IVT AirModule E 15, AirModule E 9, Airbox E 50- 90, Airbox E 130-170, Airbox S 50- 90 Installer's Manual
...
AirModule E 9/15
230V 1N~ / 400V 3N~
Installer Guide
6 720 813 268(2014/10)
6 720 809 156-00.1I
Table of Contents
Table of Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.12 Connection option EMS bus . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.1 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2 Important notices on usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.3 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Information about the heat pump . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Heating system minimum volume and operation . . . . . . . . . . . . 4
3.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Heat pump module positioning . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.7 Checks before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.8 Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Technical information - heat pump module . . . . . . . . . . . . . . . . 6
4.2 System configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Measurements, positioning distance, and pipe connections . . . . . . 11
5.1 Heat pump module dimensions and connections . . . . . . . . . . 11
5.2 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Detailed discharge pipe installation requirements (Combi model)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Preparatory pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.4 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.5 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.6 Heating system flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.7 Operation without heat pump (stand-alone) . . . . . . . . . . . . . . 15
7.8 Installation with cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.9 Installation with solar heater (only solar model) . . . . . . . . . . . 16
7.10 Installation with pool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.11 Connecting the heat pump module to the heat pump . . . . . . . 17
7.12 Connecting the heat pump module to the heating system and tap
water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.13 Low energy pump for heat transfer medium (PC0) . . . . . . . . . 19
7.14 Circulation pump for the heating system (PC1) . . . . . . . . . . . . 19
7.15 DHW circulation pump PW2 (accessory) . . . . . . . . . . . . . . . . . 19
7.16 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.17 Several heating circuits (mixing valve module accessory, see
separate instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.18 Installation of condensation sensor (accessories) . . . . . . . . . . 19
7.19 Temperature sensor installation . . . . . . . . . . . . . . . . . . . . . . . . 20
7.20 Heat pump and heat pump module filling . . . . . . . . . . . . . . . . . 22
10 Basic principles of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.1 Key and symbol overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.2 Display symbols overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.3 Using the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.4 Service menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.1 General user interface commissioning . . . . . . . . . . . . . . . . . . . 38
11.2 System commissioning via configuration wizard . . . . . . . . . . . 39
11.3 Commissioning other settings . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.4 Performing the function test . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.5 Check monitored values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.6 System handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
12 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.1 Heat pump settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.2 Booster heater settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.3 Settings for heating/cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.4 DHW settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.5 Pool settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.6 Solar system settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.7 Hybrid system settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.8 Anti-seizing protection settings . . . . . . . . . . . . . . . . . . . . . . . . 53
12.9 Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
14 Heat pump and heat pump module venting . . . . . . . . . . . . . . . . . . . . . 57
15 Heat pump module components replacement . . . . . . . . . . . . . . . . . . 58
16 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.1 Set heating system operating pressure . . . . . . . . . . . . . . . . . . 58
16.2 Pressure switch and overheating protection . . . . . . . . . . . . . . 58
16.3 Operating temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
17 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
18 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
19 Connection for IP module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
20 Commissioning protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Electric installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.1 CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 EMS-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3 Printed circuit board handling . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.6 Connecting the heat pump module . . . . . . . . . . . . . . . . . . . . . . 24
8.7 Electric box layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.8 Power supply heat pump and heat pump module 9 kW 3N~ . 29
8.9 Power supply heat pump and heat pump module 15 kW . . . . 30
8.10 Installer module circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . 31
8.11 Heat pump/heat pump module circuit diagram . . . . . . . . . . . . 32
2
AirModule 6 720 813 268(2014/10)
Key to symbols and safety instructions
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
The following keywords are defined and can be used in this document:
• NOTICE indicates a situation that could result in damage to property
or equipment.
• CAUTION indicates a situation that could result in minor to medium
injury.
• WARNING indicates a situation that could result in severe injury or
death.
• DANGER indicates a situation that will result in severe injury or
death.
Important information
This symbol indicates important information where
there is no risk to people or property.
Additional symbols
Symbol Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Table 1
1.2 General safety instructions
These installation instructions are intended for plumbers, heating
engineers and electricians.
▶ Read any installation instructions (heat pump, heating controls, etc.)
carefully before starting the installation.
▶ Observe the safety instructions and warnings.
▶ Observe national and regional regulations, technical rules and
guidelines.
▶ Record all work carried out.
Intended use
This heat pump must only be used as a heat appliance in a sealed hot
water heating system for domestic purposes.
Any other use is considered inappropriate. Any damage that results from
such use is excluded from liability.
Installation, commissioning and servicing
Installation, commissioning and servicing must only be carried out by an
authorised contractor.
▶ Only use original spares.
Electrical work
Electrical work must only be carried out by a qualified electrician.
▶ Before starting electrical work:
– Isolate the mains electrical supply and secure against
unintentional reconnection.
– Check for zero potential.
▶ Also observe connection diagrams of other system components.
Handover to the user
When handing over, instruct the user how to operate the heating system
and inform him about its operating conditions.
▶ Explain how to operate the heating system and draw the user's
attention to any safety-relevant action.
▶ Explain that modifications and repairs must only be carried out by an
authorised contractor.
▶ Point out the necessity of inspection and servicing for safe and
environmentally compatible operation.
▶ Leave the installation instructions and the operating instructions
with the user.
AirModule –6 720 813 268(2014/10)
3
Standard delivery
2 Standard delivery
1
2
TL1
4
Fig. 1 Standard delivery
[1] Heat pump module
[2] Legs
[3] Operating Instructions
[4] Installation instructions
[5] Safety assembly in loose parts
[T1] Outside temperature sensor
3 General
The language of the original manual is Swedish, other languages are a
translation of the original manual.
Only trained personnel may perform this installation.
The installer must comply with local rules and
regulations as well as the information in the installation
and operating instructions.
Cooling is disabled in the UK model to comply with
the regulations for RHI.
3.1 Information about the heat pump
AirModule are heat pump modules that are intended for indoor use and
for connection with outdoor AirX heat pumps.
The following combinations are possible:
AirModule AirX
E9 50
E9 70
E9 90
E15 130
E15 170
Table 2
The AirModule heat pump module has a built-in immersion heater.
3
5
6 720 810 350-01.1I
3.2 Application area
The heat pump module may only be used in closed heating systems in
accordance with EN 12828.
Other usage is prohibited. Any damage resulting from prohibited usage
is excluded from liability.
3.3 Heating system minimum volume and operation
To avoid multiple start/stop cycles, incomplete
defrosting or unnecessary alarms, a sufficient amount of
energy stored in the system is required. Energy is stored
in the heating system water volume, as well as in the
system components (radiators) and in the concrete
foundation (underfloor heating system).
Since the requirements vary for different heat pump installations and
heating systems, no general minimum volume is stated. Please refer to
the following prerequisites for all heat pump sizes instead:
Under floor heating system without a buffer cylinder
To ensure that a sufficient amount of energy is available for defrosting,
the largest room should not contain room thermostats but room
controllers should be used instead. At least 30 m
be regulated by a room controller, since the heat pump then will adjust
flow temperature automatically.
Radiator system without a buffer cylinder
To ensure that a sufficient amount of energy is available for defrosting,
there should be at least 4 water radiators of 500 W/unit in one system
without mixing valve. A room controller is recommended, since the heat
pump then will automatically adjust flow temperature.
Radiator and under floor heating systems on different circuits without a buffer cylinder
To ensure that a sufficient amount of energy is available for defrosting,
there should be at least 4 water radiators of 500 W/unit in the circuit
without mixing valve. No minimum floor surface is required for the
2
floor surface should
4
AirModule 6 720 813 268(2014/10)
underfloor heating system circuit with mixing valve. A room controller is
recommended, since the heat pump then will automatically adjust flow
temperature.
Only circuits with mixing valve
To ensure that a sufficient amount of energy is available for defrosting, a
buffer cylinder of at least 50L is required for heat pump sizes 5-9 and of
at least 100L for heat pump sizes 13-17.
Fan convector
To ensure that a sufficient amount of energy is available for defrosting, a
buffer cylinder of at least 10L is required.
3.4 Type plate
The data plate is found on the module roof plate.
3.5 Transport and storage
The heat pump module must always be transported and stored upright.
If needed, it may be leaned temporarily.
The heat pump module may not be stored or transported in
temperatures below – 10 °C.
3.6 Heat pump module positioning
• The heat pump module is placed indoors. Pipework between the heat
pump and the heat pump module should be as short as possible. The
pipes must be insulated ( Chapter 7.16).
• Leakage drain water from the pressure relief valve should be drained
from the heat pump module to a frost protected outlet.
• The space where the heat pump module is placed must have a floor
drain.
General
3.7 Checks before installation
▶ Check that all pipe connections are intact and have not shaken loose
during transportation.
▶ Before operation of the heat pump module, the heating system and
the water heater, including the heat pump module, must be filled and
depressurized.
▶ Wiring should be kept as short as possible to protect the system from
downtime, for example during a thunderstorm.
▶ Low voltage wiring must be separated from high voltage wiring by at
least 100 mm.
3.8 Connection principle
The principle is based on floating condensation and a immersion heater
in the heat pump module. The user interface manages the heat pump
and the heat pump module according to a set heating curve.
When the heat pump is not able to heat the house on its own, the heat
pump module automatically starts the booster heater and produces
together with the heat pump the desired temperature in the house.
DHW is prioritized and is managed by a sensor TW1 in the hot water
cylinder. While the heater is heated, the heating system heating mode is
temporarily disconnected by a 3-way valve. When the hot water cylinder
is heated, the heat pump heating mode continues.
Heating and DHW mode when heat pump is inactive:
At outside temperatures below app. –20 °C (adjustable value) the heat
pump stops automatically and cannot produce hot water. The booster
heater in the heat pump module will in this case take over both the
heating mode and the DHW production. The heat pump will restart when
the temperature gets above –17 °C.
AirModule –6 720 813 268(2014/10)
5
Technical information
4 Technical information
4.1 Technical information - heat pump module
Unit E9 E15
Electrical information
Power supply V 4001) /230
Recommended fuse size A 161) / 50
Immersion heater in steps kW 3/6/9 3/6/9/12/15
Heating installation
Connection
3)
Maximum operating pressure kPa 250 250
Minimum operating pressure kPa 50 50
Expansion vessel L 14 14
External available pressure kPa
Minimum flow L/s 0.36 0.59
Circulation pump model Grundfos UPM2 25-75 PWM Wilo Stratos Para 25/1-11 PWM
Flow max. temperature, booster
°C 85 85
only
General
Hot water cylinder volume L 190 190
Maximum operating pressure on
MPa 1
tap DHW circuit
Material Stainless steel 1.4521
IP rating IP X1
Dimensions (WxDxH) mm 600x660x1800
Weight kg 135
Table 3 heat pump module with immersion heater
1) 3N AC 50 Hz
2) 1N AC 50 Hz
3) See Connections in safety assembly
4) This depends on the type of heat pump, see tab. 11
2)
2)
400
25
1)
Cu 28 Cu 28
4)
4)
1)
6
AirModule 6 720 813 268(2014/10)
Technical information
4.2 System configurations
The heat pump and heat pump module may be installed
only in accordance with the official system solutions
provided by the manufacturer.
Other system solutions are not allowed. Any damage and
problems resulting from prohibited installation are
excluded from liability.
4.2.1 System configuration explanations
General
Installer
module
ProControl 600 User interface
CR10H Room controller (accessories)
T1 Outside temperature sensor
CC1 Buffer cylinder (accessories)
MK2 Condensation sensor (accessories)
VC0 3-way valve (accessories)
PW2 DHW circulation pump hot water (accessories)
Table 4 General
Z1 Heating circuit without mixing valve
PC1 Circulation pump, heating circuit
T0 Flow temperature sensor (placed in the safety assembly or
Table 5 Z1
Installer module integrated into the heat pump
module
in the buffer cylinder)
Circulation pump PC1 is controlled by the control unit in the heat pump
module.
If a fresh water station is installed, it must have its own control unit.
If a buffer cylinder is used, a 3-way valve VC0 must be installed in
accordance with the system solution. The 3-way valve replaces the Tunit in the safety assembly ( Chapter 5.1.1) and is connected
electrically to terminal VC0 on the installer module.
Z2/Z3 Heating circuit with mixing valve (accessories)
MM100 Mixing valve module (controller for circuit)
PC1 Circulation pump, heating circuit 2
VC1 Mixing valve
TC1 Flow temperature sensor, heating circuit 2,3..
MC1 Thermal shut-off valve, heating circuit 2,3...
Table 6 Z2
4.2.2 Non-return valve in heating circuit
T
T
1
6 720 809 064-09.1I
Fig. 2 Heating circuit
[1] Non-return valve
One non-return valve in each heating circuit is required for preventing
natural circulation in the heating system in summer mode. Natural
circulation may arise as the domestic hot water 3-way valve is open to
the heating system when the heat pump prepares DHW heating.
AirModule –6 720 813 268(2014/10)
7
Technical information
4.2.3 Heat pump with heat pump module system configuration
1
Rego 2000
4
3
HCM2000RTH2000 RTH2000Installermodul
T T
5
MC1
TC1
PC1
M
VC1
3
MK2
5
T T
PC1
T1
T0
400V AC
PW2
Airmodule E..
Fig. 3 Heat pump with heat pump module
[3] Installed in the heat pump module.
[4] Installed either in the heat pump module or mounted to the wall.
[5] Installed on the wall
400 /230 V AC
AirX ..
6 720 809 156-22.2I
8
AirModule 6 720 813 268(2014/10)
4.2.4 Heat pump, heat pump module and buffer cylinder system configuration
Technical information
Installermodul
3
RTH2000
T
HCM2000
5
T
M
1
MC1
TC1
PC1
VC1
RTH2000
4
T
HCM2000
5
T
TC1
PC1
M
VC1
2
MC1
4
Rego 2000
3
MK2
B
T1
T0
BC 100/120
VC0
400V AC
M
AB
Airmodule E..
A
Fig. 4 Heat pump with heat pump module and buffer cylinder
[3] Installed in the heat pump module.
[4] Installed either in the heat pump module or mounted to the wall.
[5] Installed on the wall
PW2
400 /230 V AC
AirX ..
6 720 809 156-22.3I
The extra expansion vessel for the heating system is
designed primarily for the volume of the buffer cylinder.
AirModule –6 720 813 268(2014/10)
9
Technical information
4.2.5 General symbol explanation
Symbol Designation Symbol Designation Symbol Designation
Pipework/Wiring
Flow - heating/solar circuit DHW Electric wire
Return - heating/solar circuit Potable water Electric wire disconnected
DHW circulation
Actuators/Valves/Temperature sensors/Pumps
Valve Differential pressure regulator DHW circulation pump
Revision bypass Pressure relief valve Non-return valve
Adjustment valve Safety assembly Temperature sensor/switch
Other
Overcurrent valve 3-way mixing valve
M
(mixing/distributing)
Overheating protection
(temperature)
Filter valve (particle filter) Thermal DHW mixing valve Outside temperature sensor
T
Shut-off valve with unintentional
closure control
Valve, motorized 3-way valve (changing, normally
M
M
M
I
II
3-way valve
(change)
closed to II)
Wireless outside temperature
sensor
...Radio (wireless)...
III
Valve, thermal 3-way valve (changing, normally
T
M
AB
A
closed to A)
B
Shut-off valve, magnetic 4-way valve
Thermometer Funnel with siphon Low loss header with sensor
T
Pressure gauge Return flow safety module in
M
Heat exchanger
accordance with EN1717
Fill / drain valve Expansion vessel with shut-off valve
Flow meter
with closure
Water filter Collector Heat meter
Air separator Heating circuit DHW outlet
Automatic air vent valve Underfloor heating circuit Relay
Compensator (devibration) Low loss header Immersion heater
Table 7 Symbols key
10
000
∏
R
J
AirModule 6 720 813 268(2014/10)
5 Measurements, positioning distance, and pipe connections
5.1 Heat pump module dimensions and connections
>
_
400
>
_
800
Measurements, positioning distance, and pipe connections
1800 304
6 720 809 156-06.1I
Fig. 5 Heat pump module minimum distance
There should be at least 50 mm between the heat pump module sides
and other fixed installations (walls, sinks, etc.). Ideal positioning is by an
outer wall or a middle wall.
304
Fig. 6 Heat pump module dimensions (mm)
6 720 810 350-09.1I
Fig. 7 Roof view dimensions
AirModule –6 720 813 268(2014/10)
6 720 809 156-11.2I
11
Measurements, positioning distance, and pipe connections
7 8
<50V
5
Fig. 8 Heat pump module connections
[1] Heat transfer medium out (to the heat pump)
[2] Heat transfer medium in (from the heat pump)
[3] Cold water inlet connection
[4] DHW outlet connection
[5] Cable feed to IP module
[6] Cable bus CAN-BUS and sensor
[7] Return to solar thermal system (only on the solar models)
[8] Flow from solar thermal system (only on the solar models)
[9] Return from safety group
[10] Flow to safety group
[11] Cable bus electrical connection
9 106
11
230V
400V
/
1
2
3
4
6 720 809 156-08.2I
5.1.1 Safety assembly
Fig. 9 Safety assembly delivery
6 720 809 156-12.2I
12
AirModule 6 720 813 268(2014/10)
Regulations
Assemble the safety assembly:
▶ First install the particle filter ([SC1], figure 10) on the T-unit.
▶ Install the other parts, but do not tighten the nuts completely on the
bypass ([4], figure 10).
SC1
4
▶ Place the flow temperature sensor in the sensor pocket ([T0],
figure 10), and secure the sensor with a cable tie.
▶ Fit the safety assembly on the heat pump module.
▶ Tighten the nuts completely on the bypass ([4], figure 10).
FC1
VL1
T0
1
GC1
23
6 720 809 156-13.3I
Fig. 10 Safety assembly fitted
[1] Circulation pump heating system connection (PC1), G1
½ (40R) adapter to heating system flow
[2] Flow to safety group
[3] Return from safety group
[4] Bypass
[SC1] Particle filter, connection G1internal thread from heating
system return
[FC1] Pressure relief valve
[VL1] Automatic air vent valve
[T0] Flow temperature sensor
[GC1] Pressure gauge
6 Regulations
The following regulations and requirements must be observed:
• Local rules and regulations, including special rules, of the
responsible power supply company
• National building regulations
• EN 50160 (Voltage properties in power grids for public distribution)
• EN 12828 (Heating systems in buildings - Design and installation of
water-based heating systems)
• EN 1717 (Water supply - Protection against pollution of potable
water)
5.2 Pipework
Pipe dimensions (mm) Heat pump module
Heating installation
Spring clip connection Cu Ø 28
Cold and hot water
Stainless spring clip connection Ø 22
Heat transfer medium
Spring clip connection Cu Ø 28
Leakage drain water/drain in both Ø 32
Table 8 Pipe dimensions
1) See Connections in safety assembly
1)
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Installation
7 Installation
NOTICE: Risk of operating problems due to pipe
contamination!
Particulates, metal/plastic filings, flax and thread tape
residue and similar material can get stuck in pumps,
valves and heat exchangers.
▶ Avoid particulates in the pipework.
▶ Do not leave pipe parts and connections directly on
the ground.
▶ Ensure that no filings remain in the pipes following
deburring.
Only qualified installers may carry out the installation.
The installer must follow applicable rules and regulations
and recommendations from the supplier.
7.1 Detailed discharge pipe installation requirements (Combi model)
The discharge pipework must be routed in accordance with part G3 of
schedule 1 of the building Regulations.
The tundish should be vertical, located in the same space as the
unvented hot water cylinder and be as close as possible and within
600mm of the safety device e.g. the temperature relief valve. The discharge pipe from the tundish should be:
• made of metal
• at least one pipe size larger than the nominal outlet size of the safety
device (larger sizes may be required if the equivalent hydraulic
resistance exceeds that of a straight pipe 9m long - refer to BS6700)
• terminate in a safe place where there is no risk to persons in the
vicinity of the discharge, and position safely from electrical devices
• have a vertical section of pipe at least 300mm long below the tundish
before any elbows or bends in the pipework.
Maximum
Size of
Valve
discharge
outlet
size
G1/2 15 mm 28 mm Up to 18 m 1.0 m
G3/4 22 mm 35 mm Up to 18 m 1.4 m
G1 28 mm 42 mm Up to 18 m 1.7 m
pipework
D1
Size of
discharge
pipework
D2
22 mm Up to 9 m 0.8 m
35 mm Up to 27 m 1.4 m
28 mm Up to 9 m 1.0 m
42 mm Up to 27 m 1.7 m
35 mm Up to 9 m 1.4 m
54 mm Up to 27 m 2.3 m
length of
straight pipe
(no bends or
elbows)
Deduct the figure
below from the
maximum length for
each bend or elbow in
the discharge pipe
Table 9
7.2 Preparatory pipework
The safety valve drain in the heat pump module should
be secured against frost and the drain pipe should lead
to a drain.
▶ Fit heating system and cold/hot water connector pipes in the space
up to the heat pump module position.
7.3 Positioning
▶ Remove the packaging according to the instructions on the
packaging.
▶ Remove the supplied accessories.
7.4 Checklist
Each installation is different. The following check list will
provide a general description of the installation process.
6 720 806 768-05.1I
Fig. 11 Typical discharge pipe arrangement
[1] Safety device (e.g. temperature relief valve)
[2] Metal discharge pipe (D1) from temperature relief valve to tunish
[3] 600mm maximum
[4] Tundish
[5] 300mm minimum
[6] Metal discharge pipe (D2) from tundish, with continous fall
[7] Discharge below fixed grating
[8] Fixed grating
[9] Trapped gulley
1. Install the heat pump module safety assembly (Chapter 5.1.1)
and fill valve.
2. Fit the heat pump module leakage water hose(s).
3. Connect the heat pump and the heat pump module
(Chapter 7.11).
4. Connect the heat pump module to the heating system
(Chapter 7.12).
5. Install the outside temperature sensor (Chapter 7.19.3) and room
controller (optional).
6. Connect the CAN-BUS wire between the heat pump and the heat
pump module (Chapter 8.1).
7. Install any accessory (mixing module, solar module, pool module,
etc).
8. Connect EMS-BUS wire (optional) to accessories (Chapter 8.2).
9. Fill up and bleed the hot water cylinder.
10. Fill up and vent the heating system before commissioning
(Chapter 7.20).
11.Connect the heating system to the electrical system (Chapter 8).
12.Commission the heating system by managing necessary settings in
the user interface (Chapter 11).
13.Vent the heating system (Chapter 14).
14.Check that all sensors show reasonable values (Chapter 12.9.2).
15.Check and clean out the particle filter (Chapter 18).
16. Check the heating system function following commissioning
(Chapter 12.9).
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Installation
7.5 Water quality
Heat pumps operate with lower temperatures than other heating
systems, which means that the thermal degassing is not as effective and
the oxygen content will never be as low as in an electric/oil/gas system.
This means that the heating system will be more sensitive to rust with
aggressive water.
Do not use any water additives except for pH-enhancer and keep the
water clean.
Recommended pH level is 7.5 – 9.
Water quality
Hardness < 3°dH
Oxygen content < 1 mg/L
Carbon dioxide, Co
Chloride ions, Cl- < 250 mg/L
Sulphate, So42- < 100 mg/L
Conductivity < 350 μs/cm
Table 10 Water quality
1) Electric anode (accessory) in the water heater is recommended for higher
chloride content. If electric anode is used, it has to be purchased in
connection with commissioning.
2
< 1 mg/L
1)
7.6 Heating system flushing
NOTICE: System damage due to objects in the pipes!
Objects in the pipes will decrease the flow and cause
operational problems.
▶ Flush out the system to remove all dirt residues
before connecting the heat pump and heat pump
module.
The heat pump module is a part of a heating system. Problems in the heat
pump module can be caused by poor water quality in the radiators/floor
loops or by constant system oxygenation.
Oxygen causes corrosion products in the form of magnetite and
sediment.
Magnetite has a grinding effect on the heating system's pumps, valves
and components with turbulent flows such as the condenser.
Heating systems which require regular filling or where the heating water
does not produce clear water during water sampling require measures
prior to the installation of the heat pump, e.g. supplementing the heating
system with magnetite filters and air vent valves.
7.7 Operation without heat pump (stand-alone)
The heat pump module can be put into operation without a connected
heat pump, for example, if the heat pump is installed at a later date. This
is called "stand-alone" operation.
In stand-alone mode, the heat pump module uses only the integrated
immersion heater for heating and DHW production.
If the heat pump module and the heating system are
filled before the heat pump is connected, then the heat
transfer medium in and out to / from the heat pump must
be connected to secure circulation ( [1] and [2],
Fig. 13).
▶ Open shut-off valves on the heat transfer circuit, if
applicable.
In connection with commissioning of stand-alone operation:
▶ Set Stand-alone mode in the service menu Heat pump ( Chapter
12.1).
7.8 Installation with cooling
Cooling is disabled in the UK model to comply with
the regulations for RHI.
Using cooling mode requires the installation of a room
controller (accessory).
Installation of a room controller with integrated humidity
sensor (accessory) makes cooling mode more secure as
the user interface automatically adjusts the flow
temperature in relation to the current dew point.
▶ Insulate all connections and pipes from condensation.
▶ Install a room controller, with or without an integrated moisture
sensor ( manual for the respective room controller).
▶ Install condensation sensors ( Chapter 7.18).
▶ Select automatic mode heating/cooling ( Chapter 12.3.2,)
▶ Make the necessary cooling mode settings: start temperature, start
delay, room temperature and dew point differential (offset), as well
as lowest flow ( Chapter 12.3.2).
▶ Set the temperature differential (delta) over the heat pump (
Chapter 12.1.1)
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Installation
▶ Turn off floor circuits in moist rooms (e.g. bathrooms and kitchens)
and use relay outputs PK2 in order to govern this ( Chapter 8.4).
7.9 Installation with solar heater (only solar model)
Using solar additional heating requires installation of a
solar module (accessory).
The solar energy coil in the cylinder is intended for
maximum added heating output of 4.5 kW. Only DHW
heating is possible with the integrated coil.
▶ Install solar panels ( panel manual).
▶ Insulate all connections and pipes.
▶ Install solar module ( solar module manual).
▶ Select Yes to the question Solar thermal sys installed during
commissioning ( Chapter 11.2).
▶ Make the necessary settings for the installed solar thermal system
( Chapter 12.6)
7.10 Installation with pool
NOTICE: Risk of malfunction!
Cooling mode is not possible if the mixing valve for the
pool is placed in a wrong position in the system. Even
other functional disturbances might arise. The mixing
valve for the pool must not be positioned so that it can
block the safety valve on the flow line.
▶ Install the mixing valve for pool on the return pipe to
the heat pump module ( [VC1] Bild 12).
▶ Install the T-pipe on the flow line from the heat pump
module, before the bypass in the safety assembly.
▶ The pool mixing valve may not be installed as a
heating circuit.
Installation of a pool module (accessory) is demanded to
use pool heating.
HS
VC1
M
Fig. 12 Pool installation example
[1] Pool module
[2] Pool
[VC1] Pool mixing valve
[HS] Heating system
1
1
2
6 720 810 931-10.3I
▶ Install the pool ( instructions for the pool).
▶ Install the mixing valve for pool.
▶ Isolate all pipes and connections.
▶ Install the pool module ( instruction for the pool module). Please
observe that the hydraulic solution that is presented in that can not
be used.
▶ Set the mixing valve running time at commissioning ( Chapter
11.2).
▶ Make necessary settings for the pool heating ( Kapitel 12.5).
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7.11 Connecting the heat pump module to the heat pump
Insulate pipes and connections against condensation if cooling is to be
used.
▶ Select pipe size according to table 11.
<50V
230V
/
400V
Installation
▶ Connect the return to the heat pump [4] to the heat transfer medium
out [1] figure 13.
▶ Connect the flow from the heat pump [3] to the heat transfer medium
in [2] Figure 13.
1
2
3
<50V 230V
/
400V
4
6 720 809 156-14.1I
Fig. 13 Heat pump connections heat pump module
[1] Heat transfer medium out (to the heat pump)
[2] Heat transfer medium in (from the heat pump)
[3] Flow from heat pump
[4] Return to heat pump
Heat
transfer
Heat pump
output (kW)
fluid delta
(K)
Nominal flow
(L/s)
Maximum pressure
drop (kPa)
1)
550.32 68 28 60
750.33 55 14 33 60
950.43 40 82160
13 5 0.62 56 14 60 60
17 5 0.81 18 15 60
Table 11 Pipe dimensions and max. pipe length for connection of heat pump to heat pump module
1) For pipes and components between the heat pump module (indoor unit) and heat pump (outdoor unit).
AX20
inner-Ø 15 (mm)
AX25
inner-Ø 18 (mm)
Maximum pipe length PEX (m)
AX32
inner-Ø 26 (mm)
AX40
inner-Ø 33 (mm)
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Installation
7.12 Connecting the heat pump module to the heating system and tap water
Pressure relief valve, non-return valve, and fill valve must
be installed on the tap DHW circuit (not included).
If there is not enough room to install the safety assembly
directly on the heat pump module connections:
▶ Extend the connections by max. 50 cm.
▶ Do not angle the connections downwards.
▶ Do not install any shut-off valves between the safety
assembly and the heat pump module.
▶ The particle filter can be installed at a bend to the left.
▶ Bends can be installed between the safety group and
the connection for the circulation pump.
Insulate the connections and pipes to the heating system from
condensation if cooling is used.
▶ Install the safety assembly ( Chapter 5.1.1).
▶ Install the pressure relief valve and non-return valve with a fill valve
for tap DHW.
▶ Drain leakage drain hoses from the pressure relief valves into a frost
protected drain.
▶ Connect the heating system circulation pump to [1] figure 14.
▶ Connect the heating system return to the particle filter [SC1]
figure 14.
▶ Connect cold water inlet to [2] figure 14.
▶ Connect DHW outlet to [3] figure 14.
▶ Connect the heating system flow to the circulation pump.
SC1
1
<50V
Fig. 14 Heating system and DHW connections heat pump module
[1] Connection for circulation pump PC1 (flow to heating system)
[2] Cold water inlet connection
[3] DHW outlet connection
[SC1] Particle filter (return from heating system connection)
230V
/
400V
2
3
6 720 809 156-05.1I
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AirModule 6 720 813 268(2014/10)
Installation
The heating system circulation pump is required and
selected based on the system pressure drop and flow
requirements.
PC1 must always be connected to the installer module in
the heat pump module according to the circuit diagram.
Relay output max. load for circulation pump PC1: 2 A,
cos>0.4. Higher load requires installation of an
intermediate relay.
7.15 DHW circulation pump PW2 (accessory)
Settings for the circulation pump PW2 is done in the control unit
(Chapter 12.4).
7.16 Insulation
NOTICE: Damage due to freezing!
In case of a power outage the water in the pipes may
freeze.
▶ Use at least 19 mm insulation for outside pipework.
▶ Use at least 12 mm insulation for inside pipework.
This is important for safe and efficient DHW heating.
1
6 720 809 156-10.1I
Fig. 15 Drain hose
[1] Drain hose
▶ Connect the drain hose with a leakage drain hose to a frost protected
drain.
7.13 Low energy pump for heat transfer medium (PC0)
PC0 heat transfer pump is PWM operated (RPM controlled). The pump
settings are managed on the heat pump module control panel.
Circulation pump speed is automatically adjusted for optimal operation.
7.14 Circulation pump for the heating system (PC1)
NOTICE: Damage due to deformation!
The circulation pump connecting pipe in the safety
assembly may bend if it is subject to heavy weight
pressure for an extended period of time.
▶ Use appropriate mounting installation for the heating
system pipes and DHW circulation pump to support
the safety assembly connection.
All heat conducting lines must have suitable heat insulation according to
applicable norms.
During cooling, all connections and lines must be condensation
insulated according to applicable norms.
7.17 Several heating circuits (mixing valve module accessory, see separate instructions)
The user interface can handle a heating circuit without a mixing valve in
standard configuration. A mixing valve module is required for each
circuit if additional circuits are installed.
▶ Install the mixing valve module, mixing valve, circulation pump and
other components in accordance with the selected system solution.
▶ Connect the mixing valve module to terminal EMS on the installer
module in the heat pump module electric box.
▶ Make settings for several heating circuits in accordance with Chapter
12.3.2.
If there is already a connection on the EMS terminal, the connection is
made parallel to the same terminal in accordance with Fig. 16. If several
EMS modules are installed in the system, these must be connected in
accordance with Fig. 33, Chapter 8.12.
7.18 Installation of condensation sensor (accessories)
NOTICE: Damage due to moisture!
Cooling below dew point will result in condensation on
the surrounding material (floor).
▶ Do not use the underfloor heating system for cooling
below dew point.
▶ Correctly adjust the flow temperature as described
in Chapter 12.3.2.
The condensation guard function will stop the cooling if condensation
develops on the heating system pipes. Condensation will develop during
cooling if the heating system temperature is lower than current dew
point temperature.
AirModule –6 720 813 268(2014/10)
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Installation
The dew point will vary depending on temperature and humidity. The
higher the humidity, the higher flow temperature is required to remain
above dew point and avoid condensation.
The condensation sensors will send a signal to the operating system
when they sense condensation and stop the cooling.
Instructions for installation and handling are included with the
condensation sensor.
7.18.1 Condensation monitoring, fan coils only
NOTICE: Damage due to moisture!
Moisture may be transferred to surrounding materials if
there are gaps in the condensation insulation.
▶ Apply condensation insulation to all pipes and
connections up to the fan element for cooling.
▶ Use condensation insulation material that is
intended for condensation cooling systems.
▶ Connect the drain to the drain outlet.
▶ Do not use condensation guard.
If only fan elements with drainage and condensation insulated pipes are
used, the flow temperature can be set to 7 °C. The lowest recommended
temperature is 10 °C for balanced cooling as the freeze guard is
activated at 5 °C.
7.19 Temperature sensor installation
The user interface in the delivery configuration automatically regulates
the flow temperature based on the outdoor temperature. A room
controller can be installed for greater comfort. If cooling mode is used, a
room controller is a must.
7.19.1 Room controller (accessories, see separate instructions)
If the room controller is installed after the system has
been put into operation, it must be selected as room
controller for heating circuit 1 in the start-up menu (
Chapter 11.2).
▶ Install the room controller in accordance with its instruction.
▶ Connect the room controller to a terminal EMS on the installer
module in the heat pump module electric box.
▶ Set room controller CR10 as remote control before the installation is
put into operation ( Room controller's instruction). CR10H does
not have this option.
▶ Make circuit settings on the room controller before the installation is
put into operation ( Room controller's instruction).
▶ Indicate when the installation is put into operation that room
controller (CR10 or CR10H) has been installed ( Chapter 11.2) as
a user interface for heating circuit 1.
▶ Make room temperature settings according to Chapter 12.3.2.
If there is already a connection on the EMS terminal, the connection is
made parallel to the same terminal in accordance with Fig. 16. If several
EMS modules are installed in the system, these must be connected in
accordance with Fig. 33, Chapter 8.12.
EMS NSC/IP
6 720 809 156-42.1I
Fig. 16 EMS connection on installer module
7.19.2 Flow temperature sensor T0
The sensor is delivered with the heat pump module.
▶ Fit the sensor in the pocket on the safety assembly ( figure 10) or
on the buffer cylinder if one is installed.
▶ Connect flow temperature sensor T0 to terminal T0 on the installer
module in the heat pump module electric box.
7.19.3 Outside temperature sensor T1
A screened cable must be used if the outside
temperature sensor cable is longer than 15 m. The
screened cable must be grounded in the inside unit. The
max. length of a screened cable is 50 m.
The outside temperature sensor cable must meet the following minimum
requirements:
Cable diameter: 0.5 mm
2
Resistance: max. 50 ohm/km
No. of conductors: 2
▶ Install the sensor on the cold side of the house, normally north facing.
It must be protected from direct sunlight, ventilation air or anything
that can affect the temperature measurement. The sensor must not
be installed directly beneath the roof.
▶ Connect outdoor temperature sensor T1 to terminal T1 on the
installer module in the heat pump module electric box.
20
AirModule 6 720 813 268(2014/10)
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