Dimplex WI 90CG User manual

INSTALLATION and

OPERATING INSTRUCTIONS

Water-Water Heat Pump

for indoor installation

Order No.: 452225.66.94 FD 8209

WI 40CG WI 90CG

CONTENTS

1 PLEASE READ IMMEDIATELY 3

1.1 Important notes

1.2 Legal requirements and guidelines

1.3 Energy-saving heat pump operation

2 APPLICABILITY OF THE

HEAT PUMP 4

2.1 Field of application

2.2 Mode of operation

3 BASIC UNIT 4

4 ACCESSORIES 5

.1 Control cable

.2 Heat pump control

5 TRANSPORT 5

6 INSTALLATION SITE 6

6.1 General notes

6.2 Sound emission

7 INSTALLATION 6

7.1 Connection of the heating system

7.2 Connection of the heat source

7.3 Connection to power supply

8 STARTUP 8

8.1 General notes

8.2 Preparation

9 MAINTENANCE/CLEANING 9

9.1 Maintenance

9.2 Cleaning the heating side

9.3 Cleaning the heat source side

10 MALFUNCTIONS/

TROUBLE SHOOTING 10

10.1 Eliminating minor faults

11 SHUTDO N 10

11.1 Shutdown during summer

11.2 Final discommissioning/disposal

12 ANNEX 11

PLEASE READ IMMEDI-

ATELY

1.1 Important notes

During transport the heat pump must

not be inclined to any side by more than 45°.

The heat pump is not attached to the

wooden grating.

Disconnect all voltage supplies prior

to opening the unit.

Service of the heat pump must be

performed by authorized and experienced

service personnel only.

The wor ing fluid R407C is free of CFC,

does not disturb ozone and is non-combustible.

Ensure the cloc wise rotating field

when connecting the supply cable.

The covering hood can not be painted.

The well water must be of the water

quality specified.

The startup procedure must follow the

Installation and Operanting Instructions for the

heat pump control.

PLEASE READ IMMEDIATELY

CAUTION !

After cleaning it is essential to neu-

tralize the system by suitable means in order to

prevent secondary damages to the heating

system.

The heat pump is not intended to meet

the increased heat requirements of de-humidi-

fying a building. Therefore it is necessary to use

dedicated equipment provided by the client to

generate the extra amount of heat needed for that

purpose.

1.2 Legal requirements and guide-

lines

The heat pump complies with all relevant DIN/

VDE regulations and EEC directives. These are

listed in the attached CE conformity statement.

Electric wiring of the heat pump must comply with

the applicable VDE EN and IEC standards.

Furthermore the electrical supply conditions

stipulated by the power provider must be

observed.

The heat pump must be interconnected with the

heat source and the heating system in compli-

ance with the relevant regulations.

Service of the heat pump must be

performed by authorized and experienced

service personnel only.

1.3 Energy-saving heat pump opera-

tion

By operating this heat pump you contribute to the

protection of our environment. Proper dimen-

sioning of the heating system and the heat source

are of prime importance for the efficiency of heat

pump operation. Low water inlet temperatures

are of particular importance. Therefore all con-

nected heat consumers must be suitable for low

water inlet temperatures. An increase in the

heating water temperature by 1 K causes an

increase in the electrical power consumption by

approx. 2.5%. An underfloor heating system with

forward temperatures between 30 and 40 °C is

particularly well suited for energy-saving oper-

ation.

CAUTION !

BASIC UNIT

The basic unit consists of the heat pump for

indoor installation covering hood and basic

control and is delivered ready for installation. The

refrigerating circuit is filled with the refrigerant

R407C. The covering hood is lined with sound

insulating material.

The basic control contains all components that

are required for heat pump operation. The power

cable and the load cable (accessories) between

heat pump and basic control have to be installed

by the client.

The well pump that is also provided by the client

has to be interfaced with the basic control. Make

sure that the rating of the motor protector istalled

by the client is sufficient for the pump in use.

1 2 3 4 5

1) Condensor 5) Flow switch

2) Liquefier 6) Terminalbox

3) Evaporator 7) Filter dryer

4) Dirt trap

The wor ing fluid R407C is free of CFC,

does not disturb ozone and is non-combustible.

The covering hood can not be painted.

APPLICABILITY OF THE HEAT PUMP

BASIC UNIT

APPLICABILITY OF THE

HEAT PUMP

2.1 Field of application

The water-water heat pump can be used in

existing or new heating plant installations. Water

is used as the heat transfer medium. The water

may be supplied from a well or similar sources.

The well water must be of the water

quality specified.

Under normal conditions an intermediate circuit

has to be provided. If the system is to operated

without an intermediate circuit it is independent

of the leagl requirements necessary to perform

a water analysis in order to be able to detzermine

the compatability of the ground water with the

evaporator of the heat pump (refer to the project

designing and installation manual for heating

heat pumps).

2.2 Mode of operation

A well pump feeds the water to the evaporator of

the heat pump. There its thermal content is

transferred to the working fluid (refrigerant) in the

refrigeration circuit.

Then the working fluid is sucked into the elec-

trically powered condensor where it is

condensed i.e. "pumped" to a higher tempera-

ture level. How-ever the electric energy used to

drive this process is not lost but is also transferred

to the working fluid.

Finally the working fluid reaches the liquefier unit

where its thermal energy is transferred to the

water circulating through the heating water

system. Depending on the operating point the

temperature in the heating water system may rise

up to 55 °C.

CAUTION !

TRANSPORT

A lift truck can be used for transporting the heat

pump over smooth surfaces. Carrier belts should

be used where it must be transported across

uneven surfaces or through staircases. The belts

can be inserted directly through the wooden grate.

As an alternative the unit may be lifted by means

of eyebolts that can be screwed into the corners

of the base frame.

The heat pump is not attached to the

wooden grate.

The heat pump must not be inclined

by more than 45° (to any side).

ACCESSORIES

TRANSPORT

CAUTION !

ACCESSORIES

.1 Control cable

Two control cables serve to interconnect the heat

pump control and the basic control unit as well

as the basic control unit and the terminal box of

the heat pump. These cables are available in

several lengths.

.2 Heat pump control

The use of a heat pump control from our product

line is mandatory for the operation of your water-

water heat pump. The heat pump control is a

comfortable electronic control device. It is avail-

able as an accessory. The heat pump control

regulates and monitors the entire heating system

in regard to outdoor temperatures hot water

heating process and safety-relevant equipment.

The functional method and the operation of the

heat pump control is described in detail in the

accompanying Installation and Operating Instruc-

tions.

45°

Eye bolt

INSTALLATION SITE

6.1 General notes

The heat pump is intended for indoor installation.

The mounting surface must be smooth solid and

load-bearing. If necessary the heat pump must

be levelled by shimming.

The installation site of the heat pump must be

chosen so that service work can be performed

easily. This is ensured by a free space of about 1

m at the front and both sides of the heat pump.

6.2 Sound emission

Owing to the sound insulation the heat pump

emits very little noise. But placing a suitable

decoupled rubber mat underneath the heat

pump base frame is recommended in order to

prevent any sound conductance to the foundation

especially in case of uneven foundations.

INSTALLATION SITE

INSTALLATION

7.1 Connection of the heating system

Before connecting the heat pump to the heating

system the heating plant should be flushed

thoroughly to prevent any particles to flow through

the heating circuit which could impair smooth

heatpump operation.

Flexible pressure hoses should be used for

connections in order to prevent noise from being

conducted to the heating circuit.

The completed heating circuit must be filled

ventilated and checked for leakage. Where the

risk of frost exists the filled system must remain

in operation continuously so that frost damage is

precluded.

7.2 Connection of the heat source

Connect the water lines from the well to the flow

and return lines of the heat source.

For this observe the refrigeration and hydraulic

plans.

The well water must be of the water

quality specified.

CAUTION !

Wärmepumpe

1 m

0,2 m

1 m 1 m

Heat pump

INSTALLATION

It must be ensured that the the power supply to

the terminals of the well pump will not be turned

off by the tariff contactor to make sure that the

cutoff delay of the well pump remains effe-

ctive.The motor protector installed by the client

must be adjusted according to the data

specified by the pump manufacturer. The

terminals for the power supply to the well pump

are X1-L11/L21/L31.

Control voltage

The basic control unit is powered by the heat

pump control via the control cable. A separate

cable to the basic control unit is not required.

Connection between the basic control unit and

the terminal box of the heat pump

The connection between the terminal box of the

heat pump and the basic control unit as well as

between the brine pump and the basic control

unit must be provided by the client.

Select the cable cross section according to the

power consumption of the heat pump (see

technical specifications) and the power con-

sumption of the used brine circulating pump.

Run the power cables in the existing plastic

tubing.

Terminals of the condenser:

X1-1/2/3/PE

X1-4/5/6/PE

Terminals of the well pump:

X1-7/8/9/PE

7.3 Connection to power supply

All components needed for connecting the

electric supply to the heat pump are located in

the basic control unit. Mount this unit to a

smooth wall surface of the building. A heat

pump control is necessary for controlling these

components. The wiring of the descrete compo-

nents contained in the basic control unit and in

the heat pump control must be provided by the

client (plug connectors).

Power supply for the basic control unit

A breaker controlling all poles with at least 3

mm contact gap (e.g. EVU blocking contactor

power contactor) and a three pole automatic

circuit breaker separating simultaneously all

external leads must be provided in the power

feed to the basic control unit. Select the wiring

cross section according to the power consump-

tion of the heat pump the technical power

connecting requirements stipulated by the

respective power provider and the require-

ments of VDE 0100. The power consumption of

the heat pump is specified in the technical

documentation. The terminals (X1-L1/L2/L3 at

the circuit breaker) are rated for a maximum wire

gauge of 16 mm².

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INSTALLATION

STARTUP

8.1 General notes

For reasons of warranty comissioning of the heat

pump should be performed by authorized service

personnel.

8.2 Preparation

Confirm the following prior to startup:

- The heat source system and the heating water

circuit must have been filled and tested.

- The shut-off valves in the well and heating

circuits must be in the correct position.

- The power supply field must rotate in the cw

direction.

- The heat pump control must have been

prepared according to the relevant installation

and operating instructions.

The startup procedure must follow the

installation and operating instructions for the heat

pump control.

CAUTION !

Control cable between the basic control unit

and the terminal box of the heat pump

The control cable between the terminal box of

the heat pump and the basic control unit is

available as a custom-made cable (see price

list). Connect the round 16-pole connector of the

control cable to the basic control unit. Slightly

rotate the connector ccw and cw to feel for the

anti-rotation lock. Then insert the connector until

the ring nut of the contactor catches. Turn the

ring nut clockwise to secure the connector in its

position. Feed both the rectangular connec-tors

through the opening in the bottom right corner of

the basic control unit and plug them into the

matching connectors (non-interchange-able).

Use the strain relief to secure the control cable

in the basic control unit . Any excessive cable

length should be kept in the cable duct or as a

loop on the wall.

Connection between the heat pump control and

the basic control unit (using the 1.5 m control

cable, see price list)

The power for the heat pump control can be

provided from the basic control unit. Plug the

round connector of the cable into the basic control

unit and connect the two rectangular connectors

to the heat pump control. A more detailed

description is contained in the instal-lation and

operating instructions for the heat pump control.

Ensure the cloc wise rotating field

when connecting the supply cable. (If the field

rotates ccw the heat pump generates no power

and is very loud.)

CAUTION !

MAINTENANCE/CLEANING

After cleaning it is essential to neu-

tralize the system by suitable means in order to

prevent secondary damages to the heating

system.

Attention - heating plant installers -

Depending on the fill water quality and volume

occasional dirt collection (rust sludge, calcerous

deposits) may occur especially in case of mixed

installations and plastic piping so that the

performance of the heating system may be

compromized. This is due to the water hardness

and the oxygen solved in the fill water and the

oxygen in the air that may enter the system at

valves, fittings and plastic pipes (oxygen diffu-

sion). To prevent this from happening we

recommend the use of a physical water treatment

device li e e.g. ELYSATOR .

CAUTION !

9.3 Cleaning the heat source side

Install the enclosed dirt trap in the heat source

inlet of the heat pump in order to protect the

evaporator from impurities. After the initial startup

the filter screen of the dirt trap should be cleaned

regularly in relatively short intervalst. As soon as

detectable impurities become less the intervalls

can be extended accordingly.

MAINTENANCE/

CLEANING

9.1 Maintenance

The heat pump operates maintenance-free.

Make sure that the heat source and heating

circuits are kept free from impurities to prevent

malfunction of the heat pump due to dirt

collections in the heat exchangers. Should a

malfunction of that type occur clean the unit as

described below.

Disconnect all voltage supplies prior

to opening the unit.

9.2 Cleaning the heating side

Oxygen may cause the formation of oxydation

products (rust) in the hot water circuit. Pipe

connections must not allow oxygen diffusion

which applies particularly to pipes used in

underfloor heating. Remnants of lubricants and

sealants may also contaminate the heating

water.

If contamination is so bad that the performance

of the liquefier in the heat pump is degraded

the installation must be cleaned by a specialist.

Based on today's experience we suggest to use

5% phosphorous acid for general cleaning or if

cleaning is required in shorter intervals 5%

formic acid .

In both cases the cleaning liquid should be used

at room temperature. Scavenging the heat ex-

changer in the direction opposite to the normal

flow is recommendable.

In order to prevent acid-containing cleaning li-

quid from entering the heating water circuit we

suggest to connect the scavenging unit directly

to the forward and return lines of the liquefier in

the heat pump.

Following that it is essential to thoroughly rinse

the system with a suitable neutralizing agent

so that all remnants of the cleaning agent are

removed from the system.

Handle acids with care. Always follow the

instructions of the occupational associations.

In case of doubt consult with the manufacturer

of the cleaning agent!

CAUTION !

SHUTDOWN

11.1 Shutdown during summer

Heat pumps used exclusively for heating pur-

poses can be shut down for the summer time

(no hot water service). This is done by means of

the operating mode selector of the heat pump

control. Please observe the Installation and

Operating Instructions.

Due to the risk of frost damages shutdown

without draining the heating circuit is permissible

only in regions where outdoor temperatures do

not drop below 0 °C .

11.2 Final decommissioning/disposal

Before removing the heat pump it is necessary to

disconnect all cables as well as the connections

to the heat source and the heating system.

Furthermore all electrical supplies must be

switched off and all valves must be closed.

Please observe the applicable environmental

regulations in regard to recycling reuse and

disposal of working materials and fluids accord-

ing to DIN EN 378 when taking the heat pump

out of operation. Especially the disposal of

refrigerants and refrigeration machine oil must

comply with the relevant regulations.

MALFUNCTIONS/

TROUBLE SHOOTING

10.1 Eliminating minor faults

This heat pump is a maintenance-free high-

quality product and should run without any

problems. Most faults that may occur can be

remedied by the user. Please refer to chapter

'Malfunctions and Troubleshooting' in the

installation and operating instructions for the heat

pump control.

If you are not successful in eliminating a fault

please contact your customer service.

Service of the heat pump must be

performed by authorized and experienced

service personnel only.

CAUTION !

MALFUNCTIONS/TROUBLE SHOOTING

SHUTDOWN

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