Danfoss ALL IN ONE Type Air-source Heat Pump Water Heater Installation guide

Danfoss
Brand
Danfoss
Model
ALL IN ONE Type Air-source Heat Pump Water Heater
Category
Heat pumps
Type
Installation guide
Installation, Service and
User Manual
DTW 300 SP
VMGFK202
If these instructions are not followed during installation and
service, Danfoss A/S liability according to the applicable war-
ranty is not binding. Danfoss A/S retains the right to make
changes to components and specifications without prior notice.
© 2011 Copyright Danfoss A/S.
The English language is used for the original instructions. Other
languages are a translation of the original instructions.
(Directive 2006/42/EC)
Contents
1 About this document and decals ............................................... 3
1.1 Introduction .................................................................................... 3
1.2 Symbols in documents ................................................................ 3
1.3 Symbols on decals ........................................................................ 3
2 Important information ................................................................... 4
2.1 General safety precautions ........................................................ 4
2.2 Refrigerant safety precautions ................................................. 5
2.3 Electrical connection safety precautions .............................. 5
2.4 Safety precautions for home-owners ..................................... 6
3 Components ...................................................................................... 7
4 Accessories ......................................................................................... 9
5 Installation Location ..................................................................... 10
5.1 Installation space ........................................................................ 10
5.2 Carrying the unit onto the site ............................................... 11
6 Piping Connection ........................................................................ 12
6.1 Water inlet and outlet pipes ................................................... 12
6.2 Temperature and pressure valve .......................................... 13
6.3 Non-return valve ......................................................................... 13
6.4 Tank affusion ................................................................................ 13
6.5 Water pressure and drainage ................................................. 13
6.6 Solar energy coil electrical instruction ................................ 13
7 Duct Connections .......................................................................... 15
8 Electrical Connection ................................................................... 18
8.1 Electrical wiring illustration ..................................................... 18
8.2 Connecting external supply voltage .................................... 18
9 Commisioning ................................................................................ 19
10 Control system ............................................................................... 20
10.1 Control panel explanation ....................................................... 20
10.2 Display explanation ................................................................... 20
10.3 Key pad ........................................................................................... 21
11 Operating instructions ................................................................ 22
11.1 Start up ........................................................................................... 22
11.2 Operational status ...................................................................... 27
11.3 Troubleshooting .......................................................................... 28
11.4 Operating Capability ................................................................. 29
11.5 Legionella prevention ............................................................... 32
12 Maintenance ................................................................................... 33
12.1 Maintenance tasks for service technicians ........................ 33
12.2 Maintenance tasks for both home-owners and
service technicians ..................................................................... 34
12.3 Special Non-error Conditions ................................................. 34
12.4 Malfunctions and Resolutions ................................................ 35
12.5 After-Sale Service ........................................................................ 35
13 Disposal Instructions .................................................................... 36
14 Technical data ................................................................................. 37
VMGFK202 – 1
1 About this document and decals
1.1 Introduction
This document contains the following:
•
Installation instructions (for authorized installation technicians)
•
Service instructions (for authorized service technicians)
•
User instructions (operational instructions for home-owners)
The instructions are also available for download at the following address:
www.documentation.heatpump.danfoss.com
1.2 Symbols in documents
The instructions contain different warning symbols, which, together with text, indicate to the user that there are
risks involved with actions to be taken.
The symbols are displayed to the left of the text and three different symbols are used to indicate the degree of
danger:
DANGER! Indicates an immediate danger that leads to fatal or serious injury if necessary measures are not
taken.
Warning! Risk of personal injury!
Indicates a possible danger that can lead to fatal or serious injury if necessary measures are not taken.
Caution! Failure to observe a caution may result in injury or damage to the equipment.
A fourth symbol is used to give practical information or tips on how to perform a procedure.
Note! Information regarding making the handling of the installation easier or a possible operational
technical disadvantage.
1.3 Symbols on decals
The following symbols can occur on decals on the different parts of the heat pump.
Warning symbols
!
Warning, danger!
Warning, hazardous electrical voltage!
Installation, Service and User Manual VMGFK202 – 3
2 Important information
2.1 General safety precautions
Caution! This product is not intended for persons (including children) with reduced physical, sensory or
psychological capacity, or who do not have knowledge or experience, unless supervised or they have
received instructions on how the apparatus functions from a safety qualified person.
Caution! The heat pump must be located on a stable base. The floor must be able to support the gross
weight of the heat pump with filled hot water tank (see Technical data).
Warning! Electrical installation may only be carried out by an authorised electrician and must follow
applicable local and national regulations.
DANGER! Only authorized refrigeration technicians may work on the refrigerant circuit.
DANGER!
•
The unit must be earthed effectively in order to avoid the risk of an electrical shock.
•
In order to avoid electric shock, fire, or injury, if any abnormality is detected, such as smell of fire, turn
off the power supply and call your service agent for instructions.
•
If the supply cord is damaged, it must be replaced to avoid hazards.
Warning!
•
Do not insert fingers, rods, or other objects into the air inlet or outlet since the fans rotate at high
speed and may cause injuries.
•
Never touch the air outlet or the horizontal blades while the swing flap is in operation. This may cause
injury.
•
Never put any objects into the air inlet or outlet. Objects touching the fan at high speed can be
dangerous, causing injuries, or seroiusly damage the unit.
Caution!
•
Do not tear off labels on the unit with the purpose of warning or reminding.
•
Never use a flammable material such as hair spray or lacquer paint close to the unit. It may cause a
fire.
4 – Installation, Service and User Manual VMGFK202
Caution!
•
Before installation, decide a safe and reliable way of conveying the unit.
•
To prevent injury, a mixing valve must be installed on the outlet if the hot water temperature may rise
over 65°C, for example, when using solar energy solutions.
•
In order to avoid injury, do not remove the fan guard on the outdoor unit.
•
At the water inlet side, a check valve must be installed.
•
Never block the connections to the temperature and pressure valve.
•
Water expands when it is heated, this means that a small amount of water is released from the system
via the overflow pipe. The water that exits the overflow pipe can be hot! Therefore, allow the water to
flow to a floor drain where there is no risk of burning yourself or causing damage to the floor and
building.
•
Do not remove the front panel. Some parts inside are dangerous to touch, and a machine malfunction
may be caused.
•
Do not touch the inner parts of the controller.
•
The heating system will stop or restart automatically. A continuous power supply for water heating is
therfore necessary, except when performing service and maintenance.
•
If the unit is installed in a space without heating, there is a risk of freezing damage if the power is
turned off during cold weather conditions. Ensure that the system is drained from water if it is
necessary to turn off the power during such circumstances.
2.2 Refrigerant safety precautions
DANGER! Only authorized refrigeration technicians may work on the refrigerant circuit.
Although the cooling system (refrigerant circuit) is filled with a chlorine-free and environmentally approved refrig-
erant that will not affect the ozone layer, work on this system may only be carried out by authorized persons.
2.3 Electrical connection safety precautions
DANGER! Electrical installation may only be carried out by an authorized electrician and must follow
applicable local and national regulations.
Caution! The electrical installation must be carried out using permanently routed cables. It must be
possible to isolate the power supply using an all-pole circuit breaker with a minimum contact gap of 3
mm.
DANGER! Hazardous electrical voltage! The terminal blocks are live and can be highly dangerous due to
the risk of electric shock. All power supplies must be isolated before electrical installation is started.
Installation, Service and User Manual VMGFK202 – 5
2.4 Safety precautions for home-owners
DANGER! The heat pump cover must only be opened by authorised service technicians.
Caution! This product is not intended for persons (including children) with reduced physical, sensory or
psychological capacity, or who do not have knowledge or experience, unless supervised or they have
received instructions on how the apparatus functions from a safety qualified person.
Warning! Children are not permitted to play with the product.
The system can be considered maintenance free but certain checks are necessary.
Before changing the control computer’s settings, first find out what these changes mean.
Contact your installer for any service work.
2.4.1 Installation and maintenance
DANGER! Only authorized installers may install, operate and carry out maintenance and repair work on
the heat pump.
DANGER! Only authorized electricians may modify the electrical installation.
DANGER! Only authorized refrigeration technicians may work on the refrigerant circuit.
2.4.2 System modifications
Only authorized installers may carry out service on the following components:
•
The air source heat pump
•
The lines for refrigerant, water and power
•
The safety valve
Do not carry out construction installations that may affect the operational safety of the unit.
2.4.3 Safety valve
The following safety precautions apply to the hot water circuit’s safety valve with corresponding drain pipe:
•
Never block the connection to the safety valve’s overflow pipe
•
Water expands when it is heated, this means that a small amount of water is released from the system via the
overflow pipe. The water that exits the overflow pipe can be hot! Therefore, allow it to flow to a floor
drain where there is no risk of burn injuries due to scalding.
6 – Installation, Service and User Manual VMGFK202
3 Components
The component image below shows diagrammatically how the air source heat pump (from now on also called the
unit) looks inside.
19
6
7
2
1
17
18
3
4
5
16
15
14
13
9
10
8
23
24
22
21
25
12
26
27
11
20
28
33
34
32
31
36
35
Figure 1. Exploded view, unit components
Table 1. Parts Name
Position Description Position Description
1 Air outlet 18 Top cover
2 Filter 19 Electronic control box
3 Evaporator 20 Compressor
4 Fan assy 21 Front cover
5 Junction box cover 22 Display
6 Rear cover 23 Cover (temperature safety function)
7 Junction box 24 Front board
8 Temperature and pressure valve 25 Cover (electrical heater)
9 Anode rod 26 Electrical heater
10 Hot water outlet 27 Water inlet
11 Temperature cut off (TCO) 28 Receiver
12 Manual reset Temperature Cut Off (MTCO) 31 Evaporator pipe temperature sensor (T3)
13 Solar sensor 32 Ambient temperature sensor (T4)
14 Solar water inlet 33 Suction temperature sensor (TH)
15 Solar water outlet 34 Discharge pipe temperature sensor (TP)
Installation, Service and User Manual VMGFK202 – 7
Position Description Position Description
16 Drain 35 Upper tank sensor (T5U)
17 Air inlet 36 Lower tank sensor (T5L)
Note! All the diagrams and figures in this manual are for explanation purposes only. They may be slightly
different, depending on model, from the real product you have purchased.
8 – Installation, Service and User Manual VMGFK202
4 Accessories
Table 2. Accessories (included in delivery)
Accessory Name Purpose Quantity
Installation, service, and user man-
ual
Installation, service, and user instruction (this manual) 1
Non-return valve Prevent water from flowing back 1
Adaptor Drain condensate water 1
Installation, Service and User Manual VMGFK202 – 9
5 Installation Location
Ensure that the following applies for the installation location:
•
Enough space for installation and maintenance shall be preserved.
•
The circulating air for each unit must be more than 700 m
3
/h.
•
The air inlet and outlet should be free from obstacles and impact from strong wind.
•
The unit must be located on a stable surface without increasing noise or vibrations.
•
If it is a floor, it must must be able to support the gross weight of a unit with a filled hot water tank (see Techni-
cal data, Page 1).
•
It is convenient for piping and wiring.
•
Depending on the installation location, it may cause the indoor temperature to decline and also create noise
disturbances. Take this into consideration when deciding the location.
Caution! Installing the unit in any of the following places may lead to malfunction of the unit:
•
A site containing mineral oils such as cutting lubricant.
•
Seaside areas where the air contains much salt.
•
Hot spring areas where corrosive gases exist, e.g., sulfide gas.
•
Factories where the power voltage fluctuates seriously.
•
A kitchen where oil permeates.
•
A location where strong electromagnetic waves exist.
•
A location where flammable gases or materials exist.
•
A location where acid or alkali gases evaporate.
•
Other special environments.
5.1 Installation space
The recommended space for maintenance purposes is shown in the following figures:
2
≥ 600 mm
≥ 600 mm
≥ 600 mm
1
3
4
Figure 2. Installation space (distance)
Position Explanation
1 Air outlet
2 Display
3 Air inlet
4 Wall
10 – Installation, Service and User Manual VMGFK202
≥ 600 mm
≥ 600 mm
≥ 800 mm
Figure 3. Installation space continued (distances)
1920 mm
650 mm
Figure 4. Dimensions
Note! The specification of 800 mm free space above the unit is only a recommendation if the room size
allows this arrangement. The reason is to provide sufficient air flow and air exchange through the unit´s
inlet and outlet. In the event that the room size does not allow this recommendation and that it is
suspected that the air volume and flow will not be sufficient, installing flexible duct connections should
be considered.
5.2 Carrying the unit onto the site
•
In order to avoid scratches or deformation of the unit surface, apply guard boards to the contacting surface.
•
Do not incline the unit more than 45° while it is moved, and keep it vertical when installing.
•
This unit is very heavy, it must be carried by two or more people, otherwise it may cause personal injury and
damage.
Installation, Service and User Manual VMGFK202 – 11
6 Piping Connection
16
4
15
3
14
27
17
13
12
10
2
1
8
9
5
Figure 5. Principal Piping Connection
Position Explanation Position Explanation
1 Upper condensate outlet 12 Valve stem
2 Lower condensate outlet 13 Expansion vessel (if required)
3 Hot water tap 14 Solar water inlet
4 Solar sensor 15 Solar water outlet
5 Drain barrel 16 Drain pipe
8 Temperature and pressure valve 17 Mixing valve
9 Anode rod 27 Water inlet
10 Hot water outlet
Warning! If a solar energy solution is installed, the water temperature can rise very quickly. Preventive
measures must be taken for the piping connections.
Note! If the water pressure is too high (above 5 bars), a pressure reducer should be installed at the water
inlet. This is the installer´s responsibility.
In principle, arrange the water pipes connections as illustrated in the above figure example.
Note! A safety valve should be installed at the water inlet of the unit.
6.1 Water inlet and outlet pipes
The specification of the water inlet or outlet (internal) thread is DN20 (RC3/4”). Pipes must be heat-resistant and
durable.
12 – Installation, Service and User Manual VMGFK202
6.2 Temperature and pressure valve
The specification of the valve connecting (internal) thread is DN20 (RC3/4”). After installation, it must be confirmed
that the drainpipe outlet is exposed in the air. If a flexible drainpipe is jointed to the pressure relief orifice of this
valve, it must be confirmed that the flexible drainpipe is directed downwards vertically and exposed in the air.
Note! A safety valve should be installed at the water inlet of the unit.
•
Do not press the handle of the temperature and pressure valve (1).
When checking the safety function, the handle is pulled towards you
until a small amount of water is released.
•
Do not dismantle the valve.
•
Do not block the drainage pipe (2). It can cause injury, if not comply-
ing with the above instruction.
2
1
6.3 Non-return valve
The specification of the Non-return valve thread in accessories is DN20 (RC3/4”). It is used to prevent backflow of
water.
6.4 Tank affusion
After all pipes have been installed, open the cold water inlet and hot water outlet and start affusing the tank.
When the water flows out from the water outlet, the tank is full. Turn off the outlet tap and check all pipes. If there
is any leakage, repair it.
6.5 Water pressure and drainage
•
If the inlet water pressure is less than 1.5 bar, a pressure pump should be installed at the water inlet.
•
To guarantee the lifetime of the tank if the water supply hydraulic pressure is higher than 5 bar, a reducing
valve must be mounted at the water inlet pipe.
•
To minimize the risk of damage due to water leakage or because of blocked drainage, it is recommended to
use a water collector.
•
2
1
3
Figure 6. Water collector
Position Explanation
1 ≤ 22 mm
2 Unit
3 50 mm larger than the diameter of the unit
6.6 Solar energy coil electrical instruction
•
This product does not provide a solar-energy control system. It only provides two signals to be used for inte-
gration with an external solar energy control system. The installer must ensure the integration between this
product and the external solar energy control system.
•
The mainboard of the unit has two deicated ports used for connecting a solar thermal, CN17 ON/OFF and
CN18 Feedback ports. These ports ensure that the unit and solar thermal does not work simultaneously.
Installation, Service and User Manual VMGFK202 – 13
•
The CN17 ON/OFF port is used for receiving the control signal of the solar energy water heating system, this
signal must be a potential free switch signal. When the unit is sending a closing signal, the system will be
blocked for operation and cannot open to heat; when the sending an open circuit signal, the system will be
activated for operation, and the unit will operate according to the preset condition.
•
The CN18 feedback port is used to send "open/stop" feedback to the solar thermal control. The feedback con-
sists of high and low level signals. When the terminal is low level (0V) for outlet, it means that the unit is in
active state; when the terminal is high level (5V) for outlet, it means that the unit is blocked for operation.
Caution! If the water temperature from the solar thermal get overheated, it may trig the built-in
temperature function in the unit.
The automatically reset temperature protection switch (TCO) is triggered when exceeding an operating tempera-
ture of 78°C. This will automatically reset when the temperature get below 78°C.
The manually reset temperature switch is trigged when exceeding a water temperature of 85°C. This switch must
be reset manually.
In either case, one of the above protective functions are triggered, the unit will shutdown, the main supply will be
cut, and the unit will completely shut-off. If integrating the unit with a solar thermal system, take protective
actions to avoid overheating of the unit.
14 – Installation, Service and User Manual VMGFK202
7 Duct Connections
Note! When connecting flexible air ducts to the unit, the airflow capacity in system will decrease.
Example of air inlet (2) and outlet (1) without flexible air ducts.
Figure 7. Air inlet and outlet without flexible air ducts
Position Explanation
1 Air outlet
2 Air inlet
Flexible air ducts can be connected to both the air outlet (1) and air inlet (2), separately, or in combination. The
distance (3) can be maximum 10 m.
Ø 190 mm
1
2
3 3
Figure 8. Connection with two flexible air ducts, one for air inlet and one for air outlet
Installation, Service and User Manual VMGFK202 – 15
Table 3. Flexible Air Duct Description
Duct Round duct Rectangle duct Other shaped ducts
Dimension (mm) ø 190 190X190 Maximum length 3 m
Straight-line pressure
drop (Pa/m)
≤2 ≤2
Straight-line length (m) ≤10 ≤10
Bends pressure drop
(Pa)
≤2 ≤2
Bends ≤5 ≤5
16 – Installation, Service and User Manual VMGFK202
Caution! If the unit has a flexible air duct that reaches outside the building, a reliable water-resistant
measure must be done on the duct, to prevent water drop from entering the inside of the unit.
1 2
3
Figure 9. Filter position at air
inlet
> 250 mm
Ø
3
1
2
Figure 10. Filter position at duct entrance
Position Explanation
1 Outlet
2 Inlet
3 Filter
Caution! To effectively drain condensate water from the evaporator, install the unit on a horizontal floor or
base. Otherwise, ensure that the drain vent is at the lowest place. The inclination angle between the unit
and the ground should not exceed 2°.
≤2
o
1
Figure 11. Inclination angle not more than 2°
Position Explanation
1 Drain
Installation, Service and User Manual VMGFK202 – 17
8 Electrical Connection
8.1 Electrical wiring illustration
Warning! Electrical installation may only be carried out by an authorised electrician and must follow
applicable local and national regulations.
L
PE
N
1 2
3 4
θ
78-100˚C
U1
U2
M
1
20
11
12
29 30
26
22
T3
T4
T5U
T5L
TP
TH
G
C
Figure 12. Wiring diagram
Position Explanation
11 TCO
12 MTCO
20 Compressor
26 Electrical heater
22 Controller
29 Compressor relay, K1
30 Electrical heater relay (UE), K2
8.2 Connecting external supply voltage
DANGER! Electrical voltage! The terminal blocks are live and can be highly dangerous due to the risk of
electric shock. All power supplies must be isolated before electrical installation is started. The heat pump
is connected internally at the factory, for this reason electrical installation consists mainly of the
connection of the power supply.
1. Route the power cable through the opening of the terminal block cover on the side of the unit and to the
terminal block. See Figure 1. Exploded view, unit components Page 7.
2. Connect the power cable to the terminal blocks according to the wiring diagram. See Figure 12. Wiring dia-
gram Page 18.
18 – Installation, Service and User Manual VMGFK202
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Danfoss ALL IN ONE Type Air-source Heat Pump Water Heater Installation guide

Danfoss
Brand
Danfoss
Model
ALL IN ONE Type Air-source Heat Pump Water Heater
Category
Heat pumps
Type
Installation guide
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