Group DEP Thermodynamic Box Installation Instructions And User Manual

Brand
Group DEP
Model
Thermodynamic Box
Type
Installation Instructions And User Manual
Installation instructions and user manual V1.5 1
www.groupdep.com thermodynamic@groupdep.com
Thermodynamic
Box
Operation and Installation Manual
Authorised sole distributor for Magic Thermodynamic Box Limited
Installation instructions and user manual V1.5 2
www.groupdep.com thermodynamic@groupdep.com
INDEX
1 INTRODUCTION 3
2 GENERAL SAFETY WARNINGS 4
3 OPERATING PRINCIPLE 5
4 TECHNICAL SPECIFICATIONS 6
5 INSTALLATION 7
5.1 INSTALLING THE LITTLE MAGIC THERMODYNAMIC BOX 8
5.2 INSTALLING THE THERMODYNAMIC PANEL 9
5.3 REFRIGERATION CONNECTIONS 11
5.4 SIGHT GLASS 12
5.5 HYDRAULIC CONNECTIONS 13
5.6 TEMPERATURE SENSOR 17
5.7 ELECTRICAL CONNECTIONS 17
5.8 PRESSURE TEST WITH NITROGEN 17
5.9 VACUUM TEST 18
5.10 FILLING OF THE REFRIGERANT CIRCUIT 18
5.11 DRAINING & BLEEDING 18
5.11 TURNING THE SYSTEM ON 19
6 DIGITAL CONTROLLER SETTING 20
7 REPAIR AND MAINTENANCE 22
8 TROUBLESHOOTING – Guidance Values 23
9 TROUBLESHOOTING - Electrical Wiring 24
10 TROUBLESHOOTING GUIDE 25
11 MANUFACTURERS INSTALLATION PACK 26
12 GENERAL CONDITIONS OF WARRANTY 27
Installation instructions and user manual V1.5 3
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1 INTRODUCTION
Group DEP is excited to bring the Thermodynamic water heating system to Australia and New Zealand. We
have worked extensively on licensing the product and we feel that it is unmatched in its efficiency by any
other renewable energy product. Group DEP is the authorized sole distributor for Little Magic
Thermodynamic Box Ltd. The Thermodynamic Box is designed to heat a domestic hot water cylinder up to
60°C. The maximum temperature is influenced by the individual installation, pipe lengths and insulation. It
uses an exterior aluminium panel to absorb energy from the ambient air. The heat exchanger is a low
resistance type manufactured from stainless steel plates. The pump used is of a composite material,
extremely light and fully compatible with potable water applications. The product has a reciprocating
compressor for quiet and efficient performance. This box has a timer with a 1 minute start delay for
protection of the compressor. With these features the Thermodynamic Box is designed to have a long,
trouble free life.
The Thermodynamic Box has integral safety devices to protect the product from internal and external
faults. An adjustable digital thermostat controls the water temperature.
Fig. 1 INTERNAL LAYOUT OF LITTLE MAGIC THERMODYNAMIC BOX
IMPORTANT
This product is not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they have been given supervision or
instruction concerning the use of the product by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the product.
This Product must be installed by a fully qualified Refrigeration plumber.
Installation instructions and user manual V1.5
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2 GENERAL SAFETY
WARNI
To avoid injury to the user
o
followed. Incorrect operati
o
The installation is the respo
n
equipment carefully before
regards damages deriving f
r
detailed here.
Ask a suitably qualified
refrigerant
may cause gas or water lea
Do not install the equipme
n
equipment: areas with corr
o
fluctuations, places with str
other special environments
.
The electrical connection s
h
standards guide.
Sufficient space should be
al
the connections of pipes an
The Thermodynamic Box s
h
installation. If turned on i
ts
The support surface shall b
e
unit without increasing noi
se
Hard waters (CaCO3 conte
n
the system. It is recommen
d
HEALTH & SAFETY: Care sh
o
the product. Check the wei
gh
for the safety of the install
er
product and in particular th
location and the mounting
structu
withstand the additional lo
a
equipment to ensure there
thermodynamic@groupdep.com
WARNI
NGS
r damage to the product the instructions within
o
n will invalidate the warranty.
n
sibility of the purchaser. Read the information
su
installing and using it. The manufacturer declin
es
r
om an incorrect installation and a failure to foll
o
refrigerant
gas plumber to install this product as
an i
ks
and invalidate any warranty.
n
t in the following places as they will lead to a m
al
o
sive gases, factories where the electrical voltag
e
ong electromagnetic waves, places with inflam
m
h
ould be carried out in accordance with that spe
cified
al
lowed for the installation and maintenance of t
h
d wiring.
h
ould always remain in a horizontal position duri
n
ts
side the compressor should be checked for sign
s
e
flat, bear the weight of the unit and be ready f
o
se
or vibrations.
n
t >200 ppm) may produce obstructions due to t
h
d
ed to use a descaler in the hydraulic circuit.
o
uld be taken when moving
gh
t before any lifting. This is
er
and customer. Ensure the
e box are installed in a safe
structu
re is adequate to
a
ds. Take care when moving
is no damage to the equipment or existing stru
ctu
4
thermodynamic@groupdep.com
the manual must be
su
pplied with the
es
any responsibility as
o
w the instructions
an i
ncorrect installation
al
function of the
e
experiences wide
m
able materials or gases,
cified
in the Australian
h
e product including
n
g transport and
s
of leakage.
o
r the installation of the
h
e lime deposits inside
ctu
re and fittings.
Installation instructions and user manual V1.5 5
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3 OPERATING PRINCIPLE
The Thermodynamic Box works on the principle of thermodynamics. It is the process of heating water in a
cylinder by using a refrigerant liquid which is circulated in an external panel (evaporator) that absorbs
energy from the ambient air. This energy excites the liquid which turns it into a gas. This gas is compressed
to create heat which is transferred to the water via the heat exchanger. Due to the uniqueness of the
direct gas evaporation principle the external thermodynamic collector can absorb heat during the day and
night in all climatic conditions (rain, cloud, sun and wind).
The Thermodynamic Box operates with sealed pressurised systems and vented systems.
When the Thermodynamic Box is added as a retrofit to an existing cylinder the existing boiler should be
fully serviced. As the box is set at 60
o
C this produces adequate protection from legionella.
There must be a temperature reduction valve fitted in accordance with Australian Standards.
Fig 2: Little Magic Thermodynamic Box Operating Principle Simplified Schematic
Installation instructions and user manual V1.5 6
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4 TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
Mean thermal capacity (only thermodynamic) (W)
840W to 2200W
M
i
n
t
o
M
a
x
Mea
n
p
o
w
e
r
c
o
n
s
u
med
(thermodynamic) (W)
3
5
0
W
t
o
6
5
0W
Typically 450W
Voltage / frequency
220-240V, 50Hz
Atmospheric temperature range (ºC)
-10°C to 50°C
Hermetic System
Refrigerant fluid and charge
R134a, 0.70kg
Max. Hot water temperature (ºC)
60
o
C
Unit Dimensions (height x width x depth) (mm)
310mm x 420mm x 345mm
Packaging dimensions (height x width x depth)
410mm x 511mm x 442mm
Thermodynamic box weight (kg)
31 kg
Maximum water circuit working pressure (bar)
8 bar
C
o
l
d
w
a
t
e
r
i
npu
t
c
onne
c
t
ion
s
(
"
)
/
H
o
t
w
a
ter
ou
t
pu
t
connections (")
¾” & ¾”
Thermodynamic panel weight (kg)
6.2kg
T
he
r
m
od
y
na
m
i
c
P
ane
l
D
i
me
n
s
i
on
s
(height x width x depth) mm
1700mm x 800mm x 25mm
T
he
r
m
od
y
na
m
i
c
p
ane
l
i
n
p
u
t/
ou
t
pu
t
c
onne
c
t
i
on
s
(thread) SAE(”)
¼” & 3/8”
T
he
r
m
od
y
na
m
i
c
u
n
i
t
i
npu
t/
o
u
t
pu
t
c
onne
c
t
i
on
s
(thread) SAE(”)
3/8” & ¼”
R134a refrigerant gas
Fig 3
Installation instructions and user manual V1.5 7
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5 INSTALLATION
It is essential that correct licenses are held to install and connect the panel to the Thermodynamic Box. All
personnel carrying out installation, maintenance or servicing of stationary refrigeration, air-conditioning or
heat pump equipment that contains or is designed to contain F-Gas refrigerants must hold the relevant
designated qualifications stated in the Australian Standards guidelines.
The plumbing work must be carried out by a plumber who is qualified to Level 3. Where necessary the
plumber must hold an Unvented Hot Water Certificate recognized by Competent Person Schemes (CPS)
approved to offer self-certification under Approved Document G.
Inside Australia the installation needs to be carried out in accordance with the country’s local regulations.
Installation Steps:
1. Install the Thermodynamic Box
2. Install the Thermodynamic Panel
3. Refrigeration connections
4. The sight glass
5. Hydraulic connections
6. Temperature Sensor
7. Electrical connections
8. Pressure test during the installation with nitrogen
9. Vacuum test during installation
10. Filling of the refrigerant circuit
11. Draining & bleeding of the hydraulic circuit
12. Temperature reduction valve
13. Turning the system on
5.1 INSTALLING THE THERMODYANAMIC BOX
Siting location
• Make sure the fixing points and fixing methods will take the weight of the
Thermodynamic Box. Please refer the Fig.2 for the fixing location of the unit.
• The Thermodynamic Box must be installed in horizontal position.
• The equipment shall not be installed in a place where it exposed to corrosive gases, major electrical
fluctuations, high electromagnetic field, inflammable materials or other hazardous areas.
• Minimum pipe diameter of 22mm should be used in the hydraulic system between the
Thermodynamic Box and water cylinder.
Installation instructions and user manual V1.5
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Handling the unit
The unit must be transported and
mo
Before handling the unit, check its
w
During handling care should be tak
en
order to avoid damage.
Installation of the unit
Step 1: Carefully remove the outer
Step 2: Fix the unit to a suitable w
all with
any possible vibration nois
e
(see end of manual)
For maximum efficiency the Therm
o
reduce pipework length and minim
i
cylinder should be insulated.
Anti-vibration
mounts
Fig.4 Positi
on
thermodynamic@groupdep.com
mo
ved in the horizontal position and should nev
er
w
eight (Section 4 “Technical Specification” of thi
s
en
to ensure it shall not be subjected to sudden
m
casing of the unit to gain access to the wall fixin
g
all with
four screws. Anti-vibration mounts with
e
should be used. These are included in the
optional
o
dynamic Box should be installed as close to the
c
i
ze bends. It is recommened that Pipework
within
on
s of fixing holes with M8 anti vibrations moun
ts
8
thermodynamic@groupdep.com
er
be turned over.
s
manual).
m
ovements or impact in
points.
M8 bolts to minimize
optional
Installation kit.
c
ylinder as possible to
within
a metre of the
Anti-vibration
mounts
ts
Installation instructions and user manual V1.5 9
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5.2 INSTALLING THE THERMODYNAMIC PANEL
• The panel can be installed, using the supplied brackets, to an exterior wall. If the panel is installed
on a roof it should be fixed in accordance with Australian Standards. Compliance is the
responsibility of the installer.
• Fix the evaporator panel in a vertical (portrait) position for the best performance, horizontal
(landscape) is also valid, with the inlet pipes situated on the lower part as per the figure 7. The
refrigeration grade copper pipes (3/8ths and ¼) connect the exterior panel to the Box.
NOTE: Care must be taken to avoid bending the panel and the refrigerant pipes.
• The system is pre-charged with 700gms of refrigerant gas for 8m of pipe length between the
Thermodynamic Box and the Panel. The pipe length can be extended up to 15 metres however for
every extra metre length of pipe 50g of refrigerant gas should be added.
• To fix the panel use the supplied brackets, fixing screws or bolts. Please see the picture below for
fixing the panel on the wall.
Fig. 5 Thermodynamic Panel Fixings
• The panel can be located on any facing aspect. Performance differences would only be applicable
during daylight hours.
• For increased performance, the panel can be installed parallel to the prevailing wind, allowing the
air to pass freely over the surface of the panel.
NOTE: If installed on the roof or similar then snow loads for the area should not exceed 1.0N/m2
and should not be exposed to wind velocities greater than 28m/s.
• Connection of the panel: Gas outlet (fig. 9) is connected to the gas inlet of the unit and liquid
inlet (fig. 9) is connected to the liquid outlet of the unit.
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RIGHT
Note: Vertical panel orientation of
fe
Incorrec
Fig 7 C
o
thermodynamic@groupdep.com
Fig. 6 Thermodynamic panel
RIGHT
W
RONG
fe
rs optimum performance allowing even flow of refr
ige
t
installation will inhibit the free flow of lubricating oil
o
rrect and incorrect placing of the panel
10
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RONG
ige
rant across the panel.
Installation instructions and user manual V1.5 11
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5.3 REFRIGERATION CONNECTIONS
Brazing
The brazing shall be carried out by qualified gas plumbers and in accordance with the current local
regulation. Any damage caused by incorrect welding procedure will invalidate any warranty.
Refrigeration Connections
NOTE: PIPEWORK SHOULD BE COMPLETED IN ACCORDANCE WITH AUSTRALIAN STANDARDS.
COMPLIANCE IS THE RESPONSIBILITY OF THE INSTALLER.
Refrigeration quality copper pipes must be used to connect the thermodynamic panel and the Little Magic
Thermodynamic Box.
This piping must be properly insulated with flexible anti-condensation insulation.
Direct contact between the refrigeration outlet and refrigeration inlet line shall be avoided to prevent
energy losses in the system.
Before brazing the piping, the system should be checked to ensure it is free of humidity and particles.
The gas piping shall be designed with as few bends as possible to minimize the load loss and it shall be
supported properly with a view not to transmit stresses or vibrations.
Please check for leaks before insulating the pipes.
Fig 8. Refrigeration connections.
Installation instructions and user manual V1.5 12
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Note: Vertical panel position is
recommended for optimum
distribution of the refrigerant.
Fig 9: Refrigeration connection between panels, Vertical and Horizontal
Both pipe ends connecting between the panel and the box need flaring. The suction pipe end needs flaring
to ⅜”. The discharge pipe end needs flaring to ¼”. Use oil to aid braising.
Do not loosen or open service ports until all connections are made and the system has been fully leak
checked and vacuumed.
5.4 THE SIGHT GLASS
Sight Glasses are installed after the filter dryer in liquid line of
refrigerating systems, in order to observe property changes of the
refrigerant and to indicate the moisture level by colours. Bubbles
indicate contamination or lack of refrigerant.
Fig 10 – Sight Glass – Only 134a Readings are applicable
Installation instructions and user manual V1.5 13
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5.5 HYDRAULIC CONNECTIONS
The Thermodynamic Box has a water inlet and outlet located on the bottom front of the Box (Please refer
the fig 1). The minimum pipe size of 22mm should be used for the water connections. Copper pipe must be
used, not plastic or push fit fittings as these may restrict the flow. Pipes within 1 metre of the cylinder must
be lagged/insulated. The hydraulic system will vary dependant on the existing type of cylinder/buffer tank.
VENTED SYSTEMS
• Water inlet and outlet connections of the cylinder should be connected as per the fig 11.
• Water inlet connection to the Thermodynamic Box should always be connected to the first ‘T’ off
point of the cylinder. The connection to the taps should be the 2nd ‘T’ off point.(fig. 11) Drain Cock
must be installed on the lowest part of the system for draining the system.
• The cylinder must be insulated to allow the Thermodynamic Unit to work correctly, if the cylinder is
naked it should be replaced or an insulating jacket installed.
• Do not fit the pipes to an existing coil in the cylinder; this may stop the Box reaching maximum
temperature and reduce performance.
• The Thermodynamic Box should be positioned as close to the water cylinder as possible to
minimise length of plumbing required. Keep bends and turns to a minimum.
• An inline Y-filter should be installed to stop dirt or debris getting into the plate heat exchanger.
Failure to install this will invalidate the warranty. This is included in the optional Installer Pack.
• A non-return valve must be installed between the water storage tank and the cylinder. Ensure that
the water pressure is sufficient to open the valve otherwise air may be drawn into the system. In
these circumstances a flappy style (penny) valve should be used. This is included in the Installers
Pack. (please see back of manual). A spring loaded valve may restrict water flow and is therefore
not recommended.
UNVENTED/PRESSURISED SYSTEMS
• Water inlet and outlet connections of the cylinder should be connected as per the fig 12.
• Water inlet connection to the Thermodynamic Box should always be connected to the first ‘T’ off
point of the cylinder. The connection to the taps should be the 2nd ‘T’ off point. (fig.12) Drain Cock
must be installed on the lowest part of the system for draining the system.
• The Thermodynamic Box should be positioned as close to the water cylinder as possible to
minimise length of plumbing required. Keeps bends and turns to a minimum.
• The installer should assemble the proper filter, pressure gauge, expansion vessel and safety devices
according to the scheme showed in fig.12.
• We recommend a potable expansion vessel of approx. 18 litres for a 200 litre water cylinder.
The installer should satisfy himself of the correct sizing dependant on cylinder size.
Installation instructions and user manual V1.5 14
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• Do not fit the pipes to an existing coil in the cylinder; this may reduce the Little Magic Box reaching
maximum temperature and reduce overall efficiency.
• An inline Y-filter should be installed to stop dirt or debris getting into the plate heat exchanger.
Failure to install this will invalidate the warranty. This is included in the optional Installation Pack.
• Ensure that the Temperature-Pressure release value is fitted to avoid over heating the cylinder as per
Australian Standards.
THE CYLINDER
The cylinder to which the Box is connected should be WRAS approved or equivalent or meet relevant
building regulations. It is the responsibility of the installer to ensure that the cylinder complies to this
standard. Inferior insulation will detrimentally affect the performance of the system.
PRESSURE DROPS
Approximate maximum system pressure drop:
• Pump speed one - 0.3 metres head,
• Pump speed two - 2.6 metres head,
• Pump speed three - 3.8metres head
All above with a flow of 0.18 Litres/sec
As a summary for 22mm copper pipe and with the flow rate of 0.18 L/sec:
• Straight pipe 0.022mhd/metre
• 90° radius bend equivalent to 0.6 metres of straight pipe
• Tee into branch equivalent to 1.1 metres of straight pipe.
• Stop valve equivalent to 7.0 metres of straight pipe.
• Check valve equivalent to 4.3 metres of straight pipe
These pressure drops do not take into account any static head pressure.
Installation instructions and user manual V1.5 15
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Fig. 11 Schematic of Vented System
Showing pipe run and Globus accessory connections
Assumes retro-fit to system with existing boiler
Installation instructions and user manual V1.5 16
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Fig. 12 Schematic of Unvented System
Assumes retro-fit to system with existing boiler
Installation instructions and user manual V1.5 17
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5.6 TEMPERATURE SENSOR
Extends to 9 metres in length and should be affixed to the body of the cylinder to record the water
temperature. Should be located half way to two thirds of the way down a foam insulated cylinder.
Pressurised cylinders will have predetermined fixing points.
VERY IMPORTANT
To ensure consistent and good contact between the probe and cylinder side a syringe of thermal paste is
included in the optional Installation Pack.
5.7 ELECTRICAL CONNECTIONS
The equipment shall be connected to the electrical system once all the refrigerant connections and
hydraulic connections are completed.
All electrical work is to be carried out in accordance with Australian standards.
The power supply is single phase: 230V / 50Hz with earth connection. This supply needs to be separately
isolated, and protected by an appropriately sized fuse. (Maximum 13Amps)
The electrical schematic of the equipment is shown in the Troubleshooting Section.
5.8 PRESSURE TEST WITH NITROGEN
After the refrigeration connection has been made between the panel and the box the piping needs to be
pressure tested to check for leaks. This should to be done by introducing Nitrogen (Oxygen free) into the
pipe work and the panel through the service port. This should be held for about 25 minutes, depending on
size of system.
Note: Please make sure the pressure does not exceed 10 Bar in the panel and the pipe work
Check the welds with soapy water for leaks or other methods as per Australian standards
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5.9 VACUUM TEST
Once the pressure test is completed and no leakage of gas has been confirmed the nitrogen can then be
removed. Connect the vacuum pump into the service port and start to vacuum the system. Hold the system
in vacuum for at least 45 minutes to 2 Torr.
5.10 FILLING OF THE REFRIGERANT CIRCUIT
The Thermodynamic Box comes with pre-charged refrigerant (R134a) of 700 grams which is enough for the
installation of up to 8m length between the panel and the main unit. Open the service ports to fill the panel
with refrigerant.
For an installation involving more than 8m length of pipe, additional refrigerant must be added at 50g per
metre up to a total length of 15 metres.
Where a 2
nd
panel is used depending on the pipe run additional R134a gas may be required.
Once the refrigerant has been released please check the refrigeration connections with suitable gas leak
detector.
5.11 DRAINING & BLEEDING OF THE HYDRAULIC CIRCUIT
Once the installation is complete the water cylinder should be checked to ensure that it is full of water and
free from air.
Bleeding points
Fig 13
Installation instructions and user manual V1.5 19
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The air should be purged from the system as follows:
Open ‘water in’ lever valve with ‘water out’ valve closed.
This allows water to enter the BLMB. Bleed system via water pump and internal air valve.
Open ‘water out’ valve.
Once the air has been bled from the main system please make sure to bleed the air from the
Thermodynamic box. The position of the bleed valve is shown in Fig 13. A radiator key is required. Also
make sure the air is bled from the pump, which can be accessed on right hand side of the product.
5.12 TURNING THE SYSTEM ON
The lead should be connected to the Controller (housed within the cover). The connector only fits one way
and SHOULD NOT BE FORCED. The External Cover should be replaced.
The Thermodynamic Box may be started once the steps described previously have been completed.
To turn the Thermodynamic Box ‘ON’, connect the product into the fused spur (please check section
8 for recommended accessories) and turn the mains supply ‘ON’.
The Thermodynamic Box digital controller will light up showing the current temperature of the cylinder and
the pump will start to run. After 1 minute time delay the compressor will start to run. This time delay
function has been introduced to improve the efficiency and the life of the compressor.
Please leave the system running for 20-30 minutes and check the sight glass to make sure it is full of liquid.
Fully functioning system should show no bubbles.
Sight glass
Fig. 14 Sight Glass Location
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6 DIGITAL CONTROLLER SETTING
TEMPERATURE ADJUSTMENT
The digital thermostat displays the temperature of the water at any time.
This thermostat is preset at 60ºC.
- To view the set point temperature of the compressor, press the P button. SP is displayed
alternatively with the set temperature. Using the buttons with the arrow pointing upwards /
downwards we can increase / reduce the set point temperature. Once set, press the “P” button or
leave and the program will revert to displaying the actual water temperature. The
temperature range is from 10 to 60ºC. .
The unit will raise the temperature to 60° (or the programmed temperature) and then switch off. It will
automatically start again to raise the water temperature once it falls to 55°C. (or 5
o
C lower than
programmed temperature).
WARNING: The programmed temperature for the unit should not ever exceed 60ºC
Fig.15 Digital thermostat scheme
D
ESCR
I
P
TION
ACTION
COMMENTS
P BUTTON
Press to show SP program mode to change
operating temperature of the compressor
The temperature of the
compressor is pre-set at 60°C
Never exceed 60°C.
UP BUTTON
Increases the temperature
DOWN BUTTON
Decreases the temperature
To modify the temperature follow the instructions in diagram 16.
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Group DEP Thermodynamic Box Installation Instructions And User Manual

Brand
Group DEP
Model
Thermodynamic Box
Type
Installation Instructions And User Manual
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