Altherma Commission Tips En

Altherma System Setup & Commissioning Guide



Outdoor Unit.

Installation Location Check that the outdoor unit is installed in a location where the following can be achieved:

a) Adequate air flow around the heat exchanger this will include any obstructions in front of the fan outlet.

b) Adequate service space around the machine that will enable components to be removed and the unit to be correctly serviced and maintained i.e cleaning of heat exchanger.

It is also important that the outdoor unit is raised from a solid surface and provisions are made for drainage of water produced during defrost operation. Failure to do this can result in this volume of water freezing inside of the outdoor unit which will affect performance and component reliability.


The example above will allow the water to drain away from the base of the outdoor unit the example below shows the effects of mounting the machine on a solid surface with no provision for drainage the ice has built up inside of the unit and is protruding from the air outlet grille.


Electrical installation The outdoor unit must be connected to the hydrobox in the following way:

Refer to the following electrical information and check that a correct M.C.B/Fuse has been installed to protect the outdoor unit. Note These are for single phase models only. Possible total current draw on sizes 006-008

Recommended fuse size on sizes 006-008

Possible total current draw on sizes 011-016

Recommended fuse size on sizes 011-016

18Amp 20Amp 28.2Amp 32Amp

Mechanical installation The refrigeration piping for Altherma should be sized at 5/8 gas and 3/8 liquid for the size 011 to 016 models and 5/8 gas and liquid for the size 006 to 008 models. This piping must be insulated and the piping lengths kept within the following guidelines: Size 006-008

Max length 30m, (20m Height diff)

Min length 3m

Pre Charged For 10 m

g/m Additional 20 g/m over 10m

Std Liquid pipe 6,4mm (1/4 inch)

Piping

Std Gas pipe 15,9mm (5/8 inch)


Size011-016

Max length 75m, (30m Height diff)

Min length 5m (3m*)

Pre Charged For 30 m

Additional 30 - 40m add 0.5Kg

Additional 40 - 50m add 1Kg

Additional 50 - 60m add 1.5Kg

Additional 60 - 70m add 2Kg

Std Liquid pipe 9.5mm (3/8 inch)

Piping

Std Gas pipe 15,9mm (5/8 inch)

Additional refrigerant will be required after the pre charged piping length is exceeded. Add the additional refrigerant volume according to the charts above. The refrigerant type is R410a and must be charged in its liquid phase. NOTE For the 011-016 models if the hydrobox is installed above the outdoor unit an oil trap should be used on the gas pipe at 10 metre intervals.


Hydrobox.

Installation Location Check the installation location of the hydrobox complies with the following: The space around the unit is adequate for servicing The space around the unit allows for sufficient air circulation There is a provision for condensate drain (only for EKHBX models) and pressure relief valve blow-off The installation surface is a flat and vertical non-combustible wall, capable of supporting the operation weight of the unit All piping lengths and distances have been taken into consideration

Electrical installation The hydrobox will require either one or two power supplies. The first supply is for the backup heater which is located inside of the box, the second supply is for the booster heater which is in the DHW tank. For installations where no DHW tank is installed only one power supply is required to the hydrobox. The size of the supply depends on the size of the backup heater these come in 3,6 & 9KW versions. The booster heater for the tank is always rated at 3KW. Before initial switch on check the following components are connected to the relevant electrical connections in the hydrobox. Terminal block X1M terminals 1,2 & 3 These are the cables from the outdoor unit. Terminal block X1M terminals L&N This is the power supply connections for the back up heater. Terminal block X2M terminals 1,2,3 & 4 These are to be connected to an external thermostat (if one is required). These must be volt free switches. Connecting terminal 4 to 1 will force heating and connecting terminal 4 to terminal 2 will force cooling. Terminal block X2M terminals 5,6 & 7 These connections are used if a cooling/heating system is installed. The purpose is to interlock the cooling and heating emitters from operating at the same time. Example CWFC, and under floor heating.


Terminal block X2M terminals 9,10 & 11 These connections are used for the three port valve (this needs to be installed if there is a DHW connected) this will then decide whether to circulate the water through the tank or the space heating circuit. For the ESBE valves terminal 9 is black, terminal 10 is blue and terminal 11 is brown. For further information see ESBE valve details document. Terminal block X2M terminals 13 &14 To be connected to Q2L (thermal protector) inside of DHW tank. This is only to be connected with systems with a tank connected. Terminal block X3M terminals L&N These are the power supply connections for the booster heater. Terminal block X4M terminals L &N These are the connections that the heater from the tank connects to. This is the switched output from the hydrobox to the heater. Plug X9A This is the plug for the thermistor that connects to the DHW tank to sense the DHW temperature.

SOLAR THERMAL CONNECTIONS KRP1B option PC board terminals YC & Y3 This is an input from the site supplied solar pump station. This input is 230Vac and should be present when the pump station pump operates. Terminal block X2M terminals 19&20 These are the connections that power the Daikin Altherma solar pump. EKSOLHAV1. Terminal block X7M terminals L&N this is to be used if a solar system is installed, this is to comply with G3 regulations. X7M is an additional connector that needs to be installed by the installation company.


Mechanical Installation

Size 008

Size 016 Hydrobox

To avoid big temperature change when switching from DHW to cooling

(hot draft)

To guarantee a minimum temperature difference between outlet plate heat

exchanger and inlet tank

To avoid big temperature change when switching from DHW to cooling

(hot draft)

To guarantee a minimum temperature difference between outlet plate heat exchanger and inlet tank

Standard minimum 5m

3 m in case

recharging on outdoor is performed


Ensure that the piping connected to the hydrobox complies with the charts above. NOTE MINIMUM FLOW RATES AND WATER VOLUMES It is vital that the minimum water volume for the systems is obeyed, it is also important to ensure that an automatic bypass valve is connected to the system for installations that have thermostatically controlled regulating valves such as TRVs. It is also necessary to allow for a minimum of 10L water volume (for the size 8 unit) and 20L (for the size 16 unit). This volume must be in the system at all times even when in full bypass operation (to prevent damage to the PHE)

EKHBH008 ERHQ006 EKHBH008ERHQ007

EKHBH008ERHQ008

EKHBX008 ERHQ006

EKHBX008ERHQ007

EKHBX008ERHQ008

Cooling (Nom) 14.7 16.5 17.6

Heating (Nom) 16.5 19.6 24.2 16.5 19.6 24.2

Water flow rate (l/min) Minimum 12

EKHBH016 ERHQ011 EKHBH016ERHQ014

EKHBH016ERHQ016

EKHBX016 ERHQ011

EKHBX016ERHQ014

EKHBX016ERHQ016

Cooling (Nom) 28.7 35.8 37.6

Heating (Nom) 32.1 40.1 45.9 32.1 40.1 45.9

Water flow rate (l/min) Minimum 16


DHW Tank

Installation Location If the system is unvented please check the diagram below for conformity with G3 regulations.

B

CD

A

E

A Pressure/Temperature Relief Valve Installed? Yes No B Combination Valve Installed? Yes No C Tundish Installed? Yes No D Expansion Vessel Installed? Yes No E - Safety Solenoid Valve Installed* Yes No * Required if the hydrobox is model EKHBH(X)007AC or if a solar system has been installed to work with the Altherma system.


D1 15mm pipe must be of a suitable material to withstand a temperature of 95C and a maximum length of 500mm from the discharge device to the tundish D2 22mm pipe must be of a suitable material to withstand a temperature of 95C and have a minimum vertical drop of 300mm and must not exceed an equivalent length of 9m from the tundish to drain off where it has to be visible but will not cause danger to persons (equivalent length is taking into account the bends within the pipe work). Pipe work must have a continuous drop of at least 1:200mm

Electrical Installation If there is a domestic hot water tank installed without solar then the system should be wired in this configuration:

11

1

2 E

X4MX2M 4

3

12E

X6M

Q2L

Q3L E4H

HYDROBOX DHW TANK

OVERVIEW OF TANK ELECTRICAL LAYOUT


If a solar system has been installed the tank should be wired in this configuration:

Ensure that the thermistor that connects to the DHW tank is tightly fixed and is located at the very back of the pocket. Heat conductive paste can be used to guarantee a good contact. This plugs into X9a on the hydrobox.

1 2

X7M

2 3 1 E

1 1 2 2 E SAFETY SOLENOID VALVE

Q2L Q2T EKUHW2

1

2 E

X4M

1

2 E

X6M

Q2L

Q3L E4H

11

X2M

4 3 3

1

4 3

Q3L Q3T 12

X2M

4 3 2 1

1 2 1 2

X8M SOLAR PUMP

EKSOLHWAV

DHW TANK

E

Pre Wired

X5M

HYDROBOX


Switches & Settings The Dip switches on the hydrobox need to be set if a) a thermostat is connected or b) a domestic hot water tank is installed. Ensure that the power is switched off when making adjustments.

Operating the system

Note: Before operating the system please ensure that the water circuit is filled to approx 1.0-2.0BAR and that all air is removed from the system. The pressure can be obtained from the manometer. After initial power on of the system you may notice that the system operates in cooling operation. This is part of the start up sequence and is not a malfunction of operation. Operate the system in space heating operation. To do this either push the ON/OFF key OR if there is a thermostat connected ensure that the stat is ON. At this time ensure that the shower head symbol (for DHW) is not on the controller display.


Then set the temperature for the target water flow using the keys below:

The target flow should be set according to the type of heat emitter.

Button

ON/OFF Button

Check points The system will now operate in heating, ensure that the heating system is balanced allowing equal T across the connected heat emitters. Check the T between the water flow and return pipes on the hydrobox. After the system has been operating for a while the ideal differential would be approx 5C. If the temperature difference is too small or too large then changing the pump speed may be beneficial. If the temperature difference is too low then decrease the pump speed. If the temperature difference is too high then increase the pump speed. These settings can be done by altering the dial on the side of the pump. Once the system has been balanced and pump speeds set leave the system to operate and then take the following readings: *Please take note of the minimum water flow rate for the machine, this is stated in the installation manual.


Hydrobox in space heating: Water flow set point C

Leaving water temp (hydrobox)

C

Return water temp (hydrobox)

Pump speed selected

1 2 3

Approx flow rate* L/Min

To calculate approx flow use the following formula: (KW) / (C T) / 4.2(Clean water) = L/Sec X 60 = Litres per min.


Domestic hot water heating

Disable the space heating function and push the shower head ON button.

Use the shower head up & down temperature keys to program DHW set temperature.

Record the following data: DHW tank temperature before switch on*

C

DHW set point temperature C

To obtain the DHW tank temperature follow instructions below:


Reading system temperatures

To read system temperatures push and hold the Automatic button for 5 seconds then use the timer up and down buttons to show the following temperature readings Sanitary water temperature sensing off sensor R5T Outdoor ambient temperature sensor Flow water temperature for space heating or cooling sensor R1T

Once the heat pump has been operating for a while (approx 30 mins) record the following data. DHW temperature (30 mins after initial switch on)

C

If the booster heater has not yet operated please push and hold the shower head on key. The showerhead symbol will now flash and an image of a heater will appear on the screen. Current of Booster heater Amps

Cooling Operation

If the system has chilled water devises installed please complete the following: Operate the system in cooling mode by turning on the controller or thermostat and ensuring that the snowflake symbol is present. Make sure the showerhead symbol is off. A cooling set point will need to be set similar to the heating water flow set point.


Water flow set point C

Leaving water temp (hydrobox) C

Return water temp (hydrobox) C

Service Codes.

To maximise the systems capabilities special attention must be given to the service codes. These parameters can effect the time the heat pump is allowed to operate, and the temperature in which the electrical heater is used to assist the space heating requirements etc. Refer to the service settings document for further information.

Altherma System Setup & Commissioning GuideOutdoor Unit.Installation Location

Electrical installationMechanical installationHydrobox.Installation LocationElectrical installation

SOLAR THERMAL CONNECTIONSMechanical InstallationSize 008 Size 016 Hydrobox

DHW TankInstallation LocationElectrical Installation

Switches & SettingsOperating the systemCheck points

Domestic hot water heatingCooling OperationService Codes.

Altherma Commission Tips En

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