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Wolf BWL-1 S Installation And Operating Instructions Manual

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Installation and operating instructions
Split air/water heat pump
BWL-1 S(B)-07/10/14
GB
Wolf GmbH • Postfach 1380 • D-84048 Mainburg • Tel. (+49) 8751/74-0 • Fax (+49) 8751/741600 • Internet: www.wolf-heiztechnik.de
Document no.: 3064298_201507 Subjecttotechnicalmodications
Integrated system log book
From:
HCM-3 FW 1.30
AM FW 1.40
2 3064298_201507
Table of contents
Contents ............................................................................................Page
Information, layout and equipment
1. Safety information / standards and regulations .........................................................5
2. General information ................................................................................................... 6
3. Information on the heat pump ................................................................................7-8
4. Standard delivery ......................................................................................................9
5. Layout .................................................................................................................10-11
6. Equipment features .................................................................................................12
7. Dimensions BWL-1S(B) ....................................................................................13-15
Siting
8. Siting information / minimum room volume .......................................................16-17
9. Siting the outdoor module .......................................................................................18
10. Siting the indoor module ........................................................................................19
11. Gravel bed and foundation diagram for the outdoor module .................................20
12. Anchoring the outdoor module and providing vibration isolation ...........................21
13. Wall mounting the outdoor module ........................................................................22
Installing the heat pump
14. Positioning the wall duct ........................................................................................ 23
15. Routing the refrigerant lines .................................................................................24
16. Connecting the refrigerant lines to the outdoor module .......................................25
17. Connecting the refrigerant lines of the indoor module ..........................................26
18. Filling the refrigerant lines ................................................................................27-28
19. Testing the refrigerant lines for leaks .....................................................................29
20. Connecting the heating/cooling circuit and the DHW circuit ............................. 30-32
21. Split heating centre with CEW-2-200.....................................................................33
Control system and power supply
22. Power supply / General information ......................................................................34
23. Connection diagram ..............................................................................................35
24. Power supply to the outdoor module ..................................................................... 36
25. Power supply to the indoor module ..................................................................37-45
25.1 Electric heater connection ............................................................................ 38
25.2 PSU / PV / Smart grid / BUS cable connection .......................................38-39
25.3 HCM-3 control PCB connection ...................................................................40
25.4 Wiring diagram for HCM-3 / AWO ...........................................................44-45
33064298_201507
Control system modules
26. Display module / programming unit installation ..................................................... 46
27. Programming unit BM-2 ........................................................................................47
28. AM display module ................................................................................................48
Operating the AM display module
29. Operating the AM display module .........................................................................49
29.1 Programming the quick start keys ................................................................ 49
Adjusting the set heating temperature .......................................................49
Adjusting the set DHW temperature ............................................................49
29.2 Boiler / status / messages ............................................................................50
29.2.1 Heat pump operating mode ..................................................................51
29.2.2 Heat pump status .................................................................................51
29.3 System data displays (menu structure) ......................................................52
29.4 Default settings / Setting options (menu structure) ....................................53
29.4.1 Language .............................................................................................53
29.4.2 Key lock ................................................................................................54
29.4.3 DHW operating mode (ECO/Comfort) ..................................................54
29.4.4 DHW quick heat-up ..............................................................................55
29.4.5 Energy saving mode (no function) .......................................................55
29.4.6 Active cooling .......................................................................................55
29.5 Heating contractor (menu structure) ..........................................................56
Contractor level
30. Contractor level password ..................................................................................... 57
31. Contractor level ................................................................................................58-78
Overview of contractor level .................................................................................58
31.1 Relay test .....................................................................................................58
31.2 System .........................................................................................................58
31.3 Parameters ...................................................................................................59
31.3.1 Overview of contractor parameters .................................................60-61
31.3.2 Description of contractor parameters ..............................................62-64
31.3.3Overviewofsystemcongurations ......................................................65
Systemcongurations .......................................................................... 66-77
31.4 Parameter reset............................................................................................78
31.5 Special..........................................................................................................78
31.6 IDU service (indoor unit)...............................................................................78
31.7 ODU service (outdoor unit)...........................................................................79
31.8 Fault history ..................................................................................................79
31.9 Deleting the fault history ...............................................................................80
31.10 Acknowledging faults ..................................................................................80
Table of contents
Contents ............................................................................................Page
4
3064298_201507
Specication
32. Sound level ............................................................................................................81
33.Conguringthedualmodepoint ...........................................................................82
34. - 48. Heating output, el. power consumption, COP ..........................................83-97
49. Heating circuit residual head .................................................................................98
50.Specication ...................................................................................................99-100
51. Sensor resistances .............................................................................................. 101
Commissioning
52. Commissioning .................................................................................................... 102
System log book
53. System log book ...........................................................................................103-107
53.1 Responsibilities of the operator .................................................................. 103
53.1.1 Annual leak test .............................................................................103
53.1.2 Compulsory documentation ..........................................................104
53.1.3 Dismantling the heat pump and disposing of the refrigerant .........104
53.2 System data ........................................................................................105-107
Information
54. Maintenance / cleaning ................................................................................108-109
55. Troubleshooting ............................................................................................ 110-112
56. Abbreviations / key .............................................................................................. 113
57.ProductcheaccordingtoRegulation(EU)no.811/2013............................ 114-117
58. Technical parameters according to EU regulation no. 813/2013 ......................... 118
DECLARATION OF CONFORMITY ............................................................................ 119
Table of contents
53064298_201507
Safety instructions
The following symbols are used in this description to highlight important
information concerning personal and operational safety:
Denotes instructions with which you must strictly comply to prevent risk or injury to
individuals, faults or damage to the appliance.
Danger due to live electrical components.
Caution: Turn off the ON/OFF switch before removing the casing.
Never touch electrical components or contacts when the ON/OFF switch is in the ON
position. This carries a risk of electrocution that could result in injury or death. The
terminals are live even when the ON/OFF switch is in the OFF position.
Indicates technical instructions that must be observed to prevent malfunction
or appliance damage.
Please note
1. Safety information,
standards and regulations
Standards / Regulations
The appliance and control accessories comply with the following regulations:
EC Directives
2006/42/EG Machinery Directive
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
DIN EN standards
DIN EN 349
DIN EN 378
DIN EN 12100
DIN EN 14511
DIN EN 60335-1
DIN EN 60335-2-40
DIN EN 60529
DIN EN 60730-1
DIN EN 55014-1
DIN EN 55014-2
National standards / directives
DE:
DIN 8901
BGR 500 Part 2
VDI 2035 Part 1-3
Drinking water ordinance
CH:
NEV (SR 743.26)
Certicateofcompetence
The handling of refrigerant and work on the refrigerant circuit must be carried
outbyarefrigerationengineerorothersuitablyqualiedperson,suchasa
heatingcontractorwithacerticateofcompetence(topara5,section3ofthe
ChemKlimaschutzV [or local regulations] in conjunction with (EC) Regulation
No. 303/2008 Category I). Applicable standards and regulations and recognised
engineering standards must be observed.
This appliance is not designed to be operated by persons
(including children) with restricted physical, sensory or
mental capacities or who lack the necessary experience
and/or knowledge, unless they are supervised by a
person responsible for their safety or have received
instructions on how to use the appliance from this person.
6 3064298_201507
The heat pump system must be sited, installed, set up and commissioned by
aqualiedcontractor,incompliancewiththeapplicablestatutoryregulations,
ordinances and directives and the installation instructions.
The tilting angle of the heat pump during transport must be no greater than 45°.
Under no circumstances must the components and pipework of the refrigerant circuit,
the heating circuit or the heat source side be used to transport the appliance.
The heat pump must only be operated with outdoor air as the heat source. The air-
conducting sides must not be constricted or obstructed.
For safety reasons, the power supply to the heat pump and the control system must
not be interrupted, even outside the heating period.
Reason: No monitoring of HC pressure, no frost protection, no anti-seizing pump
protection.
Theappliancemayonlybeopenedbyaqualiedcontractor.
Before opening the appliance, all electrical circuits must be isolated from the power
supply. Take precautions to prevent the fan from starting up unintentionally. The
system must be isolated from the power supply across all poles and safeguarded
against reconnection.
Workontherefrigerantcircuitmustonlybecarriedoutbyaqualiedcontractor.
DonotuseTeonsealantintheheatingcircuit,asthismayresultinleaks.
Never treat appliance surfaces with scouring agents or cleaning agents containing
acid or chlorine.
When siting the heat pump, position and install it securely, to prevent it slipping or
sliding during operation.
The outdoor unit may only be installed outdoors.
Only replace faulty components with original Wolf spare parts.
Observethespeciedelectricalfuseratings
(seeSpecication).
AnydamageorlossresultingfromtechnicalmodicationstoWolfcontrolsystemsis
excluded from our warranty.
Risk of water damage and faulty operation through freezing.
The heat pump is automatically protected from frost when it is switched on.
For installation in Austria:
Observe the ÖVE regulations and requirements and those of your local power supply
utility.
Thelocalpowersupplyutilitymustbenotiedwhenaheatpumpisinstalled.
The installation and operating instructions are valid as of software version
1.30 for printed circuit board HCM-3 and as of software version 1.40 for the AM
display module.
Please note
Please note
The following regulations and directives must be observed when carrying out
installation, commissioning, maintenance and repair work:
2. General information
73064298_201507
3. Information on the heat pump
The heat pump converts the low-temperature heat contained in the outdoor air into
high-temperature heat. To achieve this, air is drawn in by the fan and routed over the
evaporator (1).
The evaporator contains liquid heat transfer medium. This boils and evaporates at low
temperatures and low pressures. The required evaporation heat is extracted from the
air, which cools down in the process. The air is then released back into the atmosphere.
The evaporated heat transfer medium is drawn in by compressor (2) and compressed
to a higher pressure. The compressed, gaseous heat transfer medium is pushed into
the condenser (3), where it condenses at high pressure and high temperature. The
condensation heat is transferred to the heating water, causing the water temperature
to rise.
The energy transferred to the heating water corresponds to the energy that was
previously extracted from the outdoor air, plus the small amount of electrical energy
required for compression.
The pressure in the condenser and upstream of the expansion valve (4) is high. Via
the expansion valve, a temperature-sensitive pressure reduction occurs, causing the
pressure and temperature to drop. The cycle then starts again.
Operating principle of a heat pump
Application area
The split air/water heat pump for heating water temperatures up to 55 °C and air
temperatures down to -15 °C or -20 °C is designed exclusively for the heating of heating
water and domestic hot water. The heat pump can be used in new or existing heating
systems,takingintoconsiderationtheapplicationlimits(see"Specication").
4. Expansion valve
3. Condenser
2. Compressor
1. Evaporator
By choosing a heat pump heating system, you are helping to protect the environment
throughlowemissionsandefcientuseofprimaryenergy.Toensurethatyournew
heatingsystemoperatesatmaximumefciency,pleasebearinmindthefollowingpoints:
The heat pump heating system must be carefully sized and installed. Avoid
unnecessarily high ow temperatures. The lower the ow temperature on the
heatingwaterside,themoreefcientlytheheatpumpoperates.Ensurethatthe
controller is adjusted correctly.
Intermittent ventilation is preferable. Compared to airing with the windows
permanently tilted open, this method of ventilation reduces energy consumption
and saves you money.
Please note
Energy-efcientuseofthe
heat pump heating system
Frost protection
The heat pump is automatically protected against frost when it is switched on. The
use of anti-freeze is not permissible.
Risk of water damage and faulty operation through freezing.
Please note
Indoor module
Outdoor module
1.
2.
3.
4.
Air
Cylinder
8 3064298_201507
3. Information on the heat pump
The appliance is equipped with sensors that monitor the heating circuit and the refrigerant
circuit.
Other equipment features
Wolf heat pumps require special DHW cylinders for heating the domestic hot water;
these are available from the Wolf range of accessories.
The indirect coil surface area in the DHW cylinders must be at least 0.25 m² per kW
of heating output.
Please note
DHW cylinders
Do not use (for cleaning, polishing, etc.) or store sprays, solvents, chlorinated
cleaning agents, paints, lacquers, adhesives, salts, etc. on or in the vicinity of the
heat pump.
Under unfavourable conditions, these materials may cause corrosion in the heat
pump and other heating system components.
Onlycleanthecasingwithadampclothandamildchlorine-freedetergent.Tonish,
dry off immediately.
Corrosion protection
Water hardness
The adjustable cylinder water temperature can exceed 60 °C. Short-term operation
at temperatures above 60 °C must be monitored in order to prevent scalding. For
permanent operation, appropriate precautions should be taken to prevent draw-off
temperatures above 60 °C, e.g. thermostatic valve.
To protect against scaling, the DHW temperature must be set to max. 50 °C when
the total water hardness is 15 °dH (2.5 mol/m³) or above. If the total hardness is
16.8 °dH or above, we recommend using a water treatment facility in the cold water
supply line when heating DHW, in order to prolong the maintenance interval. Even if
water hardness is less than 16.8 °dH, an increased risk of scaling may occur in some
areas, necessitating suitable softening measures. Failure to take such measures will
result in premature scaling of the appliance and reduced DHW convenience. The
contractor should always check the local conditions.
Water treatment
VDI 2035 Part 1 lists recommendations for the prevention of scaling in heating
systems. Part 2 deals with corrosion on the water side.
When screed drying using the heater rod, particular care should be taken to ensure
that the permissible total hardness is complied with, otherwise there is a risk of
scaling and heater rod failure.
The permissible water hardness is 16.8°dH for system volumes of up to 250 litres
during operation with the electric heating rod.
Please note
In the case of high-volume systems or those where large top-up water volumes
(e.g. due to water losses) are required, the following values should be observed.
If the limit curve is exceeded, an appropriate portion of the system water must be
treated.
Example: Total hardness of the domestic hot water: 16 °dH
System volume: 500 l
i.e. at least 250 l must be treated.
System volume in l
Permissible hardness in °dH
Water treatment
necessary
No water
treatment
necessary
250 l
Operation without immersion heater
Operation with immersion heater
We also recommend a heating water pH value of between 6.5 and 9.0 for mixed
installations comprising various materials.
93064298_201507
Outdoor
module
Standard delivery
4. Standard delivery
Indoor
module
Required accessories
AM display module required, BM-2 programming unit can be used as a remote
control. Dew point monitor for cooling mode only.
f Outdoor module, fully encased in box
f Indoor module, fully encased in box
containing the following:
− Installation and operating instructions including system log book and
maintenance instructions
− Commissioning report with checklist
− Suspension bracket and assembly set for indoor module
− 3x pluggable pipework for appliance connection, Ø 28, with O-rings and clips
− Vent hose for commissioning
− Type plate supplement for the outdoor module
− Union nuts for refrigerant circuit, 2x10 / 2x16
10 3064298_201507
5. Layout
Layout BWL-1S(B) indoor module
High-efciencyheatingcircuitpump
Heating circuit pressure sensor
Vent
Pressure gauge
Safety valve
Schrader valve
Electric booster heater
(accessory for BWL-1SB)
Boiler water temperature sensor
Control electronics and power
supply connection
Condenser
Heatingcircuitowsensor(HC)
3-way diverter valve, heating / DHW
Refrigerant pressure sensor
Return temperature sensor
Refrigerant line connection
Optional use of AM display module
AWO boiler water temperature
sensor for outdoor module controller
(AWO T_boiler)
Refrigerant temperature (T_condenser)
113064298_201507
Fan
Liquid separator
4-way valve
Electronic expansion valve
Inverter compressor
Layout BWL-1S(B)-10/14 outdoor module
Layout BWL-1S(B)-07 outdoor module
5. Layout
Evaporator
Evaporator
Fan
Liquid separator
4-way valve
Electronic expansion valve
Inverter compressor
12 3064298_201507
6. Equipment features
BWL-1S(B)
Indoor module
• Demand-controlled electric booster heater
o for 2 / 4 / 6 kW depending on connection – Type BWL-1S
o For covering peak loads
o Adjustable for emergency mode or for screed drying
o Screed drying also possible without outdoor module
• Control electronics with integrated wiring chamber
• Slot for BM-2 programming unit or AM display module
• External control via 0-10V possible
• Slot for LAN / WLAN interface ISM7i
• Thermally insulated condenser made from stainless steel plates
• Variablespeedhigh-efciencypumpfortheheatingcircuit
• 3-way diverter valve for heating/DHW heating,
pressure gauge, safety valve installed
• Pressureandowsensors,plusow/returntemperaturesensors
• Refrigerant lines with insulation, Schrader valve and temperature sensor,
heating circuit connections 28 x 1
• Sound and heat insulated, sealed against formation of condensate
• Components secured in EPP, plug-in system for fast assembly
• "Smart Grid Ready" for integration into smart grids, plus EHPA quality seal
• Heating/DHW temperatures can be increased externally, e.g. by smart grid
or PV system
Outdoor module
• Version with one EC axial fan for BWL-1S(B)-07
• Version with 2 EC axial fans for BWL-1S(B)-10 and BWL-1S(B)-14
o Variable speed control, energy saving, powerful
• Evaporator with protective coating for long service life
• Sound-insulated compressor
• Inverter compressor for modulating electronic output control
• 4-way diverter valve for heating and cooling modes combined with
energy-efcientelectronicexpansionvalve
• Flared connections for refrigerant lines
• Refrigerant charge (R410A) for single line lengths up to 12 m
(max. 25 m possible)
• Flexiblesitingusingoororwallmountingsupports
133064298_201507
7. Dimensions BWL-1S(B)
Indoor module
373
440
344
790
118
695
157
214
258
97 75
50
170
170
93
50
17
167
132
28
100
143
Return, heating / DHW 28x1
Liquid line 5/8" UNF
Hot gas line 7/8" UNF
Flow, heating 28x1
Hose, safety valve DN 25
Flow, DHW 28x1
Electrical connection
14 3064298_201507
7. Dimensions BWL-1S(B)
BWL-1S(B)-07 outdoor module
1040
340
527
378
260
865
48
253
153064298_201507
7. Dimensions BWL-1S(B)
BWL-1S(B)-10 and BWL-1S(B)-14 outdoor module
900
340
705
357
1255
97
50
97
16 3064298_201507
Split air/water heat pump for
outdoor installation
Installation information:
When selecting the installation site, observe the following points:
- The heat
pump must be accessible on all sides. The air intake should preferably be
on a wall.
- The air discharge side must be free from obstruction. Since the air being
discharged is around 8 K below than the ambient temperature, premature ice
formation should be expected. Therefore do not discharge the air directly onto
walls, patios or footpaths. There should be at least 3 m clearance between the heat
pump discharge and walls, patios, footpaths, etc.
- Topreventairshortcircuitsandsoundreection,avoidinstallinginrecessesor
between two walls.
- Installation in a depression is not permitted as the cold air will sink and no air
exchange will take place.
- To avoid causing disturbance, bear in mind the sound levels and distance from
neighbouring properties when selecting a site.
- Bear in mind the prevailing wind direction / prevent air short circuits
- The condensate should drain away into the gravel bed.
- Protect air intake/discharge from leaves and snow.
- Provide thermal insulation for underground pipes.
Do not site the air source heat pump for outdoor installation in an environment that is
polluted with corrosive gases, such as acids, or alkaline gases.
Do not install in a location directly exposed to onshore winds, as this will result in a
riskofcorrosionfromthesalineair,particularlyontheevaporatorns.Inlocations
with strong winds it may be necessary to construct wind protection to divert the
onshore wind.
Strong winds may interfere with evaporator ventilation.
In areas with high snowfall or in very cold places, protective measures must be taken
to ensure that the heat pump operates correctly. Incorporate the outdoor unit into the
lightning protection system.
Do not install the heat pump with the discharge side facing the prevailing wind
direction.
When siting the heat pump in occupied / communal areas, as opposed to a separate
plant room, the minimum room volume in relation to the refrigerant charge weight
must be complied with. In accordance with EN 378-1, the following limit applies to
R410A refrigerant: 0.44 kg/m³ refrigerant per cubic metre room volume.
For refrigerant lines less than 12 m, the refrigerant charge weight provided is
sufcient.Forrefrigerantlinesbetween12mandamaximumof25mlong,an
additional 0.06 kg/m of R 410A needs to be added; consequently, a larger room
volume is required for the indoor module (see table).
Minimum room volume
Type
Refrigerant line < 12 m Refrigerant line 12 m - 25 m
Charge weight Room volume Charge weight
up to
Room volume
BWL-1S(B)-07 2.15 kg > 4.9 m³ 2.93 kg > 6.7 m³
BWL-1S(B)-10 2.95 kg > 6.7 m³ 3.73 kg > 8.5 m³
BWL-1S(B)-14 2.95 kg > 6.7 m³ 3.73 kg > 8.5 m³
8. Siting the BWL-1S(B)
173064298_201507
Only transport the heat pump by pallet truck while packaged.
Caution, risk of tipping.
To prevent damage to the appliance, the heat pump's outdoor module
must not be tilted more than 45° during transport.
The components, in particular the plastic casings and the pipework for
the refrigerant circuit and heating side, must not be used to transport
the appliance. Only use the grab handles provided when transporting
the heat pump.
Bear in mind the weight of the heat pump.
Transport to the installation site
To prevent damage during transport, the heat pump must remain packaged and on its
woodenpalletwhilebeingtransportedtothenalinstallationsitebypallettruck.
Observe the "Instructions" on the packaging.
Please note
8. Siting the BWL-1S(B)
18 3064298_201507
9. Siting the outdoor module
Air discharge
a≥1000toobstaclesobstructingtheairdischarge
a≥3000tofootpathsandpatiosduetotheformationofice,evenwhenoutsidetemperaturesareabove0°C
Clearance between outdoor module and ground
In areas with heavy snowfall, the minimum installation height must be increased or a canopy must be constructed
over the outdoor module.
Minimum clearances for the outdoor module
≥600
≥300
≥600
≥300
Air discharge
Air intake
≥300
≥300≥100
Air discharge
Air intake
≥220
≥300≥100
Fig.: Front view of outdoor module BWL-1S(B)-10/14 Fig.: Front view of outdoor module BWL-1S(B)-07
Fig.: Plan view of outdoor module BWL-1S(B)-10/14 Fig.: Plan view of outdoor module BWL-1S(B)-07
a
a
193064298_201507
10. Siting the indoor module
Minimum clearances for the indoor module
Securing the appliance with the suspension bracket
Wheninstallingtheappliance,ensurethatthexingshavesufcientload-bearingcapacity.Inaddition,takeinto
accounttheconditionofthewall,otherwiserefrigerantandwatercouldescape,resultinginariskofooding.
1. Mark the Ø12 holes to be drilled for the suspension bracket, taking into account the minimum clearances.
2. Inserttherawlplugsandtthesuspensionbracketusingtheboltssupplied.
3. Hang the indoor module into the suspension bracket using the mounting stay.
≥800
≥40
≥40
≥1000
≥150
Fig.: Front view of indoor module
Fig.: Plan view of indoor module
344
Fig.: Rear view of indoor moduleFig.: Suspension bracket
≥245
Ceiling
Mounting stay
20 3064298_201507
11. Gravel bed and foundation
diagram for the outdoor module
Baseforoorstandinginstallation
A Gravel bed as condensate soakaway
B Frost-protection base for foundation (compressed gravel, e.g. 0 – 32/56 mm),
layer thickness in accordance with local conditions and applicable building regulations
C Foundation strip
D KG pipe DN 100 with 2 pipe bends 45° (instead of 1x 90°), for refrigerant lines and electrical cables to
the indoor module, pipe requires sealing on-site (only required if routing the lines below ground level)
E Ground
F Footpath or similar
G Externalwall(naldimensions)
A
B
D
E
F
G
> 650
> 1000
> 200> 200
160
BWL-1S-07 (527)
BWL-1S-10/14 (705)
60
C
C
Y
X Y
BWL-1S(B)-07 220 mm 75 mm
BWL-1S(B)-10/14 300 mm 155 mm
/