AlphainnoTec BWP 310 User manual

830130GB/150111 - We reserve the right to make technical changes - 1

Alpha-InnoTec GmbH

Industriestrasse 3, D-95359 Kasendorf

Tel.: 09228 99060

Fax.: 09228 990629

www.alpha-innotec.de

e-mail:[email protected]

INSTRUCTION MANUAL

with Product Information

Domestic Hot Water Heat Pump

BWP 310

With control

Ventronik BWP

This instruction manual is part of the scope of supply and must be handed over to the user

of the plant. Please keep safely and show to competent persons, if necessary..

TABLE OF CONTENTS

Page

Product description 3

Scope of supply / Accessories 3

Prescriptions / Safety regulations 4

Transport / Assembly 5

Connections 6

Start-up 8

Maintenance 9

Errors / Trouble shooting 10

Environment 11

Refrigeration circuit 12

Hydraulic schematic 13

Capacity / Construction 14

Technical data 15

Control Ventronik BWP 16

Connection diagram 19

EU-Statement of Conformity 20

Guarantee Conditions 21

2-We reserve the right to make technical changes - 830130GB/150111

830130GB/150111 - We reserve the right to make technical changes - 3

Use of the domestic hot water heat pump

The domestic hot water heat pump serves exclusively for

heating domestic hot water within the speciﬁed operating

temperature limits.

Description of the domestic hot water heat pump

BWP 310 is a ready for connection heating appliance

which basically comprises the casing, the components of

the refrigeration circuit, the air circuit and the water circuit

as well as all the necessary control systems and monito-

ring systems for automatic operation.

The device is provided with a heat exchanger with appro-

ximately 0,8 m2 exchanger surface for the connection of

an additional heat generator such as a boiler, a solar in-

stallation etc.

Supported by electric power, the BWP 310 uses the heat

of the ambient air for the domestic water heating. The sto-

rage includes an immersion sleeve to be used for an ex-

ternal boiler thermostat respectively a sensor (diameter 6

mm) of an external regulation. The device is serialised with

an electric heating element (1,0 kW).

Coolant circuit

The coolant circuit is a closed system using the halide

CFC-free coolant R134a as energy source.

The heat is transferred from the air at a low evaporating

temperature (in the exchanger - evaporator) to the coolant.

The compressor sucks in the vaporized coolant and com-

presses it to achieve a higher pressure-/temperature level.

The coolant enters the condenser, where the heat gathe-

red in the evaporator and a part of the gathered compres-

sor energy is transferred to the domestic hot water. After-

wards, a throttle device (expansion valve) relieves the high

condensation pressure up to the evaporation pressure

and, in the evaporator, the coolant can again take in heat

transferred from the ambient air.

Functioning of the domestic hot water heat pump

The control unit starts the compressor as soon as there is

any need of hot water. The compressor operates as long

as the whole tank has achieved the requested temperatu-

re. Normally, the domestic hot water pump heats enough

domestic hot water to satisfy the needs of a family.

In case the domestic hot water pump cannot satisfy the

domestic hot water needs, an electric heating element

installed in the tank can be switched on by the Ventro-

nik BWP to increase the quantity of domestic hot water.

The electric heating element can be set to the requested

domestic hot water temperature (use the electric heating

element only if needed, because it consumes more energy

than the compressor). The electric heating element must

be activated manually at the control unit.

Scope of supply

● Domestic hot water pump with control unit.

Including plate and instruction manual with product infor-

mation.

Accessories

● Air duct connectors

● Temperature sensor solar / wooden boiler

● Anode

BWP 310

Product Description Scope of Supply/Accessories

4-We reserve the right to make technical changes - 830130GB/150111

BWP 310

Prescriptions / Safety Regulations

● The construction and the design of the domestic hot wa-

ter pump have been carried out in accordance with all

EU directives.

(see also EU Statement of Conformity)

Works at the domestic hot water pump must on

all accounts be carried out by competent per-

sons (DIN EN 378) in accordance with the acci-

dent prevention regulations and the following

regulations:

● The competent person must provide for the coolant to

be removed from the coolant-bearing parts as far is this

necessary to ensure the safe execution of maintenance

works and servicing.

● The competent person must provide for the risk of ﬁre

when doing maintenance works or servicing with open

coolant circuit, in particular when working with an un-

shielded ﬂame (soldering, welding etc.).

● Consider the accident prevention regulations in accor-

dance with (VBG 20).

● When doing works at the BWP 310, all electric circuits

must be switched off (unplug the power plug).

● The electrical installation of the BWP 310 must be car-

ried out by competent persons and in accordance with

all EU-standards and IEE* regulations and the regulati-

ons of the local energy supply companies.

*IEE – Institute of Electrical Engineers

● Only the use of drinking water quality is admissible (in

accordance with the Drinking Water Ordinance). Consi-

der the material compatibility for the whole water circuit.

Too high water pressure requires the use of a pressure

reducer.

● All drinking water supply points must be executed in

accordance with DIN 1988.

830130GB/150111 - We reserve the right to make technical changes - 5

BWP 310

Transport / Assembly

Storage and transport

of the domestic hot water heat pump

Basically, the domestic hot water heat pump must be in

packed condition and standing up straight without water

ﬁlling for storage or transportation. For transportation for

short ways, the heat pump may be inclined by maximum

45°. Ambient temperatures of -20 to +70°C are admissible

for the transportation and for the storage.

Transport with the lift truck

For the transport with the lift truck, the BWP 310 must be

secured to the pallet. The lifting speed must be kept low.

Due to the top-heaviness, the domestic hot water heat

pump must be secured against falling down.

Positioning of the domestic hot water heat pump:

The heat pump must be positioned on a ﬂat surface to avoid

damage.

Transport with the hand truck

● Secure the device on the hand truck against slipping

down.

● The hydraulic connections must on no account be used

for lifting purposes.

●

Care for the hand truck not to damage the hydraulic con-

nections and the front panel.

Site of installation

The location of the domestic hot water heat pump must

fulﬁl the following criteria:

The domestic hot water heat pump must only be

installed in a frost-free location.

The location must comply with the following require-

ments:

●Room temperature between +8°C + 1,5K and +35°C (for

heat pump operation).

●Good thermal insulation to the adjacent rooms.

●Condensate overﬂow.

●The air must not be too dusty.

●The underground must be sustainable (approx. 500 kg).

●Room size for recirculating air operation minimum 20m3

Consider a minimum lateral distance of 0,5 m to the left

and to the right to ensure trouble-free operation of the do-

mestic hot water heat pump as well as sufﬁcient clearance

for access for servicing. Clearance above the domestic hot

water heat pump at least 0,30 m.

Installation

● Remove the plastic protective cover from the pallet.

● Remove the protective angles.

● Remove the transportation locks from the pallet.

● Take the device down from the pallet to position it.

● Align the device in vertical position by adjusting the

stands.

Connection of the water conduits

The nominal width of the conduits for on-site installation

must be speciﬁed on-site, considering the existing water

pressure and the pressure loss to be expected in the pipe

system.

The water side installation must be carried out in accor-

dance with DIN 1988.

The water conduits may be executed in solid or ﬂexible

construction. Consider the corrosion behaviour of the used

materials in the pipe system to avoid damage.

Just like all types of pressure tanks, also the heat pump

domestic hot water tank must be provided with a type-ex-

amination tested safety valve and a non-return valve (not

delivered with the unit).

The cold water supply pipe will be on the rear side at

ground level (3/4” AG).

The maximum operating pressure is 10 bar, the maximum

operating temperature is 65°C.

If necessary, a pressure reducing valve and a potable wa-

ter ﬁlter should be installed in the supply pipe.

When preparing the on-site piping, any contami-

nations in the pipe system must be avoided (the

pipes should be ﬂushed before connecting the

domestic hot water heat pump)!

When connecting the on-site pipes to the scre-

wed joints, the pipes must be secured against

torsion with a spanner!

If no circulating pipe is connected to the heat

pump, the connection point must be sealed ac-

cordingly!

6-We reserve the right to make technical changes - 830130GB/150111

BWP 310

Connections

Connection of the condensed water tubes

Due to the cooling down of the air in the evaporator, con-

densed water is separated. The condensate overﬂow (15

mm inside diameter) at the rear side of the heat pump

must be led away from the heat pump with plastic pipes

to ensure the discharge of the condensed water. The con-

densed water quantity amounts up to 0,5 l/h, depending on

the air humidity.

A trap (siphon) is absolutely necessary. The condensed

water discharge must not be connected directly to a chan-

nel interface as the ammonia gas in the channel could af-

fect the heat exchanger plate ﬁns and components of the

heat pump.

Electrical connection

The domestic hot water heat pump is wired ready for con-

nection. Just plug the power plug in the socket ﬁtted on-

site.

Air connections

INTAKE AIR

The intake air must not contain any aggressive substances,

(Ammonia, sulphur, chlorine etc.) which could destroy me-

chanical parts!

AIR CONNECTION

When using heat pumps in connection with ducts, the op-

tional air duct connector (accessory) is necessary. Use

plain ended pipes for the intake duct and the exhausted air

duct to keep the air resistance low.

Consider the pressure loss of the pipes and the compres-

sion of the fan (see technical data).

The air ducts close to the heat pump must be laid hori-

zontally respectively slightly off-peak to the intake- and ex-

hausted air ducts to avoid the discharge of condensed wa-

ter. Ducts leading outdoor should be equipped with check

valves (with low resistance) to prevent cold air from co-

ming in during the winter time when the heat pump stands

still. We recommend to insulate the ducts completely up to

the heat pump (less sound pressure level, insulation). The

supply of fresh air from outside makes sense only at tem-

peratures > +15°C (see application limits of the domestic

hot water heat pump).

Air connections

For inserting the air duct connectors (accessories), the

cover of the casing of the BWP 310 must be opened (20

crosshead screws). Afterwards, the air duct connector can

be installed.

Consider sufﬁcient clearance above the domestic hot wa-

ter heat pump for recirculating air operation or operation

without pipe systems.

Eventual connection of a heat exchanger

The heat pump includes a heat exchanger enamelled out-

side with a heating surface of 0,8 m2. Connection with a

¾” pipe thread. The dip tube bag for the thermostat of the

heat pump may also include sensors for the control of the

heat output of the heat exchanger (for example fuel oil or

gas boiler operation).

Sensor diameter 6 mm.

Cover plate with louvre (condition when delivered).

Cover plate with air duct connector (accessories).)

Blow out

Intake

830130GB/150111 - We reserve the right to make technical changes - 7

BWP 310

Connections

The water connections are on the rear side of the heat

pump:

Condensed water tube

Central at the front side, under the front panel:

Heating element + sensor + anode

Cold water inlet Domestic hot

water-

circulation

Domestic hot

water outlet

Sensor/Immer-

sion sleeve

Anode Heating element

8-We reserve the right to make technical changes - 830130GB/150111

BWP 310

Start-up

Operation of the BWP 310 is admissible only

with a ﬁlled tank!

Switch off the system before opening the door

of the BWP 310!

Check whether the plug main board/connecting

line to the operator panel is plugged in correctly

when starting up the system!

Domestic hot water circuit

Demands on the domestic hot water circuit

On the domestic hot water side, the following material may

be included in the water circuit:

- Copper

- Stainless steell

- Brass

- Plastics

Material incompatibilities might eventually cause corrosion

damage, depending on the material used in the domestic

hot water circuit (provided by the customer). This applies

particularly to the use of zinced and aluminiferous materi-

als.

Start-up

of the domestic hot water system

- Fill and vent the domestic hot water circuit at the exter-

nal connection (open the domestic hot water taps at the

highest point, until there is no more air left.

- Test the whole domestic hot water circuit for leaks.

- Connect the heat pump to the power supply.

Test the screw connections at the drinking wa-

ter supply points of the domestic hot water heat

pump for leaks after the start-up!

Coolant circuit

The domestic hot water heat pump is ready for use. The

coolant circuit is also ready for operation. The temperature

controller automatically starts the heat pump and controls

the domestic hot water temperature.

Heat exchanger operation

1) Boiler

The heat exchanger operation applies if the domestic wa-

ter heating (for example in the winter) is supposed to be

settled by the second heat exchanger.

During this operating mode, the heat pump is switched off

(fan stage = 0). The domestic hot water temperature is

controlled by the temperature controller of the boiler.

Summer activity BWP 310 = fan stage 1

Winter activity wooden boiler = fan stage 0

During the boiler operation, an additional sensor must be

installed in the hot water heater (approach from the boi-

ler).

The maximum domestic hot water temperature in the heat

pump must not exceed max. 65°C.

If the boiler supports the BWP 310 operation, the tempe-

rature controller of the domestic hot water temperature at

the boiler must be set approximately 5K lower than the

domestic hot water temperature at the BWP 310 (P3). This

means that the boiler operates in parallel to the BWP 310

in case of large domestic hot water requirements.

Balance the sensor values when starting up the

systems.

2) Wooden boiler respectively solar system

The operation of solar systems respectively wooden boi-

lers applies if the domestic water heating is supposed to

be completed additionally. The sensor TS (T9 in the refri-

geration plan; accessories) measures the temperature. If

the temperature exceeds the domestic hot water tempera-

ture, the control Ventronik BWP may switch on a charge

pump.

The hysteresis of the temperature can be set between 0

to 5K.

The max. domestic hot water temperature to be achieved

is 60°C.

Once the storage temperature (60°C) has been achieved,

the temperature difference control will be deactivated.

Recommendations for low energy consump-

tion

The BWP 310 should not be operated over 45°C in order

to achieve a high power coefﬁcient and low losses,

The temperature controller values should be increased

only exceptionally, just as manual setting of the heating

element.

Recommendations for fan operation

Reduce the number of revolutions of the fan for silencing

during recirculating air operation without ducts.

For systems with duct systems , a high number of revoluti-

ons of the fan is necessary.

830130GB/150111 - We reserve the right to make technical changes - 9

BWP 310

Maintenance

For optimal operation of the BWP 310, consider the follo-

wing:

Pull the mains plug before opening the dome-

stic hot water heat pump and pay attention to

the fan!

Test the water system every few days for leaks and the

condensate overﬂow for obstructions after the ﬁrst instal-

lation.

Anode:

To protect it from corrosion, the enamelled domestic hot

water tank is provided with a magnesium anode installed in

the tank with a ¾” plug connection. The estimated service

life of the anode is 2-5 years. Nevertheless, you should

regularly check whether the anode is still intact, i.e. the

anode should be tested every two years and replaced in

case of corrosion or if the diameter is only 6-10 mm.

For checking the anode, switch off the system and disas-

semble the front door. It is necessary to let out the water of

the domestic hot water tank before screwing off the front

anode. For this, it is necessary to cut off the cold water

inlet and to put a tube on the drain valve for leading the

water to the next outlet. When letting out the water from

the tank, open a domestic hot water tap in order to avoid

a vacuum in the tank. As soon as the tank is empty, screw

off the anode to check it.

After having re-installed the anode, close the drain valve,

re-open the cold water supply, reﬁll the tank with water and

vent it. Once the tank is ﬁlled again and door is re-assem-

bled, switch on the power supply.

Fan:

For servicing the fan, it is enough to clean the evaporator

at regular intervals respectively as needed. Screw off the

plate. In case there are air duct connectors at the device,

dismantle the tubes atop of the unit and screw off the cover

plate. Use a brush or a bottle cleaner to clean the fan. Do

not remove the balancing weights at the fan to prevent a

higher noise level due to an unbalance as well as prema-

ture wear of the fan.

● Risk of injury by sharp-edged ﬁns.

● The ﬁns must not be damaged

Condensate tray and condensate overﬂow:

When cleaning the fan, the condensate tray must be clea-

ned at the same time. Fill water in the tray and test whether

it runs off smoothly. If not so, the drain must be cleaned.

At the same time, check whether the ﬁns of the evaporator

are clean.

Safety valve:

Integrated in the domestic hot water tank assembly, the

ﬁtter has installed a safety valve at the cold water supply

pipe. The safety valve protects the tank against overpres-

sure when the domestic hot water expands during the he-

ating. The non-return valve installed in front of the safety

valve in the cold water pipe prevents the water from ﬂo-

wing back in the cold water pipe. Due to this, the pressure

in the tank increases up to the maximum pressure of the

safety valve. Then the safety valve opens and the excess

water ﬂows off. If the safety would not be opened, the tank

would burst.

To ensure the safety valve works correctly, it must be che-

cked several times a year.

For this, press the spring-loaded lever at the safety valve

and control whether water leaks from the valve.

Damage caused by a blocked safety valve is not covered

by our guarantee conditions.

10 -We reserve the right to make technical changes - 830130GB/150111

BWP 310

Errors / Trouble Shooting

The heat pump does not work!

Check the following:

● The plug is plugged in correctly?

● The power socket is live?

● The air intake temperature is > +8°C + 1,5K?

● The heat pump has not been shut off by the

temperature controller?

● The domestic hot water temperature is

> 55°C?

● The plug connection line main board /

operator panel is plugged in correctly?

If the above questions cannot establish the error, please

contact your ﬁtter or the after sales service.

Safety devices

The domestic hot water heat pump is provided with the

following safety devices:

High temperature limiter (HD)

The high temperature limiter protects the heat pump

against inadmissibly high operating pressure in the refri-

geration cycle. In the event of fault, the high temperature

limiter (19 bar) switches off the heat pump. The heat pump

will be switched on again by manual reset of the high tem-

perature limiter. For this, dismantle the screen, take off the

facade: NOTE – do not break away the control line!

For RESET push the red

Safety temperature limiter for the

heating element (STB)

The safety temperature limiter protects the domestic hot

water system against an inadmissible rise of temperature

during heating operation. The safety temperature limiter is

attached to the heating element. The sensor is ﬁtted in the

immersion pipe of the heating element. The heating ele-

ment will be switched off as soon as the set value (90°C)

is exceeded. It is not possible to switch on the heating ele-

ment again before the domestic hot water temperature has

fallen below 90°C. For this, push the reset button on the

top side of the thermostat. Dismantle the screen, take off

the facade: NOTE – do not break away the control line!

For RESET push the small

white pin

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