IVT Greenline HC 22, Greenline HC 33 Installation Manual

Installation manual
Greenline HC
6 720 641 855-01.1I
HC 22 / HC 33
6 720 645 504 (2011/04) en
Contents
2
Contents
1 Key to symbols and safety instructions . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . 4
1.2 Safety precautions . . . . . . . . . . . . . . . . . . 4
2 Included in the delivery . . . . . . . . . . . . . . . . . . . 5
3 Installation and transport tools . . . . . . . . . . . . . 6
4 Lifting the heat pump . . . . . . . . . . . . . . . . . . . . . 7
5 Product details . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Application area . . . . . . . . . . . . . . . . . . . . 8
5.2 Type overview . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Transport and storage . . . . . . . . . . . . . . . . 8
5.5 Transport locking devices . . . . . . . . . . . . . 8
5.6 Positioning the heat pump . . . . . . . . . . . . 8
5.7 Checks before installation . . . . . . . . . . . . 8
5.8 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.9 CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.10 Handling circuit boards . . . . . . . . . . . . . . 10
6 Heating, general . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Circuits for heating . . . . . . . . . . . . . . . . . 11
6.2 Control methods for heating . . . . . . . . . . 11
6.3 Time control for heating . . . . . . . . . . . . . 11
6.4 Operating modes . . . . . . . . . . . . . . . . . . . 12
7 Dimensions and clearance . . . . . . . . . . . . . . . . 13
7.1 HC 22 - 33 . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Technical information . . . . . . . . . . . . . . . . . . . . 14
8.1 Component parts . . . . . . . . . . . . . . . . . . 14
8.2 System solutions . . . . . . . . . . . . . . . . . . . 15
8.3 Functional description of system
solutions . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.4 Technical information . . . . . . . . . . . . . . . 22
9 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1 Collector system . . . . . . . . . . . . . . . . . . . 25
10.2 Heating system . . . . . . . . . . . . . . . . . . . . 25
10.3 Siting the appliance . . . . . . . . . . . . . . . . . 26
10.4 Pipework preparations . . . . . . . . . . . . . . 26
10.5 Flushing the heating system . . . . . . . . . . 26
10.6 Setting up . . . . . . . . . . . . . . . . . . . . . . . . 26
10.7 Heat insulation . . . . . . . . . . . . . . . . . . . . . 26
10.8 Removing the front panel . . . . . . . . . . . . 26
10.9 Temperature sensor installation . . . . . . . 27
10.10 Filling the heating system . . . . . . . . . . . . 27
10.11 Filling the hot water circuit . . . . . . . . . . . 27
10.12 Filling the collector system . . . . . . . . . . . 27
11 Electrical connections . . . . . . . . . . . . . . . . . . . . 30
11.1 Connecting the heat pump . . . . . . . . . . . 30
11.2 Phase guard . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Screed drying . . . . . . . . . . . . . . . . . . . . . . 30
11.4 Electrical connection wiring diagram . . . 31
11.5 External connections . . . . . . . . . . . . . . . . 36
11.6 Other wiring diagrams . . . . . . . . . . . . . . . 37
11.7 Connection of additional heat alarm . . . . 45
11.8 Connection of hot water electric heater . 45
11.9 Connection of circulation pump
E41.E1.G1 . . . . . . . . . . . . . . . . . . . . . . . . .46
11.10 Connection of low energy pump E11.G1 . 46
12 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12.1 Panel overview . . . . . . . . . . . . . . . . . . . . . 47
12.2 On/Off button . . . . . . . . . . . . . . . . . . . . . 47
12.3 Status lamp . . . . . . . . . . . . . . . . . . . . . . . 47
12.4 Menu display . . . . . . . . . . . . . . . . . . . . . . 47
12.5 Menu button and menu dial . . . . . . . . . . . 47
12.6 Return button . . . . . . . . . . . . . . . . . . . . . 47
12.7 Mode button . . . . . . . . . . . . . . . . . . . . . . 47
12.8 Info button . . . . . . . . . . . . . . . . . . . . . . . . 47
13 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14 Installer menus . . . . . . . . . . . . . . . . . . . . . . . . . 49
14.1 Access to the functions on Installer level 49
14.2 Compressor fast restart . . . . . . . . . . . . . . 49
14.3 Temperature sensor . . . . . . . . . . . . . . . . . 49
Contents
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15 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . 50
16 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16.1 Room temperature . . . . . . . . . . . . . . . . . 57
16.2 Hot water . . . . . . . . . . . . . . . . . . . . . . . . 68
16.3 Holiday . . . . . . . . . . . . . . . . . . . . . . . . . . 71
16.4 Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
16.5 External control . . . . . . . . . . . . . . . . . . . 73
16.6 Installer . . . . . . . . . . . . . . . . . . . . . . . . . . 74
16.7 Additional heat . . . . . . . . . . . . . . . . . . . . 80
16.8 Safety functions . . . . . . . . . . . . . . . . . . . 83
16.9 General . . . . . . . . . . . . . . . . . . . . . . . . . . 83
16.10 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
16.11 Access level . . . . . . . . . . . . . . . . . . . . . . . 85
16.12 Return to factory settings . . . . . . . . . . . . 85
17 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
17.1 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
17.2 Control unit and room sensor alarm lamp 86
17.3 Alarm display . . . . . . . . . . . . . . . . . . . . . . 86
17.4 Alarm buzzer at alarm . . . . . . . . . . . . . . . 86
17.5 Acknowledgement of alarms . . . . . . . . . . 86
17.6 Alarm timer, alarm mode . . . . . . . . . . . . 86
17.7 Alarm categories . . . . . . . . . . . . . . . . . . . 87
17.8 Alarm window . . . . . . . . . . . . . . . . . . . . . 87
17.9 Alarm functions . . . . . . . . . . . . . . . . . . . . 88
17.10 Alarm log . . . . . . . . . . . . . . . . . . . . . . . . . 96
17.11 Alarm history . . . . . . . . . . . . . . . . . . . . . . 96
18 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . 97
18.1 Return to factory settings . . . . . . . . . . . . 97
18.2 Factory values . . . . . . . . . . . . . . . . . . . . . 97
19 Function check . . . . . . . . . . . . . . . . . . . . . . . . 102
19.1 Refrigerant circuit . . . . . . . . . . . . . . . . . 102
19.2 Filling pressure in collector circuit . . . . 102
19.3 Setting heating system operating
pressure . . . . . . . . . . . . . . . . . . . . . . . . . 102
19.4 Operating temperatures . . . . . . . . . . . . 103
20 Environmental protection . . . . . . . . . . . . . . . . 104
21 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 105
22 Commissioning protocol . . . . . . . . . . . . . . . . . 106
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Key to symbols and safety instructions
4
1 Key to symbols and safety instructions
1.1 Explanation of symbols
Warning symbols
Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions.
NOTICE indicates possible damage to property or equipment, but where there is no risk of injury.
CAUTION indicates possible injury.
WARNING indicates possible severe injury.
DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety precautions
General
B Read the gu ide carefu lly and keep i t to hand for fu tur e
use.
Installation and commissioning
B The heat pump may be installed and put into
operation only by a qualified installer.
Service and maintenance
B Only qualified personnel may carry out repairs.
Incorrect repairs can lead to serious risks to the user, and a reduction in savings.
B Only use original spare parts. B Service and maintenance must be carried out annually
by an authorised service representative.
Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background.
Electrical hazards are identified by a lightning symbol surrounded by a warning triangle.
Notes contain important information in cases where there is no risk of personal injury or material losses and are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.
Symbol Meaning
B a step in an action sequence
a reference to a related part in the docu-
ment or to other related documents
a list entry
a list entry (second level)
Tab. 1
Included in the delivery
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2 Included in the delivery
Fig. 1
1 Heat pump 2 Flow sensor 3 Adjustable feet 4 Outdoor sensor 5 Warranty Card 6 Guides 7 Particle filter for hot water 8 Particle filter for the heating system 9 Particle filter for the collector circuit 10 Pliers for particle filter 11 Safety valve, 4 bar
11
1
2
4
5
6
10
3
6720645504-01.1I
9
8
7
Installation and transport tools
6
3 Installation and transport tools
The heat pump may be transported only with a handling trolley/lift truck .
Fig. 2 Example of a handling trolley/lift truck that can be used during installation of a heat pump
DANGER: Personal injuries may occur. The heat pump weighs between 330 and 360 kg.
B Never lift the heat pump by hand.
6 720 616 938-22.1I
Lifting the heat pump
6 720 645 504 (2011/04) en
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4 Lifting the heat pump
Remove the packaging and the transport pallet from the heat pump. Dismantle also the front and side plates before lifting the heat pump into the building.
Fig. 3 HC22-33 with lifting belts
1 HC 22-33 with lifting belt on opposite sides 2 Attach the lifting belts to the heat pump according to the
figure
DANGER: Personal injuries may occur. The heat pump weighs between 330 and 360 kg.
B Never lift the heat pump by hand.
x 2
1
2
6 720 645 504-02.1I
Product details
8
5 Product details
HC 22-33 are ground source pumps designed to be supplemented with an external hot water heater.
5.1 Application area
The heat pump must only be used in a closed hot water heating system according to BS EN 12828. Other forms of use are not permitted. We take no responsibility for damage occurring due to non­permitted use.
5.2 Type overview
HC Ground source heat pump kW Heat output 0/35 (EN 14511)
5.3 Type plate
The type plate is located on the roof plate of the heat pump. Information about the heat pump's output, part number, serial number and date of manufacture is stated there.
5.4 Transport and storage
The heat pump should always be transported and stored in an upright position. However, the heat pump may be tilted temporarily, but must not be laid down.
The outer cover plates should be removed to avoid damage if the heat pump is transported without the supplied transport pallet.
The heat pump must not be stored at temperatures below -10 °C.
5.5 Transport locking devices
The heat pump is furnished with transport locking devices which prevent damage during transportation. Unscrew the transport locking devices installed next to the vibration dampers on the heat pump ( figure 9).
5.6 Positioning the heat pump
B The heat pump is placed indoors, on a level and stable
surface that withstands a weight of at least 400 kg.
B Adjust the rubber feet so the heat pump does not
lean.
B The ambient temperature around the heat pump must
be between 10 °C and 35 °C.
B The installer should take noice transfer to adjacent
areas into consideration when positioning the heat pump.
B There must be a drain in the room where the heat
pump is placed. This ensures that water can easily be carried away if there is a leak.
5.7 Checks before installation
B Installation of the heat pump should be performed by
a qualified installer.
B Before the heat pump is commissioned, the heating
system, hot water cylinder and the collector circuit system, including the heat pump, must be filled and vented.
B Check that all pipe connections are intact and have
not shaken loose during transportation.
B Wiring should be kept as short as possible to protect
the system from downtime, for example during a thunderstorm.
B Heat pump installation, energy drilling and collector
installation must follow applicable regulations.
B Check the water quality ( page 24, VDI 2035).
5.8 Checklist
1. Position the heat pump on an even base. Adjust the height using the adjustable feet.
2. Fit the valves, particle filters and a filling unit.
3. Install the incoming and outgoing pipes for the heat pump, as well as the expansion vessel.
4. Connect the heating unit to the heating system.
5. Install the outdoor sensor and possible room sensors.
6. Fill and vent the heating and collector systems before commissioning.
7. Carry out the external connections.
8. Connect the heating installation to the power supply.
9. Commission the heating installation by making all the necessary settings on the control panel.
10. Check the heating installation after commissioning.
11. Top up more collector circuit fluid, if required.
Only qualified installers may carry out the installation. The installer must follow applicable rules and regulations and recommendations from the supplier.
HC HC 22 HC 33
kW 21,0 33,8
Tab. 2 Type overview
Each heat pump installation is unique. The following checklist will give you a general description of how the installation should be carried out.
Product details
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5.9 CAN-BUS
The various circuit boards in the heat pump are joined by a communications cable, CAN-BUS. CAN (Controller Area Network) is a two-wire system for communication between microprocessor based modules/circuit boards.
Suitable cable for external laying is cable LIYCY (TP) 2x2x0.5. The cable must be twisted pair and screened. The screen must only be earthed at one end and to the chassis.
Maximum cable length is 30 m.
CAN-BUS cable must not be laid alongside power supply cables. Minimum distance 100 mm. They may be laid alongside sensor cables.
The connection between the circuit boards is by four wires, because the 12V-supply between the circuit boards must also be connected. The circuit boards have markings for both the 12V and CAN-BUS connections.
Switch Term is used to mark the start and end of a CAN­BUS loop. Ensure that the correct circuit board is terminated and that all other switches are in the opposite position.
Fig. 4
GND Earth CANL CAN low CANH CAN high +12V Connection 12V EWP Heat pump
CAUTION: Interference.
B The CAN-BUS cable must be screened
and laid separately from the power cable.
CAUTION: Do not mix up the 12V and CAN­BUS connections!
The processors are destroyed if 12V is connected to the CAN-BUS.
B Check that the four cables are connected
to the contacts with the corresponding marking on the circuit board.
6 720 614 967-31.2I
CAN-BUS
CAN-BUS
Product details
10
5.10 Handling circuit boards
Circuit boards with control electronics are sensitive to discharges of static electricity (ESD – ElectroStatic Discharge) when handled. To prevent damaging the components, special care is therefore required when handled.
Fig. 5 Bracelet
Damage is usually latent, and a circuit board can operate impeccably during commissioning but show signs of problems later. Charged objects may only be problematic if they are in close proximity to the electronics. Keep a distance of at least one metre from expanded polystyrene, protective plastic and other packaging, synthetic material (e.g. fleeces) and similar before starting work.
A condition for good ESD protection is a ground­connected bracelet when handling electronics. This bracelet must be put on before opening the screened metal bag/packaging or before exposing an installed board. The bracelet must be worn until the circuit board is enclosed in its screen packaging or closed electric box. Replaced, returned circuit boards must be handled in the same way.
Fig. 6
CAUTION: Never grasp a circuit board without wearing a ground-connected bracelet.
6 720 614 366-24.1I
6 720 614 366-25.1I
Heating, general
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6 Heating, general
6.1 Circuits for heating
Circuit 1; the first circuit is included by default in the control unit and is controlled by the installed flow sensor, possibly in combination with an installed room sensor.
Circuit 2 (mixed); control of circuit 2 is also included by default in the control unit and only needs to be supplemented with a mixing valve, circulation pump and flow sensor and possibly with an additional room sensor.
Circuit 3-4 (mixed); control of up to 2 additional circuits is optional. Each circuit is then fitted with a mixing valve module, circulation pump, flow sensor and a possible room sensor.
6.2 Control methods for heating
Outdoor sensor; a sensor is fitted on the outside wall of the house. The sensor sends signals to the control unit in the heat pump. Control with an outdoor sensor means that the heat pump automatically regulates the heating in the house depending on the outdoor temperature. The customer determines the temperature of the heating system in relation to the outdoor temperature by setting the heat curve on the control unit.
Outdoor sensor and room sensors (one room sensor per circuit is possible); Control with outdoor sensor supplemented with room sensor(s) means that one (or several) sensors are mounted in a central location inside the house. They are connected to the heat pump and provide the control unit with information about the current room temperature. The signal affects the flow temperature. For example, it falls when the room sensor indicates a higher temperature than the one set. Room sensors are used when factors other than the outdoor temperature influence the indoor temperature of the house. For example, this can be when a stove or fan-assisted radiator is used in the house, or if the house is sensitive to the wind or exposed to direct sunlight.
6.3 Time control for heating
Program control; The control unit offers a possibility to define two individual programs for time control of the heating.
Holiday; the control unit has a program for holiday mode, which means that during the selected period the room temperature changes to a lower or higher level. The program also allows switching off hot water production.
External control; the control unit can make settings for external control, which means that the preselected function is performed when the control unit senses an input signal.
Circuit 1 must always be installed and used.
Circuits 2 through 4 cannot have a higher flow temperature than circuit 1. This means that underfloor heating on circuit 1 cannot be combined with radiators on another circuit. Room temperature reduction for circuit 1 can affect other circuits in some cases.
When the Use temperature from circuit
with highest temperature function under Circuit 1 is used, the heat curve for Circuit 1 does not need to be adapted to the mixed
circuits. The heat pump automatically selects the highest flow temperature set point value.
It is only the room where the room sensor is located that can influence regulation of the temperature for the relevant heating circuit.
Heating, general
12
6.4 Operating modes
Without additional heat; the heat pump is sized so as to cover at least 100 % of the peak output of the house.
This choice is not in the control, choose Mixed
additional heat at Start-up and thereafter Block additional heat in the menu for additional heat
( Chapter 16.7).
With electrical additional heat; the heat pump is sized to cover less than the peak output of the house. An additional electric heat source covers the difference. The additional electric heat source is controlled by a 0-10 V signal which is connected to the mixing valve output E71.E1.Q71 on the PEL board ( Chapter 11.6.5). Otherwise, the control of the additional electric heat source functions in the same way as the control of the mixed additional heat source. The mixing valve control delay should be set to 0, since it unnecessarily extends the start delay of the additional heat ( Chapter 16.7).
With mixed additional heat; mixed additional heat source which is allowed to work in parallel with the heat pump. Connection E71.E1.Q71 ( Chapter 11.6.3). The additional heat is also used in alarm mode. For production of extra hot water and hot water peak, an additional electric heat source is required in the hot water heater.
For all operating modes shall Mixed additional heat be used.
An additional electric heat source should always be installed in the hot water heater if the heat pump should supply more than 2 flats. If an oil/gas boiler is used as a mixed additional heat source, the boiler can be installed in such a way as to generate hot water, extra hot water and hot water peak. In this case, an additional electric heat source is not required in the hot water heater.
Dimensions and clearance
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7 Dimensions and clearance
7.1 HC 22 - 33
Fig. 7 Front view
Fig. 8 Top view
All dimensions are stated in mm.: A Collector circuit out
B Collector circuit in C Return, hot water heater D Flow, hot water heater E Heat transfer fluid in F Heat transfer fluid out G Electrical connections
100 350
600
1640
6 720 645 504-03.1I
E
B
A
F
C
D
700
810
300
135
230
1200
G
100
200
300
400
500
600
6 720 614 967-8.2I
Technical information
14
8 Technical information
8.1 Component parts
8.1.1 HC 22 - 33
Fig. 9
1 Type plate 2 Collector circuit pump 3 Heat carrier pump 4 Low pressure switch 5 Condenser 6 Compressor (1 and 2)
7 Evaporator 8 Sight glass 9 High pressure switch 10 Expansion valve 11 3-way valve 12 Drying filter 13 Transport locking devices (2) and Vibration dampers (2)
6 720 614 967-5.1I
8
5
5
3
3
8
11
12
12
2
4
2
6
9
4
6
9
10
13
1
7
7
10
13
Technical information
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8.2 System solutions
8.2.1 System solution explanations
Detailed system solutions can be found in the product's planning documentation.
E10
E10.T2 Outdoor sensor
Tab. 3 E10
E11 Circuit 1
E11.C101 Expansion vessel
E11.C111 Buffer tank
E11.F101 Safety valve
E11.F111 Automatic air vent
E11.G1 Heating circuit pump
E11.P101 Pressure gauge
E11.P111 Thermometer
E11.P112 Thermometer
E11.Q101 Shut-off valve
E11.Q102 Shut-off valve
E11.R101 Non-return valve
E11. T1 Flow sensor
E11.TT Room sensor
Tab. 4 E 11 Circuit 1
E12 Circuit 2
E12.G1 Heating circuit pump
E12.P112 Thermometer
E12.Q101 Shut-off valve
E12.Q102 Shut-off valve
E12.Q11 Mixing valve
E12.R101 Non-return valve
E12.T1 Flow sensor
E12.T5 Room sensor
Tab. 5 E12 Circuit 2
E21 Compressor 1
E21 Heat pump
E21.F111 Automatic air vent
E21.G2 Heat carrier pump
E21.G3 Collector circuit pump
E21.Q102 Shut-off valve
E21.Q21 3-way valve
E21.R101 Non-return valve
E21.R102 Non-return valve
E21.T8 Heat transfer fluid out
E21.T9 Heat transfer fluid in
E21.T10 Collector circuit in
E21.T11 Collector circuit out
E21.V102 Filter
Tab. 6 E21 Compressor 1
E22 Compressor 2
E22 Heat pump
E22.F101 Safety valve
E22.G2 Heat carrier pump
E22.G3 Collector circuit pump
E22.Q101 Shut-off valve
E22.Q21 3-way valve
E22.R101 Non-return valve
E22.R102 Non-return valve
E22.T8 Heat transfer fluid out
E22.T9 Heat transfer fluid in
E22.T10 Collector circuit in
E22.T11 Collector circuit out
E22.V101 Filter
Tab. 7 E22 Compressor 2
Technical information
16
E31 Collector circuit
E31 Collector circuit, compressor 1
E31.C101 Expansion vessel
E31.F101 Safety valve
E31.F102 Safety valve
E31.F111 Automatic air vent
E31.Q21 Ball valve filling unit
E31.Q22 Ball valve filling unit
E31.Q23 Shut-off valve
E31.Q24 Shut-off valve
E31.V101 Filter
Tab. 8 E31 Collector circuit
E41 and E42 Domestic hot water tank 1 and 2
E41 Hot water heater 1
E41.E1 Hot water electric heater
E41.E1.G1 Circulation pump
E41.F101 Safety valve
E41.F102 Safety valve
E41.G6 Circulation pump hot water
E41.P111 Thermometer
E41.P112 Thermometer
E41.Q101 Shut-off valve
E41.Q104 Shut-off valve
E41.Q105 Shut-off valve
E41.Q106 Shut-off valve
E41.Q111 Balancing valve
E41.R101 Non-return valve
E41.R102 Non-return valve
E41.T3 Hot water sensor
E41.V41 Hot water
E41.W41 Cold water
E42 Hot water heater 2
Tab. 9 E41, E42 DHW tank 1, 2
E71 Additional heat
E71 Additional heat
E71.E1.F101 Safety valve
E71.E1.F111 Automatic air vent
E71.E1.G71 Circulation pump
E71.E1.P111 Thermometer
E71.E1.P101 Pressure gauge
E71.E1.Q1Q1 Shut-off valve
E71.E1.Q1Q2 Shut-off valve
E71.E1.Q71 Mixing valve
Tab. 10 E71 Additional heat
Technical information
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8.2.2 System solution without additional heat
Fig. 10 Heating circuit and buffer tank without additional heat (
Chapter 8.2.1, 8.3)
6 720 616 938-23.1I
Technical information
18
8.2.3 System solution with mixed additional heat
Fig. 11 Heating circuit, buffer tank and mixed additional heat (
Chapter 8.2.1, 8.3)
6 720 616 938-26.1I
Technical information
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8.2.4 System solution with electric additional heat
Fig. 12 Heating circuit, electric additional heat and buffer tank (
Chapter 8.2.1, 8.3)
6 720 616 938-25.1I
Technical information
20
8.3 Functional description of system solutions
System without additional heat ( Chapter 8.2.2)
Heating
Heat for E11 is taken directly from buffer tank E11.C111. Heat for E12 is taken from buffer tank E11.C111 and is shunting to the set temperature using mixing valve E12.Q11. The heat pump supplies heat to E11.C111 and keeps the temperature set on E11.T11 by starting one compressor at a time when the temperature is too low and stopping one compressor at a time when the temperature is too high.
Hot water
When the temperature in hot water heater E41.T3 falls below the set limit, E21.Q21 switches over to water heating and compressor E21 starts. Water heating continues until the temperature of E21.T8 exceeds the set stop limit.
Pump control
E11.G1 and E12.G1 start at low outdoor temperature and stop at high outdoor temperature. E21.G2 and E21.G3 are in operation when compressor E21 is in operation. E22.G2 and E22.G3 are in operation when compressor E22 is in operation. E41.G6 is in operation at set times.
System with mixed additional heat ( Chapter 8.2.3)
Additional heat and heat pump work in parallel
Heat for E11 is taken directly from buffer tank E11.C111, with possible afterheating by E71. Heat for E12 is taken from buffer tank E11.C111, with possible afterheating by E71, and is released by shunting at the set temperature using mixing valve E12.Q11. The heat pump supplies heat to E11.C111 in order to keep the temperature set on E11.T11 by starting one compressor at a time when the temperature is too low and stopping one compressor at a time when the temperature is too high. If the heat pump does not manage to supply the set temperature by itself, additional heat E71.E1.Q71 is activated and regulates E11.T1 to the set temperature.
Additional heat and heat pump work separately
When the heat pump is responsible for all of the heating, it supplies heat to E11.C111 and keeps the temperature set on E11.T11 by starting one compressor at a time when the temperature is too low and stopping one compressor at a time when the temperature is too high. When the heat pump is in operation, boiler E71 is responsible for all of the heat production. Heat for E11 is taken from buffer tank E11.C111 or from E71. Heat for E12 is taken from buffer tank E11.C11 or from E71 and is shunted to the set temperature using mixing valve E12.Q11. Switch between heat pump and additional heat operation can result from low outdoor temperature, temporary stop of the energy supply to the heat pump or activation of external input for blocking the heat pump.
Hot water
The hot water is preheated in E41 which is heated by the heat pump. When the temperature in hot water heater E41.T3 falls below the set limit, E21.Q21 switches over to water heating and compressor E21 starts. Water heating continues until the temperature of E21.T8 exceeds the set stop limit. The hot water is afterheated in E42 which is heated by additional heat E71. The heating of the hot water circulation via E41.G6 is done completely by E42. Additional heat E71 exercises full control and regulation of the temperature in hot water heater E42.
Pump control
E11.G1 and E12.G1 start at a low outdoor temperature and stop at a high outdoor temperature. E21.G2 and E21.G3 are in operation when compressor E21 is in operation. E22.G2 and E22.G3 are in operation when compressor E22 is in operation. E41.G6 are in operation at the set times. E41.E1.G1 ( Chapter 11.9) is controlled by the heat pump and is used for thermal disinfection of E41.
High temperature systems
In some heating systems the return temperature may at times exceed 55 °C. In such cases the heat pump stops (T9 > 55 °C) and restarts when E11.T1 becomes less than 65 °C.
Technical information
6 720 645 504 (2011/04) en
21
System with electric additional heat ( Chapter 8.2.4)
Heating
Heat for E11 is taken directly from buffer tank E11.C111, with possible afterheating by E71. Heat for E12 is taken from buffer tank E11.C111, with possible afterheating by E71, and is shunted to the set temperature using mixing valve E12.Q11. The heat pump supplies heat to E11.C111 and keeps the temperature set on E11.T11 by starting one compressor at a time in the heat pump when the temperature is too low and stopping one compressor at a time when the temperature is too high. If the heat pump does not manage to supply the set temperature by itself, additional heat is activated, controlling the output via 0­10 V signal so as to keep the set temperature.
Hot water
When the temperature in hot water heater E41.T3 falls below the set limit, E21.Q21 switches over to water heating and compressor E21 starts. Water heating continues until the temperature of E21.T8 exceeds the set stop limit.
Pump control
E11.G1 and E12.G1 start at low outdoor temperature and stop at high outdoor temperature. E21.G2 and E21.G3 are in operation when compressor E21 is in operation. E22.G2 and E22.G3 are in operation when compressor E22 is in operation. E41.G6 is in operation at set times.
This system solution is also suitable for 0­10V output-controlled gas/oil-fired boiler.
Enter Yes for Acknowledge hot water additional heat (Chapter 16.7) in all system solutions.
Technical information
22
8.4 Technical information
8.4.1 HC 22 - 33
Unit HC 22 HC 33
Liquid/water operation
Emitted output / COP (0/35) EN14511
1)
1) The indicated values are measured according to WPZ test methods.
kW 21.0/4.4 33.8/4.2
Emitted output / COP (0/45) EN14511
1)
kW 19.9/3.5 31.6/3.2
Emitted output / COP (0/35) EN255
1)
kW 21.6/4.8 34.2/4.4
Emitted output / COP (10/35) EN255
1)
kW 26.4/5.8 41.7/5.2 Max. cooling effect (0/35) kW 17 26 Max. cooling effect (10/35) kW 23 34
Collector circuit
Connection, collector circuit DN40, 1½ “ Working pressure collector circuit max/min bar 4 / 0.5 Incoming temperature collector circuit max/min °C 22 / -5 Outgoing temperature collector circuit min. °C -8 Mixture Ethylene glycol max/min % 35 / 30 Nominal flow collector circuit (max deviation 15%) l/s 1.3 2.3 Permitted ext. pressure drop collector circuit kPa 65 44
Heating system
Buffer tank connections DN 32, 1¼ “ Tap hot water connections DN 25, 1“ Nominal flow hot water (max deviation 15%) l/s 0.28 0.45 Working pressure heating system max/min bar 4 / 0.5 Flow buffer tank max/min l/s 0.74/0.52 1.1/0.82 Max. ext. pressure drop buffer tank at max. flow kPa 30 20 Max. ext. pressure drop buffer tank at min. flow kPa 40 40
Compressor
Step 1 (no. 1) Mitsubishi Scroll Step 2 (no. 2) Mitsubishi Scroll Max. flow temperature (no. 1/no. 2) °C 65/65 Refrigerant R 407C (no. 1/no. 2)
2)
2) Global Warming Potential, GWP
100
= 1526
kg 2,4/2,4 2,6/2,6
Sound level
3)
3) The sound level is the acoustic energy that the heat pump emits and is not affected by the surroundings. On the other hand, the sound pressure level is affected by the surroundings and is approx. 11dBA lower when measured at a distance of 1 m in a free field.
dBA 51 53
Electrical data
Electrical connection (acc. to EN 60204-1) 400V 3N~50Hz Fuse gL- gG / characteristic D (automatic) A 25 32 Max. short-circuit impedance soft starter Ω 0,42 0,47 Max. operating current A 17 22,3 Start current with soft starter A 29 30 Nominal output (0/50) kW 6,7 10,8 Nominal output (0/35) kW 5,5 8,7 Maximum effect kW 10,5 14,1 Collector circuit pump output at max. speed (no. 1/no. 2) W 310/310 390/390 Collector circuit pump output at min. speed (no. 1/no. 2) W 290/290 360/360 Heat carrier pump output at max. speed (no. 1/no. 2) W 91/91 124/124 Heat carrier pump output at min. speed (no. 1/no. 2) W 49/49 61/61
General
Dimensions (height x depth x width) mm 700 x 750 x 1620 Weight kg 330 351
Tab. 11 Teknisk information
Technical information
6 720 645 504 (2011/04) en
23
8.4.2 Motor cut-out compressor
8.4.3 Circulation pumps
8.4.4 Measurement values for temperature sensors
Compressor HC 22 HC 33
No. 1 8 A 13 A
No. 2 8 A 13 A
Tab. 12 Motor cut-out settings, compressor
Collector circuit pump (G3)
HC 22 HC 33
No. 1 Wilo TOP-S 30/10 TOP-S 30/10
No. 2 Wilo TOP-S 30/10 TOP-S 30/10
Tab. 13 Built-in collector circuit pumps
Heat carrier pump (G2)
HC 22 HC 33
No. 1 Wilo RS-25/6 RS-25/7
No. 2 Wilo RS-25/6 RS-25/7
Tab. 14 Built-in heat carrier pumps
°C Ω
T...
°C Ω
T...
°C Ω
T...
°C Ω
T...
–40 154300 –5 19770 30 3790 65 980
–35 111700 0 15280 35 3070 70 824
–30 81700 5 11900 40 2510 75 696
–25 60400 10 9330 45 2055 80 590
–20 45100 15 7370 50 1696 85 503
–15 33950 20 5870 55 1405 90 430
–10 25800 25 4700 60 1170
Tab. 15 Measurement values for temperature sensors
Regulations
24
9Regulations
The following regulations and requirements must be observed:
The responsible power supply company's local regulations and requirements, including the corresponding special rules (TAB)
BImSchG, Section 2 on installations which do not require permits
TA Lärm Technical Instruction on Noise Protection - (general regulation in accordance with the Federal Emission Control Act)
National building regulations
EnEG (Energy Saving Act)
EnEV (German regulations on energy saving thermal
insulation and energy saving building design)
EN 60335 (Safety of electric and similar household appliances) part 1 (General requirements) Part 2-40 (Particular requirements for electrical heat pumps, air-conditioners and dehumidifiers)
EN 12828 (Heating systems in buildings. Design for water-based heating systems)
DVGW, Wirtschafts- und Verlagsgesellschaft, Gas- und Wasser GmbH - Josef-Wirmer-Str. 1–3 ­53123 Bonn
– Worksheet W 101
Guidelines for drinking water protection areas; part I: protection areas for groundwater
The following DIN standards:DIN 1988, TRWI (Technical Regulations for Drinking Water Installations),DIN VDE 0100, Part 701 (Installation of High-Power Equipment with Rated Voltages up to 1000 V, Rooms with Bath or Shower),DIN 4751 (Heating Systems; Safety Systems for Water Heating Systems with Flow Temperatures up to 110 °C),DIN 4807 (Expansion Vessels)Beuth-Verlag GmbH ­Burggrafenstraße 6 -10787 Berlin
DIN 1988, TRWI (Technical Regulations for
Drinking Water Installations)
DIN 4108 (Thermal Insulation and Energy Economy
in Buildings)
DIN 4109 (Sound Insulation in High Buildings)DIN 4708 (Central Hot Water Installations)DIN 4807 and EN 13831, respectively (Expansion
Vessels)
DIN 8960 (Refrigerants -Requirements and
Symbols)
DIN 8975-1 (Refrigerating Plants - Safety Principles
for Design, Equipment and Installation ­Interpretation)
DIN VDE 0100, (Installation of High-Power
Equipment with Rated Voltages up to 1000 V)
DIN VDE 0105 (Operation of Power Installations)DIN VDE 0730 (Regulations for Devices with
Electromotive Drive for Domestic Use and Similar Purposes)
VDI guidelines, Verein Deutscher Ingenieure e.V. - P.O. Box 10 11 39 - 40002 Düsseldorf
VDI 2035 Sheet 1
1)
: Prevention of damage in water heating installations and scale formation in domestic hot water supply installations and water heating installations
VDI 2035 Sheet 2
2)
: Prevention of water corrosion
in the heating system
VDI 2081 Sound production and reduction in
ventilation systems
VDI 2715 Noise reduction at domestic hot water
and central heating systems
VDI 4640 Thermal use of the underground,
Sheet 1: Fundamentals, approvals, environmental aspects; Sheet 2: Ground source heat pump systems
Austria:
örtliche Bestimmungen und regionale
Bauordnungen
Vorschriften der Versorgungsnetzbetreiber (VNB)Vorschriften der WasserversorgungsunternehmenWasserrechtsgesetz von 1959 in gültiger FassungÖNORM H 5195-1 Verhütung von Schäden durch
Korrosion und Steinbildung in geschlossenen Warmwasserheizungsanlagen bis 100 °C
– ÖNORM H 5195-2 Verhütung von Frostschäden in
geschlossenen Heizungsanlagen
Switzerland: kantonale und örtliche Vorschriften1
1) If the drinking water has a higher °dH than what is indicated in VDI 2035, a water softener must be installed in the filling pipe to the heating system - this in order to guarantee the function of the heat pump. However, when the hardness is already greater than 3 °dH, the performance of the heat pump will deteriorate with time because of the lime deposits left on the heat exchanger surfaces.
2) The standard discusses the problems but does not set any limit values. This is why, we supplement with the following values: Oxygen content, O
2
-0.5-1 mg/l. Carbon dioxide content, CO2 ­<1 mg/l. Chloride, Cl - <100 mg/l. Sulphate, SO4 - <100 mg/l. If the drinking water exceeds the limit values for chloride or sulphate content, an ion exchange filter must be installed in the filling pipe for the heating system. Do not use any water treatment additives except agents for raising the pH level, keep the water clean.
Installation
6 720 645 504 (2011/04) en
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10 Installation
10.1 Collector system
Installation and filling
Installation and filling of the collector system should comply with applicable laws and regulations. Soil used for refilling around the collector hose must not contain stones or other sharp objects. Pressure test the collector system before refilling to ensure that the system is watertight.
When cutting the collector, it is important that no dirt or gravel enters the system. This can cause blockages in the heat pump and damage components.
Condensation insulation
Condensation insulation should be mounted on all parts of the collector circuit system.
Filling unit
A filling unit is required and should be installed close to the collector circuit inlet.
Vents
To avoid operational disturbances because of air bubbles, a microbubble separator with a venting nipple is required and should be installed between the filling unit and the heat pump.
Expansion vessel, safety valve, pressure gauge
The expansion vessel, safety valve and pressure gauge are to be provided by the dealer.
Membrane expansion vessel in the collector circuit
Select membrane expansion vessel according to:
The values apply at a pre-pressure of 0.5 bar.
Antifreeze/Corrosion preventative
Freeze protection until –15 °C should be ensured. We recommend the use of ethylene glycol.
10.2 Heating system
Flow over the heating system
When the heat pump works with a buffer tank, there can be significant variations in the flow into the heating system. However, there must be a certain minimum flow, which is solved by:
In the event of a radiator system, the setting for the radiator thermostats must be limited to a minimum temperature of 18°C.
In the event of a floor heating system, a minimum water flow must be guaranteed by ensuring that there are circuits without room temperature control or with a bypass in the floor heating distributor.
This guarantees cooling of the heating system's circulation pump and correct measurements of the flow sensor. A slight increase in flow rate above the minimum flow is accepted.
Expansion vessel
Select expansion vessel in accordance with BS EN 12828.
Particle filter
A particle filter for the heating system is included in the delivery and should be installed on the connection for heat transfer fluid in (heating system return).
A particle filter for the collector circuit is included in the delivery and is installed between the filling unit and the heat pump close to the connection for collector circuit in.
A particle filter for hot water is included in the delivery and should be installed on the connection for hot water return.
See also the system solutions ( Chapter 8.2).
Ethylene glycol
Glycol is not normally used in the heating system. In special cases, where increased protection is required, glycol can be added with a maximum concentration of 15%. Heat pump performance will however decrease.
Safety valve
Pursuant to EN 12828, a safety valve should be used.
The safety valve must be installed vertically.
Only qualified installers may carry out the installation. The installer must follow applicable rules and regulations and recommendations from the supplier.
Model Volume
HC 22 25 litres
HC 33 35 litres
Tab. 16 Volume membrane expansion vessel
WARNING:
B No other anti-freeze may be used in the
heating system.
Installation
26
10.3 Siting the appliance
Noice transfer to adjacent areas must be taken into consideration when choosing a position for the heat pump ( Chapter 8.4 for sound levels).
10.4 Pipework preparations
B Connection pipes for the collector system, heating
system and possible hot water should be installed in the premises to the heat pump location.
B An expansion vessel, a safety group and a pressure
gauge should be mounted in the heating circuit (accessories).
B Mount a filling unit at a suitable place in the collector
circuit close to the inlet.
10.5 Flushing the heating system
The heat pump is a part in a heating system. Faults in the heat pump can be caused by poor water quality in the radiators/floor loops or air penetrating the system continuously.
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 is not clear when drained, require remedial measures before the installation of a heat pump, for example the heating system must be fitted with filters and vents.
Do not use any water treatment additives except agents for raising the pH level. Recommended pH value is 7.5 –
9.
An intermediate heat exchanger is sometimes necessary to protect the heat pump.
10.6 Setting up
B Remove packing, taking care to observe the
instructions on the packing.
B Remove the supplied accessories. B Install the supplied adjustable feet and adjust the
height.
10.7 Heat insulation
All heat conducting pipes must have suitable heat insulation, applied to current standards.
10.8 Removing the front panel
B Loosen the screws, tilt the front panel outwards and
take it off.
Fig. 13
WARNING:
B Never block the safety valve outlet.
CAUTION: The heat pump may become damaged in the event of dirt or other particles in the pipework.
B Flush out the system to remove all dirt
residues.
CAUTION: The heat pump may become damaged in the event of dirt or other particles in the pipework.
B Flush out the system to remove all dirt
residues.
1.
1.
2.
6 720 614 967-4.1I
Installation
6 720 645 504 (2011/04) en
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10.9 Temperature sensor installation
10.9.1 Flow sensor T1
B Operation mode without additional heat with buffer
tank. Install the sensor in the upper part of the tank. See the installation manual for the buffer tank.
B Operation mode mixed additional heat (including
electric additional heat). Install the sensor in contact with the flow pipe immediately after the mixing valve (Q71) or after the additional electric heat.
10.9.2 Outdoor sensor T2
B Install the sensor on the coldest side of the house
(the north side). 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.
10.9.3 Room sensor T5 (accessory)
Installation location requirements:
If possible, interior wall without drafts or heat radiation.
Unimpeded circulation of room air under room sensor T5 (dotted area in figure 14 must be kept clear).
Fig. 14 Recommended installation location for room
sensor T5
10.10 Filling the heating system
B Open the heating system's valves. B Open the tap on particle filter E22.V101 of the heating
system. Open valve E22.Q101.
B Fill up the heating system until the appropriate
pressure for the installation is reached. The maximum permitted pressure is 4 bar.
B Vent the heating system. B Drain some water out of buffer tank E11.C111 in
order to flush away possible particles from the tank. Check and clean the particle filter if necessary.
B Check the pressure of the system and refill to the
appropriate pressure.
B Repeat the steps above if there is a lot of dirt in the
filter or tank.
B Check all connections for leaks.
10.11 Filling the hot water circuit
B Remove the cover of particle filter E21.V102. Position
the filter in an intermediate position.
B Position the 3-way valve E21.Q21 for heat production. B Open shut-off valve E21.Q102 a bit and fill the circuit
carefully.
B Position the filter in operating mode and refit the
cover.
B Open the shut-off valve completely and perform
manual operation of the 3-way valve E21.Q21 in both heating and hot water mode for venting.
B Check the pressure of the heating system and fill up,
if necessary, to a maximum of 4 bar.
B Check all connections for leaks.
10.12 Filling the collector system
The collector system is filled with collector circuit fluid which must guarantee antifreeze protection down to –15 °C. We recommend a mixture of water and glycol.
A rough estimate of the amount of collector circuit fluid that is required in relation to the length of the collector system and the inner diameter of the pipe can be made using table 17.
It is only the room where the room sensor is located that can influence regulation of the temperature for the relevant heating circuit.
6 720 614 366-34.1I
0,3 m
0,3 m
0,6 m
1,2 - 1,5 m
T5
Inner diameter
Volume per metre
Single pipes
Double U
pipes
28 mm 0.62 l 2.48 l 35 mm 0.96 l 3.84 l
Tab. 17 Amount of collector circuit fluid
Installation
28
The following description of filling presupposes the use of the filling station accessory. Follow corresponding steps if other equipment is used.
Fig. 15 Example of a filling unit
B Connect two hoses from the filling station to the
filling unit ( Figure 16).
Fig. 16 Filling with filling station
B Fill the filling station with collector circuit fluid. Fill
water before you fill antifreeze.
B Turn the valves on the filling unit so that they are in
filling position ( Figure 17).
Fig. 17 Filling unit in filling position
B Turn the valves on the filling station so that they are
in mixing position ( Figure 18).
Fig. 18 Filling station in mixing position
B Start the filling station (pump) and mix the collector
circuit fluid for at least two minutes.
B Turn the valves on the filling station to filling position
and fill the circuit with collector circuit fluid ( Figure 19).
Fig. 19 Filling unit in filling position
Double U pipes, each of which consists of two descending and two ascending pipes, are most often used as a rock collector.
6720614967-32.1I
Repeat the following steps for each circuit. One circuit at a time is filled with collector circuit fluid. Keep the valves closed in the other loops during the process.
6720614967-35.1I
Installation
6 720 645 504 (2011/04) en
29
B When the fluid level has fallen to 25% in the filling
station, the pump should be stopped and more collector circuit fluid should be filled and mixed.
B When the circuit is full and air no longer comes from
the return pipe, the pump should be run again for at least 60 minutes (the fluid should be clear and should not contain any bubbles).
B The circuit must be pressurized when venting is
complete. Turn the valves on the filling unit to pressure increase position and pressurize the circuit to 2.5 to 3 bar ( Figure 20).
Fig. 20 Filling unit in pressure increase position
B Turn the valves of the filling unit to normal position (
Figure 21) and turn off the pump on the filling station.
Fig. 21 Filling unit in normal position
B Disconnect the hoses and insulate the filling unit.
If other equipment is used, the following is required, among other things:
A clean container with capacity for the amount of collector circuit fluid that is required
An additional container for collection of contaminated collector circuit fluid
Submerged pump with filter, flow capacity of min. 6m
3
/h, pressure height of 60 to 80 m
Two hoses, Ø 25 mm
6720614967-34.1I
6720614967-32.1I
Electrical connections
30
11 Electrical connections
All regulation, control and safety devices on the heat pump are connected and checked upon delivery.
B According to the applicable regulations for 400 V/
50 Hz connection, a H05VV-... type 5-core cable must be used as a minimum. Select cable area and cable type that corresponds to the relevant fuse rating (Chapter 8.4) and routing method.
B Observe protection measures acc. to VDE regulations
0100 and special regulations of the local power supply utility.
B Connect the heat pump to the electric box connection
strip according to BS EN 60335 part 1 and via a switch with a minimum contact distance of 3 mm (e.g. fuses, LS switch). Other consumers must not be connected.
B Follow the relevant wiring diagram when connecting
an earth breaker. Only connect components that are approved for each market.
B Observe the colour coding when replacing circuit
boards.
11.1 Connecting the heat pump
B Remove the front panel (page 26). B Remove the electric box cover. B Route the connection cables to the electric box
through the cable gland in the roof plate of the heat pump.
B Connect the cables according to the wiring diagram. B Reinstall the electric box cover and the front panel of
the heat pump.
11.2 Phase guard
A phase guard is mounted and connected to the heat pump in order to monitor the phase sequence to the compressors during installation ( Figure 33 and 34).
There are three indicator lamps on the phase guard. When the heat pump is started the first time the uppermost lamp lights up yellow and the bottom lamp green. The lamp in the middle flashes red if there is a phase sequence error and the alarm Phase error E2x.B1 ( Chapter 17.9.11) is displayed. If so, change the phase sequence. The lamp is not lit at correct phase sequence.
The phase guard also trips on too high or too low voltage. The lamp in the middle lights red and the alarm
Phase error E2x.B1 ( Chapter 17.9.11) is displayed.
11.3 Screed drying
Screed drying must take place with continuous access to current. When screed drying is used, the electric connection should therefore be made in the standard way, see ( Chapter 11.4).
On completion of screed drying, the EVU signal can be connected (Chapter 11.4). Enable the EVU signal according to the settings under menu External control.
The screed drying process is described in ( Chapter 16.6.9).
DANGER: Risk of electric shock! B Switch off the main power supply before
starting work on the electrical part.
The heat pump's electrical connections must be able to be disabled safely.
B Install a separate safety switch that cuts
all current to the heat pump. A safety switch for each supply is required for separate power supplies.
CAUTION: Never grasp a circuit board without wearing a ground-connected bracelet ( Chapter 5.10).
The heat pump alone can not produce enough heating for screed drying. We recommend using building drying equipment.
EVU means a special electrical connection used primarily in countries like Germany and Austria.
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