/4 M22*200mm Flexible Hoses x 2 3/8 Brass Flare Nut Forged x 2 Anti-vibration mounts x 4 M5 Bolts x 5 3
1.4 Receipt and Handling of goods On receipt of the goods, all parts must be checked for damage. Do not sign for the goods until you have inspected the packaging for any defects which may indicate damage in transit. Any issues must be noted on the delivery note prior to signing, and the courier should sign also. Photographic evidence can prove very useful. Check all parts against the installation manual and your original order. Ensure that any extras identified in the installation survey have been ordered and are fully compatible with the Bunsen Air system. Bring the packed unit as close as possible to its final installation in the original packaging to prevent damage during transport. The Bunsen unit should The unit should be transported, handled and fitted in horizontal position. If it is ever turned on its side at any time, it should be returned to the horizontal position immediately, checked for leakages from the compressor, and left for at least 12 hours before switching the power on. 1.5 Health and Safety Only qualified engineers with necessary qualifications should install the Bunsen Air system. The system uses the ozone friendly R134a refrigerant and any installer should be accredited in the use of refrigerants and adhere to these practices. All safe practices should be employed according to the relevant accreditation criteria. Please ensure you have checked the weight of all components prior to handling or installing the parts. Ensure you have evaluated the structural strength of the installation location to assure it is able to support the additional loads. The Bunsen Air system is an electrical appliance which generates heat and incorporates refrigerant gas. It should therefore be kept out of the reach of children, or any persons who are unsuitable to interact with such an appliance. Improper installation of accessories and equipment could result in electric shock, short circuit leak, fire or other types of damage. Please ensure that any parts or components not supplied with your system are fully compatible and correctly installed. Protective clothing or equipment must be worn at all times for installation and servicing of the Bunsen Air units. Ensure that all packaging which has no further purpose, such as plastic wrapping, is correctly disposed of and the full installation area left in a clean and presentable state. Do not touch any parts or components which may become hot or cold due to the charging of refrigerants, forming of connections or running of the machine. Ensure correct protective clothing is used if this is necessary. Take preventative measures to ensure that the equipment is not attractive or accessible for animals to use as shelters or nesting. Ensure the integrity of the components at all times both before unpacking and after, make sure they are always stored in a safe and unobstructed place. 4
1.6 Assessing system suitability It is the responsibility of the purchaser to assess the suitability of the installation of the Bunsen Air system. Please contact the vendor if you have any questions regarding the suitability of the system. This is an electrical appliance which generates heat in the form of hot water and uses refrigerant gasses to do so. Therefore the installation location must be carefully considered. The Bunsen Air unit should be installed internally, and its location should be clear of any excessive temperature extremes, or any risk of impact or explosion. It is recommended to carry out a full risk assessment of the installation as recommended by the Health and Safety Executive prior to commencement. The intended user of the Bunsen Air system should also read and fully understand this installation manual. If any questions are not answered please contact your distributor directly to gain satisfactory explanation. 1.7 Technical survey For all installations a technical survey should be carried out prior to starting an installation. A thorough survey will cover all areas relevant to the installation. It is recommended to develop this survey into a form which is recorded as part of your installation process. Many additional areas can be introduced, however typical considerations are: Access details for the property Location of the Bunsen Air heat pump unit Confirm installation of the Bunsen is within 3m of the cylinder Structural integrity of the proposed location Record or description of the installation environment Cylinder type, suitability and existing system records Sound proofing of the installation area Electrical supply to the installation area Safety considerations of the installation area Distance and access of the flow/return to the panel Elevation from the Heat pump to the panels Siting of the external panel maximum distance 10m Assessment and plan of the refrigerant piping route Description/record of the proposed panel installation position Structural integrity of the proposed panel installation position Full risk assessment of the property and installation locations 5
2.0 BUNSEN AIR SYSTEM TECHNICAL INFORMATION BUNSEN AIR HEAT PUMP UNIT Please See Fig.1 Fig.1 Casing: 1.2mm Chassis Base: 1.5mm galvanized steel Insulation: Acoustic sound absorbing layer on Casing & Chassis Water pipework connections: 3/4" Compressor: Sealed hermetically, covered with an exterior layer to prevent heat loss and absorb unnecessary vibrations Refrigerant:1.0kg R134a- Tetrafluoroethane, global warming potential (GWP) 1430 Refrigerant circuit: New circulation circuit design to increase overall efficiency Heat exchanger: High performance steel shell & tube heat exchanger Pump: High rate potable water compliant Compact design with low noise level, suitable for indoor installations Controls: For full details of the benefits and features See the Bunsen Air Controller Manual Performance: Thermal power (Max.) 3500w Electrical input (Min.) 400w Water temperature 55 C (default setting, maximum temperature 60 C) Dimensions and Weight Height 380mm Width 480mm Depth 230mm Weight 34kg Connections Water inlet 3/4" Water outlet 3/4" Refrigeration inlet 3/8" Refrigeration outlet 1/4" Power supply 230V / 50Hz 6
Specifications Operating current (Max.) 13 A Refrigerant charge (R134a) 1.0kg Sound Level 45 db Operating pressure (Max.) 7 Bar EXTERNAL SOLAR PANEL Please see Fig.2 Finish: Powder coated aluminium solar collector Thickness: 2mm aluminium for increased mechanical strength Protection: Corrosion resistant and adaptability to all weathers Fixing Orientation: Can be installed in a landscape or portrait Fixing Points: Six fixing points per panel Installation Angle: Minimum of 10 degrees up to 90 degrees on vertical walls Connections Input Pipe Fittings: 1/4 Output Pipe Fittings: 3/8 Dimensions and Weight Height 2000mm Width 800mm Frame Depth XXXmm Weight 7kg 3.0 HEAT PUMP UNIT INSTALLATION Fig.2 3.1 Installation location of the heat pump unit The Bunsen Air Heat Pump unit should be installed internally. The unit is not designed for external installation. The Bunsen Air Heat Pump unit should be installed within 3 meters of the cylinder for maximum efficiency. The mounting position must be checked for structural suitability as well as sound or vibration emitting suitability. The installation location should be free from: obstructions around the unit for future servicing any risk of impact any risk of any flammable, corrosive or dangerous gases or items any risk of extremes of temperature risk of corrosive gases electromagnetic wave or devices which could disturb the functionality of the control unit damp or risk of water ingress 7
3.2 Mounting the heat pump unit (See Fig.3) Must be fitted vertically and must be correctly levelled. The Bunsen Air should be fixed to the supporting wall using the provided two triangular mounting brackets in the installation kit. Fig.4 Fig.3 3.3 Fixing the triangular mounting brackets (See Fig.4) (a) Ensure the supporting wall is structurally strong enough to support the weight of the Bunsen Air. (b) Check that the fixings provided are adequate for fixing to the chosen surface. If not use the correct type of fixings. (c) Drill 2 fixing holes on to the desired fixing location on the wall for each mounting brackets. Ensure that the gap to the centre of the brackets is 260mm as shown in the diagram. Place a plastic anchor bolt in each of the drilled holes. (d) Fix two triangular mounting brackets on to the wall using the 2 self-tapping screws on each one of the brackets. (e) Fix the Bunsen Air onto the brackets and secure with the provided bolts. 3.4 Fix the Bunsen Air onto the mounting brackets (See Fig.5) Using the provided fittings, secure the Bunsen Air unit to the triangular mounting brackets. Ensure the rubber Gaskets are well positioned as these will assist with reducing any vibrations from the heat pump unit. The brackets have slots to allow some adjustment on the positioning of the Bunsen Air on the brackets. The Bunsen Air must not be in contact with the supporting wall in order to limit any vibrations being transferred to the wall creating noise. ENSURE A GAP BETWEEN THE BUNSEN AIR AND THE SUPPORTING WALL 8
Fig.5 4.0 SOLAR PANEL INSTALLATION 4.1 External solar panels location Under testing the additional performance of the solar panels is not taken into consideration, however good siting of the panels can significantly add to the operating efficiency of the system. The panels will generate higher performance for the system based on: Ambient air temperature warmer locations Air Flow - so wind is a positive contributor Sunlight south facing gives optimum solar exposure Rain rain will contribute to warming the panel Wherever possible take advantage of natural free additional performance enhancement. There are no moving parts to the external solar panel, the only requirement is that the proposed location be structurally sound. Consider the distance and flow of the pipework needed to link the external solar panel to the internal Bunsen Air Heat Pump unit. This must be kept as short as possible both for operating efficiency and heat loss. THE MAXIMUM DISTANCE BETWEEN THE BUNSEN AIR HEAT PUMP UNIT AND THE EXTERNAL SOLAR PANELS IS 10 METERS (See Fig.6) 9
10m Max. Fig.6 External Solar panels can be installed in the landscape or portrait orientation. It is essential that the gas inlet/outlets are located at the lowest point. (See Fig.7) Incorrect installation of the panels can cause damage to the system and will negate the warranty. Fig.7 External Solar panels can be installed on pitched roofs or frames. It may be necessary to order some additional mounting parts, particularly when the installation location is on and existing pitched roof with a covering such as concrete tiles, slates etc. Discuss the best mounting for these roof types with your distributor. Where the solar panel is to be fitted on a vertical wall, the fittings provided should be sufficient. Always check the fixings you have are suitable for the material you are fixing to. 4.2 Solar panel minimum pitch The solar panels must be installed on a pitched angle. This is to ensure correct flow of the refrigerant. The panels must be installed at a MINIMUM pitch of 10 degrees, and can be put up to 90 degrees for vertical wall installations. Failure to install the panel with the required pitch will cause incorrect flow of refrigerants and lead to damage to working parts. The warranty will be void for such installations. ** SOLAR PANELS MUST NOT BE INSTALLED FLAT ON THE GROUND** A MINIMUM OF 10 DEGREES PITCH IS NEEDED 10
4.3 Solar panel Orientation (See Fig.8) Panels must be installed with the refrigerant pipes facing downwards for the panel for Landscape installations, and at the bottom for Portrait installations. Panels must be BOTH portrait or BOTH landscape. They must be at the SAME LEVEL to ensure the panels are equally supplied with pressure from the Bunsen Unit. Failure to install the panel with the pipework in the correct position will cause affect the flow of refrigerants and lead to damage to working parts. The warranty will be void for such installations. Correct (pipes downwards) Fig.8 Wrong (pipes up) Landscape Orientation Correct (pipes at bottom) Wrong (pipes at top) Portrait Orientation 11
4.4 Solar Panel Connections (See Fig.9) Pipework connections should be carried out by an accredited refrigeration engineer. (a) The external solar panel has a 1/4 male flare connection Liquid inlet and 3/8 male flare connection gas outlet that connect the panel to Bunsen Air. Connecting copper refrigeration pipework must be flared and secured using corresponding size of flare nuts. To help eliminate leaks, use refrigeration oil on the thread of the flare connections before tightening the flare nut. (b) The Liquid inlet has the ¼ pipework and is the single pipe inlet. The Liquid outlet is the double pipe outlet combined to the 3/8 connection fitting. Fig 9. 4.5 Solar Panel Fixing Points (See Fig.10) The Solar panels have six fixing points per panel. Use all six are used for all installations to fix the panels to any surface. Fig.10 12
4.6 Vertical Wall installation To fix the panel to a vertical exterior wall or structure, use the supplied L-brackets, nuts, bolts, fixing screws and plugs which are all supplied with the panel. Ensure that the fixings are fully suitable for use with the material you will fix to. If not change to the correct fixings. There are six fixing points per panel, and all six should be used when fixing a panel See Fig.10. Fix the L brackets to the solar panel as shown in Fig.11. Ensure the Bolts are fixed with the bolt head facing out. Fix and secure the thermodynamic panel to a wall as show in the diagrams below. Fig.12 Panel mounting One Fig.11 Panel mounting Panel mounting Three Panel mounting Four Panel mounting One Panel mounting Two Panel mounting Three Fig.12 Panel mounting Four 13
4.7 Pitched Roof Installation Where you are able to position the external solar panel onto a pitched roof you may wish to access some alternative non-penetrative solutions rather than screwing into the roof covering. Installations onto typical roof coverings such as Concrete tiles, slate and clay tiles may benefit from using roof hooks and a rail system to avoid drilling holes through the roof coverings and preserve the integrity of the roof covering. There are many solutions available so contact your supplier to discuss alternative roof mounting parts. 5.0 REFRIGERANT PIPEWORK AND INSTALLATION 5.1 Installation of refrigerant pipes All refrigeration work must be carried out by an accredited installer in accordance with EN378. Installation by a nonaccredited installer will negate the warranty. Use only the copper piping provided, or equivalent standard product. Lower grade product will affect the performance of the system. Do not loosen any service ports at this stage on the Bunsen Unit only after full leak testing and vacuuming has been carried out. The External Solar Panels have 2 fittings, the 1/4 male flare connection Refrigerant Liquid inlet and 3/8 male flare connection gas outlet line which can be seen in Fig.13 Show Liquid in and gas out and sizes. Fig.13 Connect the provided 3/8 copper refrigeration pipework to the solar panel using the provided Flare Nuts. Ensure that refrigeration oil is used on the thread in order to reduce the risk of leakage when tightening the flare nut. Connect the 2 pipe lines to the corresponding input/output ports on the Bunsen Air units using the fittings provided. The Bunsen Outlet must be connected to the Solar Panel Inlet. The Bunsen Inlet must be connected to the Panel outlet. 14
Fig.14 5.2 Pipework lengths must be equal Any liquid/gas will take the path of least resistance, therefore in order to ensure that the flow of the refrigerant around the panels is even, all pipework must be even. Y shape fittings are provided for connecting panels, using these fittings allows you to ensure the pipework is EQUAL IN LENGTH. (See fig.15 and Fig.16) FAILURE TO ENAURE PIPEWORK IS EQUAL DISTANCE WILL STOP THE SYSTEM WORKING CORRECTLY. Fig.15 Fig.16 15
5.3 Pipework lengths and refrigerant pre-charge PIPEWORK TO THE 2 PANELS MUST BE OF EQUAL LENGTH If pipework is not of equal length, or does not have equal resistance due to uneven installation, then the panels will not be equally supplied with refrigerant and the system will not perform correctly. The Bunsen air unit is pre-charged with R134a refrigerant for installs where the solar panel is up to 10 meters in distance from the heat pump unit. This means 20 meters of pipework 10 each for the flow and return. This distance can be increased up to a MAXIMUM of 15 meters (total of 30meters of pipework). In order to do this additional charge of refrigerant will need to be introduced to the system SEE INTRODUCING ADDITIONAL CHARGE. However it is important to note that increasing beyond the 10m distance will have an effect on the performance of the system. The longer the distance and the greater the load, the harder the pump and compressor will need to work. This increases the load on the power required to run the system, and makes the components work harder. In addition, the longer lengths of pipe runs will cause additional heat losses to the system. When running pipework between the Panel and the Bunsen take the most direct route, and where possible limit the need for bends in the pipework. Ensure that the pipes are securely located to avoid any chance of vibration or stress on any part of the pipework. Bends, vibration or stresses will all cause additional resistance to the flow, and therefore to the working performance of the system. All flow and return must have clear physical separation to ensure they do not come into contact with one another. 5.4 Insulation of refrigerant pipework (See Fig.17) Correct insulation of pipework reduces heat loss and ensures correct physical separation of the refrigeration pipes. Ensure that all pipework is fully insulated with flexible anti-condensation standard insulation. Failure to insulate pipe work will significantly affect the efficiency of the system. 16
5.5 System pressure testing When the refrigerant pipe connections are completed, the system must be fully checked for any leaks. This is done by introducing OFN (Nitrogen) to the system via the service ports shown in Fig.18 The Nitrogen should be supplied to the system to a pressure of 8 Bar. The system Pressure must not go above 10 Bar at any stage or the integrity of the system will be affected. During this process all connections must be fully checked for leaks. The system pressure must remain constant for a MINIMUM OF 45 MINUTES. If any leaks are detected then once rectified, the full pressure testing process must start again from the beginning. 5.6 System vacuuming This is a critical part of the process. Ensure this is carried out as a minimum to the standards and timings provided in the manual. Failure to do so will result in early failings of components which will clearly show deterioration due to insufficient Vacuuming which will negate the warranty. Moisture evacuation must be recorded to a minimum of 2 Torr. Photographic evidence of gauge levels is recommended. Ensure that all connections, vacuum pump and gauges are correct for use with R134a fluid. Having fully tested for leaks in the system, the system can be vacuumed. This is done using the relevant vacuum which is attached to the service port shown in diagram below Fig.18 Keep the stop valves closed Fig.18 Connect the hose from the vacuum pump to the 3-way valve Create a vacuum with the pump connected to the pressure tap to the 3-way valve (for 30 minutes) until a value of -1bar has been attained. Photographic evidence of gauge reading is recommended. Once the vacuum process has been concluded (30 minutes), turn off the pump and the gauge should always display the same value Turn off the gauge taps. 17
5.7 System refrigerant charge The Bunsen Air system is pre-charged with 1000g of R134a refrigerant, sufficient to support a distance run of up to 8 meters (10m in each direction) to the External Solar Panel. If the pipe runs are over the 10meters, then additional refrigerant must be added to the system. See below - Process for adding extra charge before continuing. Having fully vacuumed the system, the Gas In & Liquid Out valves can be opened by rotating anti-clockwise as shown in the Diagram below Fig.19 in order to charge the system. Fig.19 For all installations of over 8m pipe distance between the External Solar Panel and the Bunsen Heat Pump additional charge of R134a is required at a rate of 50g per meter of additional distance (1 meter additional distance is 1 meter of flow and one meter of return). Additional refrigerant is added according to the chart below: Distance (M) Pipe Length (M) Added Charge (g) 10 or less 20 or less No additional Charge 5.8 Process for adding extra charge: 11 22 50 12 24 100 13 26 150 14 28 200 15 MAX 30 MAX 250 MAX Fig.20 Having Pressure tested the system, and fully evacuated the system, release additional gas into the system according to the requirements in Fig.20. Gas should only be added by weight. It is recommended that photographic evidence is taken to confirm any additional charge. Once the correct amount of additional gas has been added, the pre-charged gas can be released. 18
6.0 HYDRAULIC INSTALLATION 6.1 Hydraulic functionality Make sure water quality complies with EU directive98/83 EC. Water quality is important to the success of the system. Using water which does NOT meet the stated quality requirements can cause a considerably reduced service life of the equipment. The responsibility for this is entirely that of the user. All works carried out by any installer must comply with the any local Water Regulations as well as any local or national building regulations. It is recommended that the Bunsen Air unit be installed as close to the cylinder as possible to limit pipework and therefore limit losses to the system. All pipework must be fully lagged or insulated. 6.2 Dip pipe assessment and installation (See Fig 21) The Dip Pipe is a mechanical method of ensuring that the water coming out of the cylinder to the Bunsen Air unit is from lower in the cylinder where the water temperature is cooler than that higher in the cylinder. The system is the same for use in vented or unvented cylinders, however as all cylinders are different sizes the units are soldered into place for each size requirement. The aim is to have the finished pipe at a level of around 400mm from the bottom of the cylinder. Assembly of the dip pipe: The adapter B has different sized hole in each end. Solder the pipe D into the correct sized hole in B Attach the T Piece C and elbow A mechanically as per diagrams The reducer E is already part of D for simple installation. Cut pipe to extend D to a height of 400mm from the bottom of the tank. fig.21 19
6.3 Hydraulic connections Tubing and connections used must meet with British Standards. All pipe work must be of 22mm sizing. Insufficient tube size will cause the system to go into an error status. Failure to use the correct size and standard of tubing will negate the warranty. When facing the Bunsen Air unit, the water inlet and outlet are located on the bottom front of the unit. See Fig.23 Fig.23 Flexible hose pipes should be used for connecting to the Inlet and Outlet fittings to ensure correct flow speeds and limit any vibrations from the Bunsen Air unit being transferred to the pipework of the property. All pipework between the Bunsen Air unit and the cylinder should be insulated with a suitable thickness of insulation to prevent heat losses. The cylinder to which Bunsen Air is fitted should be assessed for adequate levels of insulation. Action must be taken to ensure sufficient standards are met. A Y-Filter should be added to the system for future servicing requirements. See Vented and Unvented Diagrams. See Fig.24 Fig.24 6.4 Unvented cylinder installations The Unvented Installation diagram 25 shows the correct installation points for the pipework to connect to the Bunsen Air unit. 20
As shown ensure that the water inlet connection should be connected to the first T off point to the cylinder. Also shown is that the connection to the taps should be the 2 nd T off point. The location of the Bunsen Air should be as close as possible to the existing cylinder. This limits the amount of installation pipework, and reduces losses to the system which are caused by heat loss in pipework, and resistance in the system caused by long pipe runs and bends to the pipework Fig.25 (unvented cylinders) 6.5 Vented cylinder installations The Vented Installation diagram 26 shows the correct installation points for the pipework to connect to the Bunsen Air unit. The location of the Bunsen Air should be as close as possible to the existing cylinder. This limits the amount of installation pipework, and reduces losses to the system which are caused by heat loss in pipework, and resistance in the system caused by long pipe runs and bends to the pipework. 21
Fig.26 (vented cylinders) 6.6 Refill system and purge water Once Hydraulic connections are completed, the system must be filled with water and any air purged form the system. The Valve shown in figure below can be used to purge any air from the system. Where the Bunsen installation is below the level of the flow and return additional purging will be necessary. Use the air bleed valve as shown: 22
Fig.27 7.0 TEMPERATURE SENSOR INSTALLATION (See Fig.28) Fig.28 The temperature sensor is the means of the Bunsen Air unit monitoring the temperature of the cylinder. The sensor cable extends to a length of 10m. For all cylinders the ideal place for locating the sensor is two thirds down from the top of the cylinders (pressurised cylinders will have specific fixing points on them already). In order to get reliable and solid contact from the sensor and the cylinder side, the provided thermal paste must be used. 8.0 ELECTRICAL INSTALLATION Electrical Connections Electrical connection of the Bunsen Air system should only be carried out once all the refrigerant and hydraulic systems have been completed and fully tested and the water tank filled. Connections should always comply with the installation regulations in force in the country in which the thermodynamic equipment is installed. Installation work should be carried out by an accredited engineer. The Bunsen Air requires a single phase: 230V / 50Hz power supply with an earth connection. This should be separately isolated and protected by an appropriately sized fuse. (max 13Amps). The Bunsen Air is supplied with an appropriate fused Spur. See Fig.29 23
Fig.29 The Bunsen Air has a relay to allow the connection of a back-up immersion heater. The rating of the heater must not exceed 20 Amps. Bunsen Air Circuit Schematic Fig.30 Fig.30 9.0 TEST AND COMMISIONING System Start up Power up the system by switching on the power to the Bunsen Air at the fused spur. The water pump will starts immediately, and the compressor will start to work after the water pump has run for around 90 seconds. IMPORANT Before powering up the unit ensure all air has been bled from the system. See Fig 31. When the pump starts to run us the air bleed valve to remove any air from the unit, and check the power of the meter, the power consumption must more than 40 watts. Fig.31 The controller unit is pre-set to a default temperature of 55 C with 5 C drop auto start. 24
10.0 CONTROLLER FUNCTIONS See the dedicated Controller Instructions Manual 11.0 MAINTENANCE 1. Cleaning of the panel should rarely be necessary, as the panels will self-clean as it rains therefore frequent cleaning is not advised. However if there is build-up of dirt, dust etc., and you wish or need to clean the solar panel, then do so when the panel is not in direct sunlight as the panels can get hot. Clean with water only - a hose-pipe or if necessary very gently with a non-abrasive sponge to ensure you do not damage the active coating on the panel. 2. If you wish to clean the Bunsen Air unit, ensure the power is disconnected before you start. Clean only with a damp non-abrasive cloth, or if necessary non-abrasive detergent. 3. If the Bunsen Air is likely to be out of use for long periods of time, it is advisable to drain off the hydraulic system and isolate the electrical supply to the unit. 4. The Y filter should be checked and cleaned annually. 12.0 TROUBLESHOOTING This section provides information for diagnosing and correcting certain troubles which may occur with the unit. Troubleshooting and corrective actions may only be carried out by a qualified technician. - Before touching electric terminal parts, turn off power switch and other applicable power supply. - Never leave the unit unattended during installation or servicing when the live parts are exposed. - Do not touch water pipe works during and immediately after operation, as the pipes might be hot and it could burn your hands. To avoid injury, give the pipework time to return to normal temperature or be sure to wear protection gloves. - Do not touch any switch with wet hands to avoid electric shock. 25
13.0 GENERAL CONDITIONS OF GUARANTEE General Warranty Conditions The Bunsen Air Unit warranty is from the manufacturer Solamics Ltd, to the end customer. The installer or sales company should always be the end-users first point of contact in the event of a breakdown or other malfunction of the product. Only if or when confirmed that there is a fault with the Product and not with the installation design or operation, then contact should be made with Solamics. SOLAMICS LTD is not responsible for any shipping costs or labour costs associated with guarantee returns. The Bunsen Air Unit must be installed in direct compliance with the manufacturer s installation manual and any other documents. The Bunsen Air Unit must be installed only by specifically qualified engineers and according to the laws of the land of installation. The provided Warranty Card must be completed within 14 days of purchase of the Bunsen Air unit and registered via email to info@solamics.co.uk. Confirmation of this registration will be provided within a further 14 days. Failure to register the warranty card will limit the warranty period to 1 year from date of purchase. In the event of a breakdown or other malfunction of the Bunsen Air Units, no warranty is provided for labour, shipping costs or any compensation claims relating to a unit malfunction. Only if or when it is confirmed that there is a fault with the Bunsen Air, and not with the installation design or operation, should the product warranty be pursued. In the case Solamics Ltd provide replacement for a unit, Solamics Ltd are not responsible for any other costs during the service procedure in that period, including (but not limited to) logistics fare, labour cost, any kind of compensation. Also the replacement may have a little flaw on its surface, and the warranty excludes any general defect. In the event of a replacement being supplied, the remainder of the original warranty entitlement will be transferred to the replacement device. In this case, you do not receive a new warranty since your entitlement is documented at Solamics Ltd. Nothing in this warranty shall be deemed to vary such Terms and Conditions of Sale, which shall have priority over this warranty. Solamics Ltd. shall make final determination of warranty eligibility. Solamics Ltd reserves the right to conduct inspections at site during and/or after installation to ensure compliance, and to assess any trends in product failures. Solamics Ltd may carry out monthly reviews of warranty claims by installers and any persistent or repetitive defects or failures may be investigated by Solamics Ltd. Warranty The warranty is provided by Solamics Ltd to the end customer. The warranty provides repair or replacement guarantee on Bunsen Air units on a return to factory basis. The periods of warranty are listed below Solamics Solar Collector Panels: Bunsen Air Heat Pump Unit: 10 years 2 years This warranty includes all defects of components and manufacturing. If a device becomes defective during the agreed Solamics Ltd warranty period and provided that it will not be impossible or unreasonable, the device will be, as selected by Solamics Ltd: 26
repaired by Solamics, or exchanged for a replacement device of equivalent value according to model and age. Exclusions to the warranty The Warranty shall be deemed Null and Void if the product: is not used for the purpose for which it was designed is not installed or assembled as per the manufacturer s instructions installation is not carried out by engineers certified to F-Gas standards as necessary the hydraulic installation is not carried out by engineers suitably accredited all relevant standards, regulations and codes in force at the time have been followed breakdown is due to incorrect handling, electrical discharges, flooding, humidity or by improper use of the apparatus has been installed in an unsuitable environment freezing or overheating warranty is transferred to anyone other than the original owner has been moved from its original place of installation is damaged due to unsecure installation/anchoring has any non-authorised modifications or parts attached or incorporated is damaged due to unsuitable or detrimental water supply i.e. non potable sources is damaged due to any external forces fire, vandalism, impacts of any nature is installed outside the stated operational parameters is not serviced according to the installation manual instructions Warranty Card is not registered Attention: Technical Assistance costs even within warranty periods shall be covered by the client. Where no justifiable breakdown of the system is evident the client shall cover the call out charge and technical support charge. Warranty Registration Card Solamics Ltd. provides a Warranty Registration Card with every Bunsen Air unit. The installer must provide that homeowner warranty registration card to the homeowner end user forthwith upon completion of installation and commissioning. The installer must give all reasonable support to the end user for entry of the relevant system and product data required for completion of that card. The Warranty Registration Card does not affect any statutory rights which an end user may have against the installer in connection with the sale of goods and/or supply of services. The installer must explain that the registration card is registered via the distributor. 27