We reserve the right to modify technical specications without prior notice.
83033000eUK – Translation of the original operating manual
Operating Manual
Decentralised
drinking water station
for combination with a heat pump
2
Contents
INFORMATION FOR USERS AND
QUALIFIED PERSONNEL
PLEASE READ FIRST ....................................................................................................2
SYMBOLS ........................................................................................................................2
FUNCTIONAL PRINCIPLE .......................................................................................... 3
INTENDED USE .............................................................................................................3
DISCLAIMER ...................................................................................................................3
SAFETY .............................................................................................................................3
CUSTOMER SERVICE ................................................................................................... 3
WARRANTY / GUARANTEE ......................................................................................3
DISPOSAL........................................................................................................................3
OPERATION .................................................................................................................... 3
CARE OF THE UNIT ......................................................................................................3
MAINTENANCE OF THE UNIT .................................................................................3
INSTRUCTIONS FOR QUALIFIED PERSONNEL
SCOPE OF SUPPLY .......................................................................................................4
Installation and assembly ..................................................................................4
Connection to the pipe system .......................................................................5
COMPONENTS .............................................................................................................. 5
Proportional controller .......................................................................................5
Heat meters ............................................................................................................5
Temperature maintenance ...............................................................................6
Domestic hot water mixing valve ..................................................................6
FLUSHING, FILLING AND VENTING ......................................................................6
Heating circuit .......................................................................................................6
Domestic hot water circuit ................................................................................8
INSULATING THE HYDRAULIC CONNECTIONS ............................................... 8
DISMANTLING ..............................................................................................................8
TECHNICAL DATA ........................................................................................................9
PERFORMANCE CURVES ...........................................................................................9
DIMENSIONED DRAWINGS ...................................................................................10
83033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Please read rst
This operating manual provides important information on handling the
unit. It is an integral part of the product and must be stored so that it is
accessible in the immediate vicinity of the unit. It must remain available
throughout the entire service life of the unit. It must be handed over to
subsequent owners or users of the unit.
Read the operating manual before working on or operating the
unit. Especially the chapter on safety. Always follow all instructions
completely and without restrictions.
This operating manual possibly contains descriptions that seem
incomprehensible or unclear. In the event of any questions or if any
details are unclear, contact the factory customer service department or
the manufacturer's local partner.
Since this operating manual was written for several dierent models of
the unit, always comply with the parameters that apply to the respective
model.
This operating manual is intended only for persons assigned to work
on or with the unit. Treat all constituent parts condentially. They are
protected by copyright. They may not be reproduced, transmitted,
copied, stored in electronic systems or translated into another language,
either wholly or in part, without the express written permission of the
manufacturer.
Symbols
Information for users.
Information or instructions for qualied personnel.
DANGER!
Risk of fatal electric shock!
DANGER!
Indicates a direct impending danger resulting in severe injuries or death.
WARNING!
Indicates a potentially dangerous situation that could result in serious
injuries or death.
CAUTION!
Indicates a potentially dangerous situation that could result in moderate
or slight injuries.
ATTENTION
Indicates a potentially dangerous situation, which could result in
property damage.
NOTE
Emphasised information.
€
ENERGY SAVING TIP
Indicates suggestions that help to save energy, raw materials
and costs.
383033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Reference to other sections of the operating manual.
Reference to other documents of the manufacturer.
Functional principle
Compact, preassembled assembly with two hydraulic circuits, which
transfers the heat from the primary circuit from a storage tank via a plate
heat exchanger to the continuously owing domestic hot water circuit
(secondary).
Intended use
Drinking water station for domestic water heating using the continuous
ow principle.
Operate the unit only within its technical parameters.
“Technical Data / Scope of Supply” overview.
Disclaimer
The manufacturer is not liable for losses resulting from any use of the
unit which is not its intended use. The manufacturer's liability also
expires:
•
if work is carried out on the unit and its components contrary to the
instructions in this operating manual.
•
if work is improperly carried out on the unit and its components.
•
if work is carried out on the unit which is not described in this
operating manual, and this work has not been explicitly approved
by the manufacturer in writing.
•
if the unit or components in the unit have been altered, modied or
removed without the explicit written consent of the manufacturer.
Safety
The unit is safe to operate for its intended use. The construction and
design of the unit conform to current state of the art standards, all
relevant EN regulations and all relevant safety regulations.
Every person who carries out work on the unit must have read and
understood the operating manual before starting any work. This also
applies if the respective person has already worked with such a unit or a
similar unit or has been trained by the manufacturer.
WARNING!
Only qualied personnel (trained heating, refrigeration engineers)
may carry out work on the unit and its components.
Customer service
For technical information please contact your tradesman or the
manufacturer's local partner.
“Customer service” overview in the heat pump operating
manual.
Warranty / Guarantee
For warranty and guarantee conditions, please refer to the purchase
documents.
Contact the responsible dealer regarding all warranty and guarantee
matters.
Disposal
When withdrawing the old unit from service, comply with the relevant
local laws, guidelines, directives and standards concerning recovery,
reuse, recycling and disposal.
see “Dismantling", page 8
Operation
Pay particular attention to the following, to ensure that your domestic
hot water station operates eciently and in an environmentally friendly
way:
€
ENERGY SAVING TIP
Do not set the domestic hot water temperature at the
thermostatic mixing valve higher than necessary. The
unit operates most eciently at low domestic hot water
temperatures (≈ 45 °C).
Do not set the heating water temperature in the storage tank
higher than necessary.
For limits of use see “Technical data", page 9
Care of the unit
You can clean the outer surfaces of the unit with a damp cloth and
proprietary household cleaning products.
Do not use cleaning or care products that contain abrasives, acids and/
or chlorine. Such products would irreparably damage the surfaces and
could also cause technical damage to the unit.
Maintenance of the unit
The drinking water station does not need any regular maintenance.
In areas with hard water the heat exchanger can fur up.
CAUTION!
Unit components may be cleaned and ushed only by customer
service personnel authorized by the manufacturer. Use only liquids
recommended by the manufacturer.
After ushing the heat exchanger with chemical cleaning
agent, any residues must be neutralised and the system ushed
intensively with water. Always note and follow the technical data of
the respective heat exchanger manufacturer.
4 83033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Scope of supply
Compact, preassembled decentralised hot drinking water station, with
proportional controller, dierential pressure controller, thermostat valve
for maintaining the temperature, thermostatic mixing valve and plate-
type heat exchanger.
Check the delivery for outwardly visible signs of damage.
Check to make sure that the delivery is complete.
Any defects or incorrect deliveries must be reported immediately.
Dispose of the transport and packaging materials properly and under
ecological aspects.
ATTENTION
Use only the original accessories of the unit manufacturer.
1 Bleed valve
2 Plate heat exchanger
3 Dierential pressure controller
4 Option for installing heat meter, installation section 110 mm, 3/4"
(meter not included in scope of supply)
5 Temperature maintaining valve, heating circuit
6 Installation option for heat meter sensor
7 Stopcocks
8 Installation option for cold water meter (meter not included in
scope of supply)
9 Flow restrictor disc 15 l/min (installed) ,
18 l/ min and 12 l/min (enclosed in a bag in the housing of the
domestic hot water station)
10 Proportional controller
11 Thermostatic mixing valve
ALSO INCLUDED:
Flow restrictor discs (2), 1 gasket
Transport to installation location
To prevent transport damage, leave the packaging on until the drinking
water station has been moved to its place of installation.
INSTALLATION AND ASSEMBLY
Always comply with the applicable local accident prevention regulations,
statutory regulations, guidelines and directives.
ATTENTION
Install the domestic hot water station only in a dry and frostproof
location, xed to a wall suitable for carrying the weight of the drinking
water station.
It may be installed in dry walling stud sections or solid (reinforced
concrete or masonry) structures. The minimum installation depth
required is 110mm.
Remove the front panel and frame trim.
Use lag bolts (not included) to x the drinking water station in the
wall.
Mounting options:
583033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
CONNECTION TO THE PIPE SYSTEM
Dirt and deposits in the heating circuit and domestic hot water circuit
can cause malfunctions. Flush pipes thoroughly before connecting the
domestic hot water station.
ATTENTION
During the connection work, secure the unit's connections against
twisting, in order to protect the pipes and ball valves from damage.
1 Cold water –
inlet 3/4ʺ IG
2 Domestic hot
water – outlet
3/4ʺ IG
3 Cold water –
outlet 3/4ʺ IG
4 Heating water
– outlet 3/4ʺ IG
5 Heating water
– inlet 3/4ʺ IG
Components
PROPORTIONAL CONTROLLER
- The proportional controller controls the heating water ow rate,
which is required to heat the domestic hot water.
– In heat pump mode the proportional
controller should be set to “maximum”
(red dot).
– To maintain a nominal delivery
temperature of 45 °C, the cold water
ow must be limited as follows:
– Heating water in the storage tank
50°C > 12 l/min
– Heating water in the storage tank
55°C> 15 l/min
– Heating water in the storage tank
60°C > 18 l/min
Flow restrictor disc:
The domestic hot water ow can be limited by using ow restrictor discs
(supplied) at the cold water inlet in the proportional controller (installed
15l/h).
HEAT METERS
– The heat meter sections can receive heat meters installed on site
(110mm x 3/4ʺ AG).
– The heat meter sensors are installed in the sensor pockets of the
stopcocks.
– We recommend the use of ultrasonic heat meters, as these have low
pressure losses.
6 83033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
DIFFERENTIAL PRESSURE CONTROLLER
– Dierential pressure controller for maintaining the dierential
pressure in the heating water during large load changes
–
Continuously adjustable from 50 to 300 mbar (preset in the factory)
–
To maintain the given performance specications the dierential
pressure must be set to “maximum” (300 mbar factory setting)
TEMPERATURE MAINTENANCE
– Temperature limiting valve for maintaining the heating water ow
temperature at the domestic hot water station inlet (should be
slightly above the set delivery temperature).
– Continuously adjustable temperature setting
DOMESTIC HOT WATER MIXING VALVE
– Thermostatic mixing valve for thermostatic control of the delivery
temperature
– Continuously adjustable temperature setting from 35°C to 60°C
– The recommended delivery temperature of 45°C
– If the temperature is higher there is a risk of scalding
– If the temperature is higher there is a risk of the plate-type heat
exchanger furring up
Flushing, lling and venting
ATTENTION
The system must be absolutely free from air before commissioning.
HEATING CIRCUIT
WATER QUALITY FOR THE FILL AND MAKE-UP WATER ACCORDING
TO VDI 2035 PART I AND II IN HOT WATER HEATING SYSTEMS
Use of modern, energy-ecient heat pump systems is becoming
increasingly widespread. Their ingenious technology enables these
systems to achieve very good eciencies. The decreasing space available
for heat generators has led to the development of compact units with
increasingly smaller cross-sections and high heat transfer capacities. This
means the complexity of the systems and the material diversity are also
increasing, which plays an important role especially in their corrosion
behaviour. We ensure continuous technological advances, but all these
technical renements require the system to be operated with correctly
lled heating water. The heating water not only aects the eciency
of the system, but also the life of the heat generator and the heating
components of a system.
The guide values of VDI 2035 Part I and Part II must therefore be complied
with as minimum requirements for proper operation of the systems. Our
practical experience has shown that the safest and most trouble-free
running of the systems is achieved with so-called low-salt operation.
VDI 2035 Part I gives important information and recommendations
regarding scaling and its prevention in heating and domestic hot water
heating systems.
VDI 2035 Part II primarily deals with the requirements for reducing
heating water corrosion in hot water heating systems.
PRINCIPLES OF PART I AND PART II
The occurrence of scaling and corrosion damage in hot water heating
systems is low, if
– proper planning and commissioning is carried out
– the system is closed in corrosion terms
– adequately dimensioned pressurising is integrated
– the guide values for the heating water are complied with
– and regular servicing and maintenance are carried out.
A system log should be kept, in which the relevant planning data is
entered (VDI 2035).
DAMAGE THAT CAN OCCUR IN CASE OF NON-COMPLIANCE
– Malfunctions and the failure of components (e.g. pumps, valves)
– Internal and external leaks (e.g. from heat exchangers)
– Cross-section reduction and blockage of components (e.g. heat
exchanger, pipes, pumps)
– Material fatigue
– Gas bubbles and gas cushion formation (cavitation)
– Negative eect on heat transfer (formation of coatings, deposits) and
associated noises (e.g. boiling noises, ow noises)
783033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
LIMESCALE – THE ENERGY KILLER
Filling with untreated drinking water inevitably leads to the precipitation
of all calcium as scale. The consequence: limescale deposits form on the
heat transfer surfaces of the heating. The eciency falls and the energy
costs rise. A rule of thumb is that 1 millimetre of limescale deposit causes
an energy loss of 10%. In extreme cases it can even cause damage to the
heat exchangers.
WATER SOFTENING TO VDI 2035 – PART I
If the water is softened before the heating is lled, in accordance with the
VDI 2035 guidelines, no scale can form. This eectively and permanently
prevents limescale deposits and the resulting negative eects on the
entire heating system.
CORROSION – AN UNDERESTIMATED PROBLEM
VDI 2035, Part II, deals with the problem of corrosion. Softening the
heating water can prove to be insucient. The pH value can signicantly
exceed the limits of 10. pH values higher than 11 can set in, which
even damage rubber seals. The VDI 2035, Part 1 guidelines are indeed
fullled, but, VDI 2035, Part 2 prescribes a pH value between 8.2 and
maximum10.
If aluminium materials are used, which is the case in many modern
heating systems, a pH value of 8.5 must not be exceeded, because
otherwise there is a threat of corrosion – and aluminium is attacked
without the presence of oxygen. Therefore, apart from softening the
heating ll and additional water, the heating water should also be
appropriately conditioned. This is the only way to comply with the
VDI 2035 requirements and the recommendations and installation
instructions of the heat pump manufacturer.
Part 2 of VDI 2035 also points out the reduction in total salt content
(conductivity). The risk of corrosion is far lower if deionised water is used
than is the case if the system is operated with salty, i.e. softened water.
Even if drinking water has been softened beforehand, it contains
dissolved, corrosion-promoting salts, which act as electrolytes due to the
use of dierent materials in the heating system and therefore accelerate
corrosion processes. This can ultimately result in pitting.
ON THE SAFE SIDE WITH LOW-SALT OPERATION
The problems listed above do not occur at all with low-salt operation,
as the heating water contains neither corrosive salts such as sulphates,
chlorides and nitrates nor alkalising sodium hydrogen carbonate. The
corrosive properties of deionised water are very low and in addition, fur
cannot form in the boiler. This is the ideal approach for closed hot water
circuits, in particular, because even a low oxygen input into the heating
circuit can also be tolerated.
In general, when the system is lled with deionised water, the pH value
sets itself within the ideal range due to “self-alkalinisation”. If necessary,
a pH value of 8.2 can be very easily alkalised by adding chemicals. In this
way, optimum protection of the entire heating system is achieved.
MONITORING
Analytical recording and monitoring of the relevant water values and
the added conditioning substances is of decisive importance. Therefore,
they should be monitored regularly using appropriate water test
equipment.
For further information refer to VDI 2035.
Open the heating circuit shut-o valves slowly.
Fill the heating circuit via ow and return and vent with the bleed
valve
Bleed valve
8 83033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Open the stopcocks slowly.
Flush and vent the domestic hot water circuit by opening the
domestic hot water sanitary delivery points (taps) slightly.
Insulating the hydraulic connections
Insulate the domestic hot water circuit and the heating circuit according
to the relevant local standards, guidelines and directives.
Dismantling
Only qualied heating or refrigerating system personnel are allowed to
remove the unit from the system.
Components of the unit must be recycled or disposed of properly in
accordance with the relevant regulations, standards and directives.
DOMESTIC HOT WATER CIRCUIT
DOMESTIC HOT WATER QUALITY REQUIRED
Water constituent Concentration (mg/l or ppm) Time limits
Stainless Steel Plate heat exchanger
copper brazed
Stainless Steel
Plate heat exchanger
Alkalinity (HCO
3
-
)
< 70
70 - 300
>300
≤ 24 h
0
+
0/+
+
+
+
Sulphate (SO
4
2-
)
< 70
70 - 300
>300
–
+
0/–
+
+
+
+
HCO
3
-
/ SO
4
2-
> 1.0
< 1.0
–
+
0/–
+
+
Electrical
conductivity
< 10 μS/cm
70 - 300 μS/cm
300 - 500 μS/cm
> 500 μS/cm
–
0
+
0
–
+
+
+
+
pH
< 6,0
6,0 - 7,5
7,5 - 9,0
> 9,0
≤ 24 h
0
0
+
0
0
+
+
+
Ammonium (NH
4
+
)
< 2
2 - 20
>20
≤ 24 h
+
0
–
+
+
+
Chloride (Cl
-
)
< 100
100 - 200
200 - 300
> 300
–
+
+
+
0/+
+
+
+
–
Free chloride (Cl
2
)
< 1
1 - 5
> 5
≤ 5 h
+
0
0/–
+
–
–
Hydrogen sulphide (H
2
S)
< 0,05
> 0,05
–
+
0/–
+
+
Free (aggressive)
carbon dioxide (CO
2
)
< 5
5 - 20
> 20
–
+
0
–
+
+
+
Total hardness (
0
dH) 4,0 - 8,5 – + +
Nitrate (NO
3
-
)
< 100
> 100
–
+
0
+
+
Iron (Fe)
< 0,2
> 0,2
–
+
0
+
+
Aluminium (Al)
< 0,2
> 0,2
–
+
0
+
+
Manganese (Mn)
< 0,1
> 0,1
–
+
0
+
+
In general: pH-Wert <6 increases the risk of corrosion.
pH-Wert >7,5 reduces the risk of corrosion.
+ Good resistance under normal conditions
Sulphates and nitrates act as inhibitors of pitting corrosion caused by
chlorides in pH-neutral environments.
0 Corrosion can occur, especially if other factors are evaluated
with 0
SFe
3+
and Mn
4+
can increase the risk of local corrosion in stainless steels.
SiO
2
> 150 ppm increases the risk of calcication.
– Use not recommended
983033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Technical data
Unit designation TWS 3 DZ(S)
Drinking water Delivery temperature: Setting range ı Factory setting °C 35 - 60 ı 45
Drinking water ow rate: Delivery quantity l/min 3 - 18,5
Nominal drinking water conditions: Inlet ı Outlet °C ı °C 10 ı 45
max. delivery quantity with heating water temperature ≥ 60°C l/min 18,5
max. delivery quantity with heating water temperature 55°C l/min 15
max. delivery quantity with heating water temperature 50°C l/min 12
max. allowable operating pressure, drinking water side bar 10
min. allowable operating pressure, drinking water side bar 2
Heating water Limit of use: Heating water temperature °C 50 - 90
Limit of use: Heating water ow rate l/h 180 - 1300
Pressure loss ı Flow rate bar ı l/h 0,3 ı 1300
Dierential pressure controller, factory setting mbar 300
max. allowable operating pressure, heating water bar 3
Installation location Indoors ı Outdoors • applicable ı — not applicable • ı —
Surface mounted ı Flush mounted • applicable ı — not applicable — ı •
Installation data Housing dimensions: Height ı Width ı Depth mm ı mm ı mm 750 ı 580 ı 115
Total weight kg 24
Connections Heating water inlet ... Rp 3/4ʺ IG
Heating water outlet ... Rp 3/4ʺ IG
Drinking water inlet ... Rp 3/4ʺ IG
Drinking water outlet ... Rp 3/4ʺ IG
Temperature maintenance integrated: • ja — no •
Dierential pressure valve integrated: • ja — no •
Heat metering integrated: • ja — no —
813314a
Performance curves
Legend: 813314
“
TW
Drinking water ow rate
“
HW
Heating water ow rate (primary side)
Temp. HW Heating water temperature, primary side
10 83033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Dimensioned drawings
750
580
38
51
0
40
105
170
235
365
535
705
105
115
B
A
F
1 4 532
15077001
8
7
6
5
4
3
2
1
www.alpha-innotec.de
D - 95359 Kasendorf
Industriestraße 3
Alpha-InnoTec GmbH
1
1
Ers. d.
Ers. f.
A
B
C
D
E
F
F
E
D
C
B
A
4
3
2
1
Benennung
Zust.
Änderungstext
Datum
Von
Blatt
von
Werkstoff
Gewicht
Maßstab
1:10
Det. Maßstab
Datum
Name
Erstellt
Gepr.
Norm.
23.1.2013
Aepfelbach
toleranz
Allgemein-
Oberflächen
ArtikelNr.
Schutzvermerk ISO 16016 beachten
DIN ISO 2768 -c
Aepfelbach
23.1.2013
Aepfelbach
22.1.2013
RA
23.1.2013
PEP 010-2012
-
819427
Frischwasserstation
Trinkwarmwasserstation TWS 3DZ
Legend: D819427- A Front view
All dimensions in mm. B Side view from left
F View from underneath
Item Designation Dim.
1 Cold water inlet Rp 3/4ʺ IG
2 Domestic hot water Rp 3/4ʺ IG
3 Cold water outlet Rp 3/4ʺ IG
4 Heating water outlet Rp 3/4ʺ IG
5 Heating water inlet Rp 3/4ʺ IG
1183033000eUK– Translation of the original operating manual – We reserve the right to make technical changes without notice.
Made by ait-deutschland GmbH
/