Planning and installation
Basic Line Ai1 Geo
Heating station
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: +49 2323 9376 0, Fax: +49 2323 9376 99
Service: +49 2323 9376 350
E-Mail: info@waterkotte.de Internet: http://www.waterkotte.de
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Copyright  2014 by:
WATERKOTTE GmbH,
Gewerkenstraße 15, 44628 Herne, Germany
All rights reserved. Reproduction, duplication as well as translation of this publication, or excerpts therefrom, require prior written approval by WATERKOTTE
GmbH.
Illustrations and diagrams serve as explanatory description and shall not be
used as drawings for construction, offers or installation.
All specifications comply with the state of technology at time of
printing; we reserve the right to make changes that serve technical progress.
This publication has been prepared with all reasonable care.
WATERKOTTE GmbH does not assume any liability for remaining errors or
omissions, or for possible damages.
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Content
1
2
Safety ..................................................................................................................................... 6
1.1
Intended use ...................................................................................................................... 6
1.2
Basic safety precautions .................................................................................................... 6
1.2.1 Keep information available .................................................................................... 6
1.3
Before initial use ................................................................................................................. 6
1.3.1 Environmental protection ...................................................................................... 7
1.3.2 Modifications and repairs on the heat pump ......................................................... 7
1.4
Hazards ............................................................................................................................. 7
1.5
Specific types of hazards ................................................................................................... 9
1.6
Operator's duty of care ...................................................................................................... 9
1.7
Other applicable documents .............................................................................................. 9
Functional principle of an heat pump ...................................................................................... 10
2.1
3
Product description ............................................................................................................... 11
3.1
4
Description of operation Basic Line Ai1 Geo .................................................................... 10
Overview .......................................................................................................................... 11
Components and installation .................................................................................................. 13
4.1
Heating system Basic Line Ai1 Geo ................................................................................. 13
4.2
Structure .......................................................................................................................... 13
4.2.1 Heat pump module ............................................................................................. 13
4.2.2 Compressor ........................................................................................................ 13
4.3
Electrical equipment......................................................................................................... 14
4.3.1 Electrical resistance heating ................................................................................ 14
4.3.2 Domestic hot water heating system .................................................................... 14
4.3.3 Heat source ........................................................................................................ 14
4.3.4 Electronic heat pump control .............................................................................. 14
4.3.5 Sensors .............................................................................................................. 14
4.3.6 COP-counter ...................................................................................................... 15
4.3.7 Options ............................................................................................................... 15
4.4
Hydraulical equipment ..................................................................................................... 15
4.4.1 Domestic water heating technology .................................................................... 15
4.4.2 Domestic hot water tank ..................................................................................... 15
5
Transport .............................................................................................................................. 16
6
Installation ............................................................................................................................ 18
6.1
7
8
Environmental conditions for installation .......................................................................... 18
6.2.1 Heat pump base ................................................................................................. 19
Installation of heat pump and tank ......................................................................................... 20
7.1
Accessories (scope of delivery) ........................................................................................ 20
7.2
Installation ........................................................................................................................ 21
7.2.1 Dismantlement/ Assembly of the heat pump (service event) ................................ 22
7.2.2 Temperature sensor ............................................................................................ 23
7.2.3 Removing of the housing .................................................................................... 23
Installation und connection .................................................................................................... 24
8.1
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Connection (rear) ............................................................................................................. 24
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9
8.2
Connecting dimensions ................................................................................................... 25
8.3
Connection to heating system ......................................................................................... 26
8.3.1 Installations provided by customer ...................................................................... 26
8.3.2 Heat pump with underfloor heating ..................................................................... 26
8.3.3 Heat pump with radiators (natural cooling not possible) ...................................... 27
8.4
Connection to heat source ............................................................................................... 27
8.4.1 Residual head ..................................................................................................... 29
8.4.2 Water glycol systems .......................................................................................... 30
8.4.3 Groundwater heat source ................................................................................... 30
8.4.4 Groundwater quality ............................................................................................ 30
8.4.5 Water-Glycol mixture in the installation ................................................................ 31
8.4.6 Flow Monitoring .................................................................................................. 32
8.4.7 Filter .................................................................................................................... 32
8.4.8 Cleaning .............................................................................................................. 32
Electrical work....................................................................................................................... 34
9.1
Electrical installation ......................................................................................................... 34
9.2
Electrical heat generator for startup and standby ............................................................. 35
9.2.1 Initial heating of buildings during winter months .................................................. 35
9.2.2 Startup of electrical heat generator (EWE) ........................................................... 36
9.2.3 Parallel operation: Heat pump and electrical heat generator ................................ 36
9.3
Heat generator, thermostat settings ................................................................................. 36
9.4
Installation instructions for an external sensor .................................................................. 36
9.4.1 Instalation of the cabling ..................................................................................... 37
9.5
Electrical connection ........................................................................................................ 38
9.5.1 Electrical wiring diagram (3x 400 V) ..................................................................... 38
9.5.2 Electrical wiring diagram (1x 230 V) ..................................................................... 39
9.6
Controller ......................................................................................................................... 40
9.7
Terminals ......................................................................................................................... 41
10
Plan and MSR-equipment...................................................................................................... 42
11
Hydraulic diagramm Basic Line Ai1 Geo ................................................................................. 43
12
Commissioning ..................................................................................................................... 44
12.1 Pre-startup checks .......................................................................................................... 44
12.2 Initial start-up of the machine ........................................................................................... 45
12.3 Control of the entire operation ......................................................................................... 46
12.4 Turning off the heat pump ................................................................................................ 46
12.5 Turning off the heat pump for a longer time ..................................................................... 46
13
Troubleshooting .................................................................................................................... 47
13.1 Possible faults and solutions ............................................................................................ 47
13.1.1 Fault at input side (LP fault) ................................................................................. 47
13.1.2 Ausgangsseitige Störung (HD-Störung) ............................................................... 47
13.1.3 Fault in compressor motor .................................................................................. 47
14
Safety measures ................................................................................................................... 48
14.1 Pressure limits of compressor .......................................................................................... 48
14.2 Motor protection against excessive temerpature .............................................................. 48
14.3 Refrigerator oil ................................................................................................................. 48
15
Maintenance and care ........................................................................................................... 49
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Connection diagram .............................................................................................................. 50
16.1 Basic Line Ai1 Geo with underfloor heating ...................................................................... 50
16.2 Basic Line Ai1 Geo with underfloor heating and individual room control ........................... 51
16.3 Basic Line Ai1 Geo with hydraulical deflector ................................................................... 52
16.4 Basic Line Ai1 Geo with radiators .................................................................................... 53
16.5 Legend hydraulic schemes .............................................................................................. 54
17
Technical data ...................................................................................................................... 56
Note: This symbol mark applies only to countries within the European Union (EU).
This symbol mark is in compliance with Directive 2002/96/EG, Article 10. The
product has been designed and manufactured with high-quality materials and
components which are suitable for recycling.
This symbol means that electrical and electronic equipment, at the end of its useful life, shall be disposed of separately from household waste. Please dispose of
this equipment at your designated collection point or local recycling centre.
In the European Union, different collection systems are available for used electrical
and electronic equipment. Please help us to conserve the environment we live in!
Do not release R410A into the atmosphere:
R410A is a fluorinated greenhouse gas according to Kyoto Protocol and has a
global warming potential (GWP) of 1980.
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Safety
1 Safety
1.1 Intended use
Your WATERKOTTE heat pump is used for space heating and cooling, and heating of domestic water.
Project planning of the heat source system must be performed in compliance with
the technical information provided by WATERKOTTE for layout of heat source systems.
Heat pump shall only be turned on after the refrigerant connections are completely
filled, and the other hydraulic circuits are completely filled and vented, and all electrical connections are properly completed.
Commissioning may only be carried out by trained professionals. Damages
caused by non-compliance with above mentioned items are not covered by the
warranty (see enclosed Exclusion of Warranty).
Risk of total loss!
The device may only be switched on when the hydraulic circuits are completely
filled and vented, and all electrical connections are properly.
The commission may only be performed by trained specialist staff. Damages
resulting from failure to observe the points above, are not in the scope of the
warranty (see attached warranty-exclusion).
1.2 Basic safety precautions
1.2.1
Keep information available
In addition to the operating manual, also furnish operating instructions in terms of
Labour Protection Law and Work Equipment ordinance.
Keep all safety and operating signs on the heat pump in fully legible condition at all
times. Replace damaged or illegible signs immediately.
1.3 Before initial use
Before initial use of your WATERKOTTE heat pump, familiarise yourself with:

Operating and control elements of your WATERKOTTE heat pump

Equipment of heat pump

Operation of heat pump

Immediate surroundings of heat pump

Safety devices of heat pump
Before initial start, perform the following steps:
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
Ensure that all safety devices are installed and function as intended.

Check heat pump for visible damage. Remedy any detected defects immediately. Heat pump must be in perfect condition during operation!

Ensure that only authorised personnel is in the work area of the heat pump
and that no other persons are endangered when heat pump is started.
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Safety
 Remove all objects and other materials that are not required for operation of
the heat pump from the work area of the heat pump
1.3.1
1.3.2
Environmental protection

Observe the regulations regarding waste avoidance and proper waste recycling or disposal when performing any kind of work on and with the heat
pump.

Ensure that particularly during installation and maintenance work, as well as
when placing out of operation, pollutants such as grease, oil, refrigerant, solvent- containing cleaning fluids, etc. do not contaminate the ground or enter
the sewer system!
These materials must be collected, stored, transported and disposed of in
appropriate containers.
Modifications and repairs on the heat pump
For safety reasons, no unauthorised modifications shall be performed on the heat
pump.
Thus, all intended modifications are subject to written approval by
WATERKOTTE.
Use only original spare parts from WATERKOTTE.
Original spare parts are specially designed for your heat pump. Externally procured parts provide no guarantee that they are designed and manufactured in
compliance with relevant usage and safety requirements.
Parts and special equipment not delivered by WATERKOTTE are not approved for
use on the heat pump.
1.4 Hazards
Observe the following points to avoid life-threatening injuries and damages to the
heat pump during operation:
Warning! Risk of electric shock!
Do not use water or other liquids to clean the unit!
Keep all electrical supply units locked at all times!
Any work on the electrical equipment of the heat pump shall only be performed by
professional electricians!
Attention! Risk of suffocation!
The packing is not a toy. The packaging must be disposed of environ-mentally
acceptable.
Risk of burns!
During operation, surface temperatures (compressor and pressure line) can
climb above 100 °C or drop below 0 °C.
Do not remove housing cover during operation!
Allow heat pump to cool down before removing cover.
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Safety
Risk of injury!
Risk of chemical burns when skin comes in direct contact with lubricant leak.
Wear suitable clothing when performing maintenance work on the heat pump!
Risk of injury in case of leakage in cooling circuit!
Skin contact with refrigerant may cause freezing of tissue and frostbites. High
vapour concentrations can cause headaches, dizziness, fatigue, nausea and
even unconsciousness. Irregular heartbeat (arrhythmia).
Avoid contact with refrigerant! Do not expose to heat, sparks, naked light or
other ignition sources!!!
Risk of total loss!
The heat pump is not a toy!
Keep children away from the heat pump, in particular from the operating input
device (touch screen). Read the accompanying technical manual.
Electrostatic charge!
Electronic components can be damaged by electrostatic processes.
Ground yourself before touching electronic components.
Risk of total loss!
Repeated restart of heat pump can result in total loss!
In case of heat pump failure, before restart an inspection by qualified
and authorised personnel must be performed.
Leaking Liquids!
Due to test bench operation, the heat pump can have ethylene glycol residues.
Risk of total loss!
The device may only be switched on when the hydraulic circuits are completely
filled and vented, and all electrical connections are properly.
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Safety
1.5 Specific types of hazards
To avoid damage to machine or life-threatening injuries during installation of machine, the following points must be observed:

Machine parts that are improperly placed or incorrectly attached can fall down
or overturn.

Sharp-edged machine parts that are still exposed and accessible can result in
injury.

Incorrectly installed lines (e.g. insufficient bending radius) can cause smouldering and cable fires.

1.6 Operator's duty of care
Your WATERKOTTE heat pump has been designed and built on the basis of a risk
analysis and after careful selection of standards to be observed. Thus, your heat
pump is state-of-the-art and provides for maximum safety. In practice, however,
this safety can only be ensured by taking all necessary measures. As operator of
the heat pump it is your responsibility to plan these measures and oversee their
implementation.
You must ensure that:

The heat pump is only used as intended (see also chapter 1.1, „Intended
use“).

The heat pump is only operated in perfect, fully functional condition and safety
devices are checked regularly to ensure that they are working properly.

The operating manual is available in perfect condition at the heat pump at all
times.

The heat pump is operated, maintained and repaired only by adequately qualified and authorised personnel.

None of the safety and warning notices on the heat pump are removed or
damaged.
1.7 Other applicable documents

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Operating manual: WWPR WATERKOTTE heat pump controller.
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Functional principle of an heat pump
2 Functional principle of an heat pump
The heat pump is used to produce thermal energy for space heating and domestic water heating if required. The medium used as heat source (WQ) is the ground.
It is also possible to cool a building.
To utilise ground as thermal energy, for domestic water heating and cooling in
your home, you need the following:

a heat source (borehole with geothermal energy probes or groundwater extraction / discharge)
 heating system Ai1 QE
 domestic hot water tank
Figure 1: Energy share while using a geothermal energy pump
2.1 Description of operation Basic Line Ai1 Geo
The WATERKOTTE heating central Basic Line Ai1 Geo uses a heat pump as heat
generator. At the heat source side the medium is cooled down in the vaporizer
about 3 to 4K with the help of this device. The hereby won energy is made usable
for heating purposes by transport through the cooling circle up to a higher temperature level.
Heating energy is given to the medium about the liquefier at the heating side, so a
temperature rise about 5K is reached.
On this way building heating and domestic water heating can be done.
The configuration of the heat source system must be planned in accordance with
the technical information of WATERKOTTE GmbH heat source installation instructions.
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Product description
3 Product description
3.1 Overview
Figure 2: Basic Line Ai1 Geo (closed)
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1
Display
2
ON/ OFF-switch
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Product description
Figure 3: Basic Line Ai1 Geo (open)
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1
Tank for domestic hot water
2
Control board
3
Connecting terminal (400 V – series)
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Components and installation
4 Components and installation
4.1 Heating system Basic Line Ai1 Geo
All components of the heating system are mounted in a protective steel plate
housing which is intended for installation inside. The base frame consists of a
bent, thick-walled sheet steel. Together with the rear panel frame, which also consists of a thick-walled sheet steel, it forms a unit. Side panels, cover, front and the
tilt-mounted, ergonomic control panel can be removed.
All housing parts are optionally available in high-gloss white or stainless steel finish. Sound insulation ensures low noise emissions.
4.2 Structure
Complete hot water heating system with integrated central hot water supply run,
consisting of: heat generator (heat pump), heat-source technology, electrical resistance heating for start-up and stand-by, control and electrical control, storage
stainless steel integral foam insulation), full-constant Electrical and Control Engineering, touch display with BASICPRO software, Smartphone Control with
BASICPRO Mobile Software, diagnostic system.
All hydraulic connections positioned on the back. All units within the scope Vicemounted with removable, all-round heat and sound insulated lining, colour signal white (RAL 9003).
4.2.1
Heat pump module
The heat pump unit includes the whole hydraulic technology. The built-in console consists of compressor and heat exchanger.
4.2.2
Compressor
The compressor features a fully hermetic design in approved leading scroll technology (fig. left). Evaporator and condenser are designed as soldered stainless
steel plate packs with reverse flow circuits, according to state-of-the-art development, tailored to the new non-flammable safety refrigerants that will be required by
law in the future. In combination with ester oil (biodegradable), this guarantees optimum lubrication conditions, low friction losses and therefore the highest possible
life expectancy for the compressor according to the latest industrial research findings.
The cooling circuit is designed in accordance with the relevant safety regulations.
Manufacturing quality is carried out based on ISO 9001ff, supplemented by an automated computer-monitored quality test (pressure stress and helium leak test) in
addition to inspection of all parameters in a subsequent trial run.
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Components and installation
4.3 Electrical equipment
The electrical connections are made via the internal terminal (on the construction
profile). The implementation of the electrical cable is carried by the rear wall (with
the strain relief).
The internal terminal connects the entire sensor, all queries, all relay outputs, digital circuit, the compressor and the electrical heating element. The WATERKOTTE
WWPR-controller is supplied with a control panel mounted on the 24 VAC transformer.
An integrated web interface is available for remote monitoring via the Internet.
4.3.1
Electrical resistance heating
Located in the heating flow, power 6 kW. Used to support initial heating in the
winter and during the standby function; automatic or independent control via the
built-in mechanical thermostats.
4.3.2
Domestic hot water heating system
Consisting of: heating circulation pump (speed-controlled / energy class A), air
separator with automat. air diverter, connections for heating flow and return are fitted externally to facilitate installation in the rear panel frame.
4.3.3
Heat source
Consisting of: heat source circulator speed controlled (energy efficiency class A),
connections for ahead and return facilitates installation in the rear wall frame outwards.
4.3.4
Electronic heat pump control
The heat pump control (control panel is pictured) is included in the delivery scope
of the WATERKOTTE heat pump.
Use in other than WATERKOTTE heat pumps will void any warranty claim.
The control is used to control and monitor heating systems that are operated with
WATERKOTTE compact heat pumps according to technical guidelines of
WATERKOTTE head pump GmbH.
The following tasks are performed: everything to do with regulation (depending on
the external temperature with pilot room guidance), control, monitoring, selfdiagnosis, saving of data in cases of breakdown.
WATERKOTTE explicitly states that function warranty will become void if used on
systems not approved by WATERKOTTE. Any liability for consequential damages
due to incorrect function within these systems shall be explicitly excluded.
Info: Technical details, operation and warning messages (see Operating manual
for Heat pump control).
4.3.5
Sensors
The control's sensor system consists of: Pressure transmitter for evaporation and
condensation pressure, sensors for temperature detection in all circuits, external
wall sensor in accessories kit, pilot room sensor and hot water sensor (optional).
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Components and installation
4.3.6
COP-counter
A WATERKOTTE COP counter is already integrated in the heat pump control. For
additional information, please refer to Operating manual for Heat pump control.
4.3.7
Options
Mixer accessories: sensor, three ways valve, additional control module.
Expansion kit: for pool heating, mixer circuits.
Pool accessories: sensor, additional control module.
Buffer tank: standard tank
Heat source accessories: heat exchanger for ground water, flow rate monitoring,
antifreeze concentrate, heat source distributor.
Heating accessories: underfloor heating system, underfloor heating head station,
distribution cabinet, convectors.
Heat pump accessories: Digital soft starter (for retrofitting at 3 x 400 V compressor design), basement pad.
4.4 Hydraulical equipment
4.4.1
Domestic water heating technology
Stainless-steel plate heat exchanger made in high vacuum solder technology that
works with counter flow and bronze charge pump for indirect water heating up to
60 °C.
4.4.2
Domestic hot water tank
In system-specific design,volume 170 l, test pressure 12 bar. tank made of stainless steel, insulated with Neopor RG, (heat loss < 80 W at 60 °C). Connections for
cold and hot water in the rear. An automatic legionella protection circuit ensures
hygienic quality of drinking water.
Note: Accessories as fittings, additions and security group and expansion vessel
are not included. They are optionally available.
4.4.3
Heat transfer medium
The unit may only operate with heat transfer media approved by Waterkotte.
These are Water-Glycol-mixes:
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
25 Vol. % Waterkotte-Ethylen-Glycol or

33 Vol. % Waterkotte-Propylen-Glycol
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Transport
5 Transport
For easy transport the heat pump will be supplied in two packaging: heat pump
unit and housing.
 Exercise particular caution when transporting the units. The unit weighs 245 kg
depending on model. Do not use the packaging straps to carry the unit. Wear
protective gloves for unpacking and transporting the unit to prevent hand injuries from cooling fins or other parts.
 Observe the transport information on the packaging.
 Observe the specified storage requirements.
 The units may not be stacked.
 Machine may only be lifted by the proposed construction struts (left and right
side outside).
Figure 4: Installed machine (delivery status)
 Machine may only be transported in upright position
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
Ensure proper disposal of packaging materials. Packaging materials, such as
nails or other metal or wooden parts, may cause injuries.

Please also read chapter "General safety information“.
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Transport
5.1 Transport to installation site
Units of the Basic Line Ai Geo series are delivered ready-to-connect with separate
metal housing. For transport purposes, two people are required because the head
pump unit weights about 125 kg. During transport it must be ensured that appropriate means of transport are used (lift truck, transport rollers, handcart).
Unit must be transported upright!
Transport in tilted position (45°) is permitted only temporarily during insertion.
Horizontal transport results in oil displacement in compressor and can cause
damage during start-up.
After carton is removed or opened it is not permitted to tilt the unit by applying
pressure to the pipelines or housing enclosure; this could result in bent housing
parts and pipelines.
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Installation
6 Installation
 Installation of the heat pump must be performed on a flat and horizontal surface.
 We recommend a concrete base
Recommendation:

Wall clearance left, right and on top must be at least 400 mm.
 Wall clearance in rear must be at least 200 mm.
Figure 5: Recommendation - wall clearances
6.1 Environmental conditions for installation
The room must be dry. Room temperature should be between
+10 °C and +30 °C.
To facilitate maintenance, the use of a base plate is recommended. Acoustics in
installation rooms with rigid walls can noticeably increase operating noise.
Counter measure: acoustic insulation of one of the opposite wall or ceiling surfaces.
6.2 Creating the foundation and installing heat pump
Within the device an electrically driven air compressor is used, causing the vibration. For the best attenuation of the vibration it gets placed on rubber mounting
feet, the weight and the excitation get balanced on. The hydraulic connections are
also connected with flexible hoses. In this way the transmissions of the vibrations
is reduced to a minimum. An additional improvement can be obtained by creating
an heat pump size corresponding base (see below), are achieved with an insulating pad made of polyurethane rubber.
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Installation
6.2.1
Heat pump base
1
Heat pump
2
Insulation strip (polyethylen / PE)
3
Insulation material (3 layer, polyurethan rubber)
4
Supporting subsurface
5
Insulation material
6
Screed
7
Concrete plinth
Dimensions concrete plinth (mm)
Series
Basic Line Ai1
Geo
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Width
x
Depth
x
High
850
x
880
x
150
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Installation of heat pump and tank
7 Installation of heat pump and tank
7.1 Accessories (scope of delivery)
Piece
Item No.
Description
1
Z21241
Installation manual Basic Line Ai1 Geo
1
Z21327
User manual: Control
1
Z15312
Installation document: Acceptance and Installation Data
1
Z20086
Isolated removing Tool (for the removing of the housing)
1
Z13122
Outdoor wall mounted sensor (accessories box heat pump)
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Installation of heat pump and tank
7.2 Installation
The heat pump gets delivered completely installed. Transport the heat pump
module to the intended site. Align the heat pump module in a horizontal position.
To do this, use the set screws for height adjustment (under the corners of the
unit), width across flats 30 m.
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Installation of heat pump and tank
7.2.1
Dismantlement/ Assembly of the heat pump (service event)
When it is necessary to dismantle the heat pump you are able to split the upper
and the lower part.
Procedure:
 Switch the heat pump currentless (fuse box)
 Close the hydraulical circuit and void the drinking water storage
 Free the connecting hose to the storage (up and low), see the pictures
Figure 6: Storage connectings (left: storage connecting top with vent valve)
 Separate the electrical connection to the display and the temperature sensor
 Free the 16 lens head screws at the montage strives (see at the picture)
 Lift the storage module and put it on a plane area
Figure 7: Rear safed with lens-head screws (Pos. 1)
Note: For lifting the storage module you need sveral people.
The module weights about 59 kg.
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Installation of heat pump and tank
7.2.2
Temperature sensor
The provided temperature sensor is already inside the immersion sleeve.
7.2.3
Removing of the housing
Front and side panel are removable for transport and assembly cases.
Order of removing : At first the front panel, than the two side panels.
A removal tool is delivered with the heat pump. Use this tool to remove the panels
and avoid damage.
Procedure:

Keep distance between the dismantling tools and the sheet edge to keep
the retaining pin undamaged (see figure).

The dismantling tool should be exact between front and side panel with
moderate force.
Notice: The Display in the front connected with two connections (see at the picture). Separate the connection on the backside, after you have removed the front
panel.
Procedure:
Pos.1 –Raise the switch out of the suspension clamp with the screwdriver.
Pos.2 –The plug of the bus cable has a retaining tab. Press this up and unplug the
cable.
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Installation und connection
8 Installation und connection
8.1 Connection (rear)
Pos.
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Description
Thread
A
Connections for
compressors,
heating element,
sensor etc.
1
Hot water OUT
G ¾“ i
2
Cold water IN
G ¾“ i
3
Heat source IN
(heat pump entry)
G 1¼“ a
flat sealing,
seal: Z14872
4
Heat source OUT
(heat pump exit)
G 1¼“ a
flat sealing,
seal: Z14872
5
Heating flow
G 1¼“ a flat
sealing:
Z14872
6
Heating return
G 1¼“ a
flat sealingl:
Z14872
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8.2 Connecting dimensions
Figure 8: All connections in mm, Basic Line Ai1 Geo (rear)
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8.3 Connection to heating system
The connected systems should be technically clean and free from air. Steel pipes
and other steel components in the water circuit shall not be used when connecting diffusion-open surface heating system. In exceptional cases an effective corrosion inhibitor must be added and a dirt trap (0.8 mm mesh) connected before entry into the unit. The system must then be marked accordingly and the maintenance instructions of the supplier must be followed strictly. Designation for inlet
and outlet must be observed. When there is danger of frost, add antifreeze to protect against formation of ice.
To ensure tension-free connection of the heat pump, a flexible connection is required!
Tip:
We recommend the use of external shut-off devices (ball valves) at all connections.
Thus, if service is required, only the minimum amount of heat transfer medium has
to be drained from the system and time-consuming venting measures can be
avoided.
In factory default setting, the pipe ends are closed with plastic caps. When connection is performed, these caps must be removed and the connecting unions
screwed on with suitable gasket.
To tighten the screw connections, resistance at the cap must be provided with
suitable tool.
To prevent corrosion and scale formation in the heating system (circulating
pumps, radiators, etc.), the heating water must be treated according to VDI 2035
(e.g. with corrosion inhibitor).
To find the volume flow at heating side for the corresponding heat pump, please
refer to the performance table, (5K spread).The heating connections (1¼“) feature
an external pipe thread for flat-sealing connections with union nut and insert.
In the heat pump is installed:
• An air separator with 6 kW electrical resistance heating
8.3.1
Installations provided by customer
An expansion tank and a safety group (manometer, relief valve) have to be installed by customer.
Mounting position see diagram (chap.16).
A second pressure expansion tank must be connected if, for instance, a compact
condensing boiler (for domestic hot water production with the WATERKOTTE water heater) or a buffer tank (for heating) is planned.
8.3.2
Heat pump with underfloor heating
 The use of steel pipes and other steel components is not permitted in the heating circuit of underfloor heating systems. Use stainless steel, copper, brass or
plastic - such as PE - for instance.
 In case of single room control, a buffer tank (corrosion-free) and a differential
pressure overflow valve must be installed in the heating system (see diagrams).
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200 litre buffer tank (enamelled or stainless steel) should be sufficient for this
series.
 When the living space controlled by single room control is less than 1/3, a
buffer tank is not required if the remaining 2/3 floor circuits remain open.
8.3.3
Heat pump with radiators (natural cooling not possible)

On systems with steel radiators an effective corrosion inhibitor must be added
and a dirt trap (0.8 mm mesh) connected before entry into the unit. The system must then be marked accordingly and the maintenance instructions of the
supplier must be followed strictly.

Heating systems with radiators require the installation of a buffer tank (connected in parallel) (see diagrams). The size of the tank must be calculated. The
heat pump control regulates the temperature of the buffer tank. After the tank,
the components (circulation pump, mixing valve ...) must be controlled with an
optional WATERKOTTE mixing control.

If the formation of deposits is to be expected (e.g. strong contamination)
based on water quality, cleaning must be performed in regular intervals.
Cleaning can be performed by flushing.
Procedure:
The plate heat exchanger is to be flushed with a suitable cleaning agent in
counter-flow direction. If chemicals are used for cleaning, please ensure that
they are compatible to stainless steel, copper or nickel. Failure to comply can
result in destruction of plate heat exchanger!
8.4 Connection to heat source
The following can be used as heat source:

The ground, by connection to a horizontal geothermal absorber (e.g. PEpipe20x2) or a vertical geothermal absorber (geothermal probes).

The groundwater, by connection to a well system, using an accessories kit
available from WATERKOTTE to monitor the flow at heat source side and
separation heat exchanger (heat source side).

The layout of the heat source system must be according to the
WATERKOTTE dimensioning information.

Refer to the performance table to find the volume flow for the corresponding
heat pump.

The heat source connections (1¼“) feature an external pipe thread for flatsealing connections with union nut and insert.
A circulation class A pump is installed at heat source side. Optional equipment,
energy class A pumps: The circulation pumps are offered with internally coated
housing (plastic).
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Type (pump):
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Heat pump type /
circulation pump
Heat source
Heating
Heat source pump
energy class A
Stratos Para 20/1-7
(infinitely variable)
Stratos Para 20/1-7
(infinitely variable)

To prevent formation of condensation, the heat source lines inside the house
must have diffusion-tight insulation.

In case of water glycol systems, it is not permitted to use steel pipes and other steel components in the water circuit. Use stainless steel, copper, brass or
plastic - such as PE - for instance.
Steel pipes and other steel components should also be avoided in groundwater systems.
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8.4.1
Residual head
Residual head, heating side (B0/W35):
Heat pump
Flow rate
m³/h
Basic Line
Ai1 Geo
5005.5
Basic Line
Ai1 Geo
5006.5
Basic Line
Ai1 Geo
5008.5
Basic Line
Ai1 Geo
5010.5
0.8
1.0
1.3
1.7
20/7.5
20/7.5
20/7.5
20/7.5
7.1
6.8
6.9
5.3
Basic Line
Ai1 Geo
5005.5
Basic Line
Ai1 Geo
5006.5
Basic Line
Ai1 Geo
5008.5
Basic Line
Ai1 Geo
5010.5
0.9
1.1
1.4
1.9
20/7.5
20/7.5
20/7.5
20/7.5
6.0
5.6
5.6
4.8
T 5K
Pump (class A)
Residual headT 5K
mWS
Residual head, heat source side (B0/W35):
Heat pump
Flow rate
m³/h
T 4K
Pump (class A)
Residual headT 4K
mWS
Residual head, heating side (W10//B8/4//W35)
Heatpump
Flow rate
m³/h
Basic Line
Ai1 Geo
5005.5
Basic Line
Ai1 Geo
5006.5
Basic Line
Ai1 Geo
5008.5
Basic Line
Ai1 Geo
5010.5
1.1
1.3
1.7
2.3
20/7.5
20/7.5
20/7.5
20/7.5
6.1
5.0
5.0
2.9
T 5K
Pump (class A)
Residual headT 5K
mWS
Residual head*, medium circle, heat source side (W10//B8/4//W35):
Heat pump
Flow rate
m³/h
Basic Line
Ai1 Geo
5005.5
Basic Line
Ai1 Geo
5006.5
Basic Line
Ai1 Geo
5008.5
Basic Line
Ai1 Geo
5010.5
1.2
1.4
1.9
2.5
20/7.5
20/7.5
20/7.5
20/7.5
5.6
5.2
5.2
3.1
T 4K
Pump (class A)
Residual headT 4K
mWS
** medium circle 15% Ethylen-Glykol and 85% water
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Installation und connection
8.4.2
Water glycol systems
Since Basic Line Ai1 Geo is already equipped with a heat source pump, the heat
source system can be directly connected to the heat pump. There is no need for
an additional heat source module. To prevent frost damage, the heat source system must be filled with about 30 % WATERKOTTE ethylene glycol (freezing point
at about -15 °C). The heat source system must be properly filled with the operating media and vented.
8.4.3
Groundwater heat source
For groundwater heat pumps the installation of a separation heat exchanger is
absolutely essential to avoid direct damage to the heat pump. The intermediate
circuit must be filled with about 15 % ethylene glycol. The following WATERKOTTE
accessories are required for groundwater application:

Filter

Flow monitoring
 Separating heat exchanger
8.4.4
Groundwater quality
When using groundwater, the following limits (see table and diagram) must be observed. If limits are exceeded, a separation heat exchanger is used.
The soldered plate heat exchanger consists of embossed stainless steel plates
1.4401 or AISI 316. You must therefore take the corrosion behaviour of stainless
steel and the solder material, copper, into account.
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Water content+ specific values Unit
pH-value
Repletion-Index SI (delta pH-value)
Total hardness
Conductivity
Filterable solid
Chloride
Free chlor
Hydrogen suphide(H2S)
Ammoniak (NH3/NH4+ )
Sulfat
Hydrogen carbonat
Hydrogen carbonat / sulfat
Sulfid
Plate heat exchanger,copper-solded(standard)
Plate heat exchanger,
nickel-solded(optional)
7 - 9 (under observation SI
6 - 10
Index)
-0,2 < 0 < +0,2
No definition
6 - 15
6 - 15
10...500
No definition
<30
<30
See chart next page, over 100°C no admit of chlorid
<0,5
<0,5
<0,05
No definition
<2
No definition
<100
<300
<300
No definition
>1,0
No definition
<1
<5
<100
No definition
Nitrat
°dH
µS/cm
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
Nitrit
mg/l
<0,1
No definition
Iron, dissolved
mg/l
<0,2
No definition
Mangan
mg/l
<0,1
No definition
mg/l
<20
Free aggressive carbonit acid
No definition
Tabel 1: Corrosion resistance of brazed plate heat exchangers to water ingredients
The values above are reference values which can vary under certain operating
conditions. If you have any questions, please call us at: Tel. :(+49) (0) 2323 93760.
No use
Use without problems
Figure 9: Admit contents of chlorid depending on the temperature
8.4.5
Water-Glycol mixture in the installation
Ground water plants without cooling: Minimum 15 % WATERKOTTE ethyleneglycol in the separating heat exchanger – vaporizer circle.
Earth plants without cooling: Minimum 25 % WATERKOTTE ethylene-glycol in the
heat source circle.
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8.4.6
Flow Monitoring
When using water as heat source, the evaporator of the heat pump can be destroyed by ice formation due to lack of water (frost damage). Repeated switching
on of heat pump in an improper forced manner may easily result in total loss. For
this reason, we specify a reliable protective measure against lack of water.
The protective measure consists of two devices that function independently of one
another:
a) Temperature limit by controller: For this purpose, the controller is configured for
operating mode "Heat source water" This solution allows that:

a warning is generated if value drops below +1 °C and

operation is interrupted when value drops below -1 °C.
b) Because the measure mentioned under a) cannot react quick enough in case
of sudden lack of water, an additional low water safety device must be provided.
A low water safety device consists of a float-type volume display with adjustable
limit indicator (limit indicator is a Reed contact).
Function:
The heat pump control switches the compressor on with a time delay to "pump
heat source". The start of the compressor is only enabled if the minimum water
volume is present during the lead time and the limit indicator did not respond. This
device remains active during the entire operation of the heat pump. If water volume drops below the permissible level during operation, the heat pump is shut
down. This device provides maximum security because it virtually covers all risks,
such as filter contamination, evaporator contamination, overloaded well, etc.
Damages caused by freezing of evaporator result in exclusion of warranty!
8.4.7
Filter
To prevent contamination, the media inlets of the evaporator and heat exchanger
must be equipped with a filter (0.8 mm mesh). Contamination in the heat exchanger can cause corrosion and - in some applications - freezing of the heat exchanger!
8.4.8
Cleaning
If the formation of deposits is to be expected (e.g. severe contamination) based on
water quality, cleaning must be performed in regular intervals. Cleaning can be
performed by flushing. The plate heat exchanger is to be flushed with a suitable
cleaning agent in counter-flow direction.
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If chemicals are used for cleaning, please ensure that they are compatible with
stainless steel or copper. Failure to comply can result in destruction of plate heat
exchanger!
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9 Electrical work
Before carrying out electrical work:

Warning! Risk of electric shock!
Install circuit breakers for personal protection.

Any work on the electrical equipment of the machine shall only be performed
by professional electricians!

For the power lines, use standard cables of sufficient capacity. Otherwise
there is a risk of short circuits, overheating or fire.

When installing power lines, do not apply tension to the cables. Loosened
connections pose a risk of cables slipping from terminals or breaking; this can
result in overheating or fire.

Should it be necessary, disconnect all feed lines from the house fuse box.
Risk of total loss!
The device may only be switched on when the hydraulic circuits are completely
filled and vented, and all electrical connections are properly.
9.1 Electrical installation
Follow the wiring diagram!
The installation must be performed by an accredited professional. He is also responsible for the proper installation according to regulations and initial commissioning.
For electrical installation, the regulations of VDE/EN as well as of EVU must be observed.
For wiring, standard lines must be used.
Mains connection cable, if not connected to fixed installation:
Type H05VV-F.
Connection cables 230 / 400 V and remote cables / sensor cables must be installed with separate cables.
Minimum diameter of connection cables 1.5 mm².
Attention: Terminals in connection terminal max. 4 mm². Vacant terminals may not
be used as support terminals for additional wiring.
Please note:
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
All plug connections used in the heat pump control may not be connected or
disconnected under voltage – disconnect mains voltage.

Before accessing connection terminals, all power supply circuits must be interrupted.

The relay circuit board (WWPR) may only be connected or removed by professionals.

Install and remove relay circuit board only in voltage-free state.

All connections performed directly at the plug connections of the relay circuit
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board must be established with flexible lines; if necessary, intermediate terminals must be used.

We recommend the use of an earth leakage circuit breaker (RCD), not exceeding 30 mA.
 Replacement of mains connection cables may only be performed by customer
service or a similarly qualified person.
 If the machine is equipped with a plug, it is important, that this one is accessible after the installation. If no plug is used, you have to provide a separation of
all pole with a notch of 3.0 mm to the pins.
If variable speed pumps are operated (electronic frequency control), you have
to add a separation or coupling relays for inductive or capacitive loads (AC3 /
16 A / 230 V). In no case, the variable-speed pumps are directly wired to the
relay of the heat pump. The installation is carried out on site by a qualified electrician. For further inquiries, we advise you gladly.
9.2 Electrical heat generator for startup and standby
9.2.1
Initial heating of buildings during winter months
Humid, cold building condition represents a deficiency due to neglected drying
measures. As a result, the initial heat requirement is significantly higher.
The reason for this: The mass of the building must reach the required temperature. Turning on the heat results immediately in a considerable evaporation in
screed, masonry and ceilings.
About 1 kWh heat is required per kg water. As a result of the construction humidity, the K-factor of the external walls can rise to twice its value. The increased heat
requirement for ventilation, particularly if interior is not finished yet, must be added.
In the process it is possible that power requirement and energy consumption exceed the standard value by 100 %. Since the situation mentioned happens quite
frequently, the heat pump is equipped with an additional electrical heat generator
(EWE).
The additional energy consumption must be attributed to construction costs and
not to heating costs.
What must be considered when heat pump functions as heat generator?
When a heat pump uses groundwater as heat source, the extended runtime is
without consequence if the performance of the drawing well and return well is secured. In this case, the support by the electrical heat generator is not even necessary, as long as the fact that room temperature is reached only slowly is of no
concern.
When using a heat pump with geothermal heat source, there are concerns about
the excessive demand of the heat source under the conditions stated. There is
always a risk when the heat pump has to work in permanent mode for days. The
heat source cannot regenerate itself continuously; in unfavourable cases the
ground can be subject to frost action in areas with horizontal withdrawal.
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9.2.2
Startup of electrical heat generator (EWE)
The EWE is an additional device with many uses, operation without heat pump
(compressor automat switched off):
After the heating circuit has been filled and vented, the EWE can be operated; the
WWPR controller must be parameterised accordingly.
At the domestic distribution a check must be performed to ensure that the automats are switched on and the electrical counter rotates accordingly. Due to safety
reasons, a label placed on the controller cover must refer to the temporary solution, i.e. „Electrical heat generator temporarily activated“.
The operating mode described above also corresponds to standby mode as reassuring option for total failure!
Before commissioning of the heat pump, the special condition described above
must be reversed.
9.2.3
Parallel operation: Heat pump and electrical heat generator
The settings have to be configured by the user (refer to WWPR manual). This
means that the electrical heat generator is automatically connected (automats
switched on at domestic distribution) if heat output is insufficient. This also applies
if a malfunction occurs at the heat pump.
If the limit of the flow temperature „Heat source“ is set to an according value, e.g.
-6 °C, the EWE also automatically connects when value drops below this limit,
thus relieving the heat source.
9.3 Heat generator, thermostat settings
The thermostat of the heat generator is permanent adjusted to 75 °C.
9.4 Installation instructions for an external sensor
AGS 54
The external sensor must always be installed vertically (even if temporary), with
cable entry pointing downward. Next, screw connection must be tightened
enough to allow sealing insertion of cable and to prevent water from entering the
housing.
When performing temporary installation, sensor might have to be mounted on
board, which is fastened to a wall (outdoor).
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9.4.1
Instalation of the cabling
You can use the cable entry for electrical wiring to the heat pump via two openings on the top of the unit (rear). The cables are routed in a recess of tank isolation
to the front of the unit. There is a mounting plate for fixing the cable.
Using the supplied cable ties you can fix the cable and realise a strain relief.
Use the stain relief (Pos.1) to fix the cable. The terminal is on the front of the
switch panel (Pos.2).
Figure 10: Installation position of terminal (Pos..2)
For the connection of external cabling, it is necessary to work at the electrical
switch panel.
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9.5 Electrical connection
9.5.1
Electrical wiring diagram (3x 400 V)
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9.5.2
Electrical wiring diagram (1x 230 V)
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9.6 Controller
Deutsch
Englisch
Français
U1 –
U2 –
U3 –
U4 –
U5 –
U6 –
Verdampfungsdruck
Temp. Sauggas
Kondensationsdruck
Temp. Quelle Ein
Temp. Quelle Aus
Temp. Außen / 0-10V Heizen
U1 –
U2 –
U3 –
U4 –
U5 –
U6 –
U7 –
Temp. Raum / 0-10V Kühlen
U1 – Evaporation pressure
U2 – Temp. suction gas
U3 – Condensation pressure
U4 – Temp. source entrance
U5 – Temp. source exit
U6 – Temp. outdoor / 0-10V
heating
U7 – Temp. room / 0-10V cooling
U8 – Temp. Vorlauf
U9 – Temp. Rücklauf
U10 – Temp. Speicher
U11 – Temp. Warmwasser
U12 – Phase / Drehfeld
J9 – Erweiterungsbus
J12 – EVD1
J14 – Touch Display
J15 – pgD1-Display
Y1 – Pumpe Quelle
Y2 – Pumpe Heizung
Y3 – Pumpe Warmwasser
Y4 – Kompressor 1
Y5 – Kompressor 2
Di1 – Störmeldung Quelle
Di2 – Störmeldung Heizung
Di3 – SG-Ready-A / EVU
Di4 – SG-Ready-B / Sollwertbeeinflussung
Di7 – HD-Schalter
Di8 – ND-Schalter
Di9 – MS1
Di10 – MS2
NO1 –
NC1 –
Out2 – Ext. Wärmeerzeuger
Out3 – Kompressor 1
Out4 – Kompressor 2
Out5 – 4-Wege-Ventil
NO6 – Pumpe Quelle
NO7 – Pumpe Heizung
NO8 – Speicherentladepumpe
NO9 – MKV Hzg/WW => WW
NC9 – MKV Hzg/WW => Hzg
NO10 – MKV Hzg/Klg => Klg
NC10 – MKV Hzg/Klg => Hzg
NO11 – Multifunktionsausgang
NO12 – Stetiges Kühlsignal
U8 – Temp. flow
U9 – Temp. return
U10 – Temp. buffer
U11 – Temp. hot water
U12 – Phase / Rotary field
J9 – Extension bus
J12 – EVD1
J14 – Touch Display
J15 – pgD1-Display
Y1 – Pump source
Y2 – Pump heating
Y3 – Pump hot water
Y4 – Compressor 1
Y5 – Compressor 2
Di1 – Failure message source
Di2 – Failure message heating
Di3 – SG-Ready-A / EVU
Di4 – SG-Ready-B / Setpoint influence
Di7 – HP-Switch
Di8 – LP-Switch
Di9 – Motor protection MS1
Di10 – Motor protection MS2
NO1 –
NC1 –
Out2 – Ext. heat generator
Out3 – Compressor 1
Out4 – Compressor 2
Out5 – 4-way-valve
NO6 – Pump source
NO7 – Pump heating
NO8 – Buffer unloading pump
NO9 – MBV Htg/HW => HW
NC9 – MBV Htg/HW => Htg
NO10 – MBV Htg/Cool => Cool
NC10 – MBV Htg/Cool => Htg
NO11 – Multifunctional exit
NO12 – Continuous cooling signal
NO13 –
NO13 –
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Pression évaporation
Temp. gaz aspires
Pression condensation
Temp. entrée captage
Temp. sortie captage
Temp. exter / 0-10V chauffage
U7 – Temp. pièce / 0-10V rafraîchissement
U8 – Temp. départ chauffage
U9 – Temp. retour chauffage
U10 – Temp. ballon tampon
U11 – Temp. ECS
U12 – Panne phase
J9 – Bus d‘extension
J12 – EVD1
J14 – Touch Display
J15 – pgD1-Display
Y1 – Pompe captage
Y2 – Pompe chauffage
Y3 – Pompe ECS
Y4 – Compresseur 1
Y5 – Compresseur 2
Di1 – Message de panne captage
Di2 – Message de panne chauffage
Di3 – SG-Ready-A / Coupure externe
Di4 – SG-Ready-B / Valeur consigne
Di7 – Interrupteur HP
Di8 – Interrupteur BP
Di9 – Protection moteur MS1
Di10 – Protection moteur MS2
NO1 –
NC1 –
Out2 – Producer de chaleur ext.
Out3 – Compresseur 1
Out4 – Compresseur 2
Out5 – Vanne-4-voies
NO6 – Pompe captage
NO7 – Pompe chauffage
NO8 – Pompe décharge ballon
NO9 – Vanne Ch/ECS => ECS
NC9 – Vanne Ch/ECS => Ch
NO10 – Vanne Ch/Rafr => Rafr
NC10 – Vanne Ch/Rafr => Ch
NO11 – Sortie multifonction
NO12 – Signal rafraîchissement constant
NO13 –
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Electrical work
9.7 Terminals
X0 Supply
400 V
L1/L2/L3/PE
Compressor
L1/L2/L3/N/PE
Electrical heater
L1/N/PE
Control voltage
X0 Supply
230 V
L/N/PE
Compressor
L/N/PE
Electrical heater
L/N/PE
Control voltage
X1 230 V
1/N/PE
230 V-Continuous voltage
3/4/N/PE
Ext. heat generator
5/N/PE
Cool signal
6/N/PE
SSM
7/8/N/PE
MKV HZG/WW -> Hzg(7)/WW(8)
11/N/PE
Pump source
12/N/PE
Pump heat
13/N/PE
Pump hot water
14/N/PE
Storage charging pump
X2 Sensors/
Signals
1/GND
Interference pump source
2/GND
Interference heating/STB
3/GND
Ext.shutdown / SG-Ready A
4/GND
Ext.setpoint influen. / SG-Ready B
5/GND
Temp. out / 0-10 V Hzg
6/GND
Temp. room / 0-10 V Klg
7/GND
Temp. hot water
12/GND
Temp. tank
X4 Expansion
-/+/GND
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Plan and MSR-equipment
10 Plan and MSR-equipment
MSRNo.
Instrumentation
Component
PIC/1
Measurement of pressure readout in the controller display and control in the electrical switchboard.
Pressure transmitter ND
TIC/2
Measurement of temperature, readout in the controller
display and control in the electrical switchboard.
NTC 10K, gauge: suction gas overheating
TIC/3
Measurement of temperature, readout in the controller
display and control in the electrical switchboard.
NTC 10K, gauge: condenser OUT =
Heating flow
TIC/4
Measurement of temperature, readout in the controller
display and control in the electrical switchboard.
NTC 10K, gauge: condenser IN =
Heating return
PIC/5
Measurement of pressure, readout in the controller
display and control in the electrical switchboard.
Pressure transmitter HD
PZ+/6
Safety pressure relief valve.
Safety pressure switch
TIC/7
Measurement of temperature, readout in the controller
display and control in the electrical switchboard.
NTC 10K, gauge: heat source IN Vd
TIC/8
Measurement of temperature, readout in the controller
display and control in the electrical switchboard.1
NTC 10K, gauge: heat source OUT Vd
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Hydraulic diagramm Basic Line Ai1 Geo
11 Hydraulic diagramm Basic Line Ai1 Geo
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No.
Component
01
Compressor
02
Condenser
03
Refrigerant inspection glass
04
Refrigerant filter
05
Expansion valve
06
Evaporator
07
Circulation pump (heat source)
08
6 kW electronical heating element
09
Air separator (heating)
10
Circulation pump (heating)
11
3-way motor ball valve
12
Domestic hot water tank
13
Filling and waste valve
14
Automatic bleed valve
A
Heat source
B
Heating
C
Domestic hot water
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Commissioning
12 Commissioning
During commissioning of machine, anticipate the following specific risks:
Risk of total loss!

Faulty connections can cause unexpected startup of machine / uncontrolled
machine operation.

Mix up of connections causes motor to run in wrong direction; this could
damage the machine.

Incorrectly wired connections can destroy electrical / electronic components.

Electrostatic processes / power failure can pose a risk for electronic components and also result in software errors.
To avoid damage to machine or injuries during commissioning of machine, the following points must be observed:

Commissioning of machine shall only be performed by qualified persons, in
compliance with safety instructions.

Activate all safety devices and emergency-stop switches prior to commissioning.

Check motor for correct direction of rotation prior to commissioning.

Also read chapter 1.2
12.1 Pre-startup checks
Before starting the heat pump, check the requirements according to the following
checklist.
All electrical feed lines in the corresponding cross-sections are
wired to the terminals, as per connection plan.
The fuses in the fuse box are in compliance with the specifications
in the connection plan (LS switch, type C for compressor feed
line!).

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The hydraulic connections for heat source, space heating and domestic hot water are connected.
The hydraulic systems are filled with operating media and properly
vented.
Shut-off devices are open.
Before operation, check if all plates, fuses and other protective devices are
properly installed. Components that are rotating, hot or under high voltage
can cause injuries.

Do not touch switch with wet hands. This poses a risk of electric shock.

The unit must be grounded. Do not connect the ground wire to gas or water
lines, lightning rods or telephone grounding lines. Improperly grounded unit
poses a risk of electric shock.

Use circuit breakers (ground fault interrupter). Failure of unit or fire may result
from circuit breaker when capacity exceeds specifications.

Do not touch refrigerant tubes with bare hands during operation. The refriger-
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Commissioning
ant tubes are hot or cold, depending on condition of flowing refrigerant. Contact with tubes poses a risk of burns or frostbite.
12.2 Initial start-up of the machine
Figure 11: ON / OFF-switch (arrow)
switch lights => Power on (Normal operation)
The initial start of the heat pump is performed by a qualified WATERKOTTE system partner. After all checks have been conducted, proceed as follows:
1. Switch OFF main switch and all circuit breakers (control voltage, compressor and electrical heating element).
2. Switch ON circuit breaker for control voltage.
3. Switch ON main circuit breaker at the unit.
4. Now perform controller setting according to WWPR operating manual
5. Switch ON the circuit breaker of the compressor. Wait for compressor to
start.
6. Check rotating field of compressor - with correct rotating field and voltage
on all three phases, there is no message on display.
7. If the message F102 failure phase rotating field appears on the display,
check first, whether all three phases have voltage. If this is the case, interchange two phases at the terminal blocks in the terminal to reverse the
rotating field.
8. Finally, switch ON the circuit breaker for electric heating.
Risk of total loss!
Repeated restart of heat pump can result in total loss! In case of heat pump failure, an inspection by qualified and authorised personnel must be performed before restart.
Info: Controller settings must only be performed during initial startup of machine.
This is not required for restart, since the settings have been saved (settings remain
saved even in case of power failure).
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Commissioning
Info: During initial start-up, the specified limits are often exceeded, thus numerous
warning messages could appear.
For this reason, the warning messages occurring during this period can be disabled by service personnel, see Operating manual for heat pump controller.
After completing installation and wiring and tubing of indoor and outdoor units,
check for refrigerant leaks, loose power supply or control wiring, wrong polarity,
and ensure that no single phase in the power supply is disconnected.
Compressor will not operate unless the power supply phase connection is correct.
12.3 Control of the entire operation
This heat pump is equipped with an efficient electronic control system. All necessary settings and options are described in the operating manual of the controller.
Tip: The correct use of the controller saves money. Particularly the correct settings
of flow temperature, hot water temperature, heating curve and heating times can
result in substantial cost savings.
12.4 Turning off the heat pump
Procedure:

Switch OFF the main switch at the heat pump.

Turn OFF the circuit breakers: Compressor, control voltage and electrical
heating element.
12.5 Turning off the heat pump for a longer time
- see 12.4 -
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Troubleshooting
13 Troubleshooting
13.1 Possible faults and solutions
13.1.1 Fault at input side (LP fault)

Faulty extraction of water or water glycol.

Water glycol circuit insufficiently vented.

Water glycol pour point too high.

Evaporator contaminated, icy.

Refrigerant circulation interrupted (stop valve closed, filter dryer contaminated).

Dirt trap clogged.

Temperature of heat source too low.

Water in condenser too cold (below 20 °C).

Quick temperature change in condenser.

Insufficient refrigerant (see inspection glass).

Incorrect setting of controller parameter.
 Sensor incorrectly aligned or insufficiently attached.
13.1.2 Ausgangsseitige Störung (HD-Störung)

Interrupted or insufficient water circulation (possibly not enough heating circuits open).

Hot water temperature too high.

Air in water circuit.

Dirt trap clogged.

Circulation pump defective or incorrect rotation direction.
 Incorrect setting of controller parameter.
13.1.3 Fault in compressor motor
 Overheating of motor winding; possible causes: Failure of a phase, mechanical
failure due to lack of lubrication, lack of refrigerant, defects in refrigerant regulation, operation with incorrect refrigerant, excessive temperature of pressurised
gas.
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Safety measures
14 Safety measures
14.1 Pressure limits of compressor
The cooling circuit is protected against unacceptable excessive pressure by a
type-tested pressostat. The switch interrupts the control voltage of the compressor contactor. Restart is locked by the central control unit and must be manually
reset. Manipulation of safety switches is prohibited and is a violation of UVV
VBG20 (accident prevention regulations for cooling devices). In any case, it will result in exclusion of warranty.
The high pressure pressostat is placed in the pipe of the refrigerant medium at the
exit of the condenser.
Shift points (R410A):
45.0 bar OFF ---
35.0 bar ON
14.2 Motor protection against excessive temerpature
Fully hermetic compressors are equipped with a bimetal switch that disconnects
the power supply and connects again after cool down to protect against excessive motor temperatures; an error message is not generated.
14.3 Refrigerator oil
Use only the specified oil type (ester oil ICI Emkarate RL 32-3MAF); noncompliance will result in exclusion of warranty and certainly cause malfunctions.
Improper manipulation to the refrigeration cycle leads to total loss and the loss of
warranty. Any work on the hydraulic circuit of the heat pump shall only be performed by skilled workers!
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Maintenance and care
15 Maintenance and care
We recommend annual maintenance of the heat pump. Thus you provide the reliability and efficiency of your heat pump. For more information, please contact your
WATERKOTTE service partner.
In the maintenance the technical condition of the heat pump system is checked
(target-actual comparison). This provides a diagnostic measurement of the thermodynamic section ensures that the efficiency is maintained on the top.
Typical inspection:

Check heating circuit: System pressure, function of expansion tank, venting,
rotation direction of pump and volume setting.

Check water glycol circuit: Level, if necessary pressure, water glycol pour
point, rotation direction of pump.

Groundwater: Check dirt trap and clean if necessary, rot. direction of pump.

Check cooling circuit: Screw connections, tightness, level (inspection glass),
refrigerant control, diagnosis measurement log.

Check setting of control.

Leak test: The statutory inspection intervals depend on the refrigerant volume.
For more information, see the heat pump logbook.
Tip:
A continuous diagnosis (CD) is performed with help of the WWPR controller. If the
measured values or queries are beyond the permissible range in the respective
mode, the controller issues a warning.
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Connection diagram
16 Connection diagram
16.1 Basic Line Ai1 Geo with underfloor heating
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Connection diagram
16.2 Basic Line Ai1 Geo with underfloor heating and individual room control
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Connection diagram
16.3 Basic Line Ai1 Geo with hydraulical deflector
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Connection diagram
16.4 Basic Line Ai1 Geo with radiators
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Connection diagram
16.5 Legend hydraulic schemes
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
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Description
Underfloor heating
Heat pump
Indoor module
Outdoor module
Flexible connections
Fitting group for flushing and venting
Dirt trap integrated in ball valve
Flow rate monitoring
Groundwater pump
Plate heat exchanger
Motor-operated changeover ball valve (interruption-free)
Optimised thermal tank (compact condensing boiler)
Optimised thermal tank (return series storage)
Temperature sensor
Radiators or convectors
Bronze pump
Pressure regulator
Backflow preventer
Safety valve
Valve, control deviation 1 to 2 Kelvin
Diaphragm expansion tank for domestic water systems
Diaphragm expansion tank with isolation fitting
Domestic cold water
Domestic hot water
Circulation
Domestic water heater
250 l domestic hot water tank
Air separator with air diverter
Differential pressure overflow valve
Pressure controlled circulation pump
Charging and draining valve
Circulating pump
Air separator with vent, gauge and safety valve
Safety group
Safety valve with vent and gauge
Tacosetter for hydraulic compensation
Supply compact condensing boiler 250 l
Pool
Motor-driven mixer
Solar diaphragm expansion tank with isolation fitting
Heat source module
Heat source module natural cooling
Motor-driven changeover ball valve, interruption-free (heating and cooling)
2nd heat generator
Check valve
Balancing valve for hydraulic compensation
Dirt trap
Motor-driven changeover valve
Motor-driven valve
Connections integrated coil tube heat exchanger
Pool heat exchanger
Ball valve
Optimised thermal tank with integrated smooth pipe heat exchanger
Geothermal energy probes
Compact condensing boiler 1000 l to 2500 l
Thermostat valve
Temperature controller
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Connection diagram
No.
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
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Description
Gravity brake
Tichelmann hydraulic expansion set
Tichelmann hydraulic basic set
Solar connection set
Collector temperature sensor
Vacuum tube
Electrical resistance heating
Compact condensing boiler 400 liter with domestic water heater (SET 454)
Control valve
Exterior temperature sensor
Pilot room sensor
Motor-driven ball valve
Safety group with safety valve, pressure regulator, backflow preventer and diaphragm expansion tank with
flow fitting for domestic water systems.
215 l plastic tank
Funnel
Copper immersion tube with suction strainer, non-return valve and pump connection
Self-priming pump WJ 301 EM with 2m connecting cable (230V), rated input 1100 W, connections suction side and pressure side Rp1"
1500 mm flow-line hose with 1 1/4“ union nut with 2 gaskets and reducing nipple 1 1/4“a x 1“a
1500 mm return flow hose with 1 1/4“ union nut with 2 gaskets
Air separator, safety group with gauge, air diverter, safety valve, diaphragm expansion tank with isolation
fitting.
Motor-operated changeover ball valve (domestic hot water preparation)
Motor-driven changeover ball valve (pool)
Multilayer filter for pool water cleaning
Pool water - disinfection system
PH value control and correction system
Pool water drain
Pool water circulation pump
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Technical data
17 Technical data
The individual specifications and filling quantities of your heat pump system, refer
to the type plate.
Performance tabel: Basic Line Ai1 Geo with R410A
Groundwater source heating
Power cons./output. W10/W35, kW2)
Performance factor W10/W354)
Groundwater flow rate, m³/h (∆t=3K)
Groundwater flow rate, minimum m³/h 1)
Heating water flow rate, m³/h (∆t=5K)
Operational limit
Basic Line
Ai1 Geo
5005.5
1.1/6.6
6.3
1.6
0.7
1.1
Heat source ground
Power cons./output B0/W35, kW2) (3x400 V)
Performance factor (COP) B0/W352) (3x400 V)
Power cons./output B0/W35, kW2) (1x 230 V)
Performance factor (COP) B0/W352) (1x 230 V)
Heat source flow rate3), m³/h (∆t=3K)
Heating water flow rate, m³/h (∆t=5K)
Max. power input heat source pump, W
Max. power input heat pump, W
Operating limit
Basic Line
Ai1 Geo
5006.5
Basic Line
Ai1 Geo
5008.5
Basic Line
Ai1 Geo
5010.5
1.3/7.7
1.6/10.2
6.2
6.5
1.8
2.5
0.9
1.3
1.3
1.7
W10/W60
1.1/4.8
4.6
1.1/4.8
4.5
1.2
0.8
1.3/5.7
4.6
1.3/5.7
4.5
1.4
1.0
2.2/13.5
6.0
3.3
1.7
2.5
1.7/7.6
4.9
1.7/7.6
4.7
1.9
1.3
2.2/10.1
4.7
2.2/10.0
4.4
2.5
1.7
70
70
B-5/W60 B0/W65
Compressor
Vollhermetic-Scroll
Sound power level 9614-2 dB(A)
46
47
48
48
28 (52)
28 (60)
43 (83)
51,5 (108)
14 (45)
22 (45)
26 (45)
Electrical data 3x400 V, 50 Hz (series 1x230 V, 50 Hz)
Starting current (unreduced), A
Starting current soft start, A
Max. operating current, A
Customer-supplied main fuse, compressor A
Customer-supplied control fuse, A
Max. operating current (electrical heating) A
Customer-supplied main fuse (electrical heating) A
Electrical heating element, kW
14 (45)
4.8 (10.5)
C16A (C20A)
4.8 (12.8)
6.2 (17.1)
7.4 (22.8)
C16A (C20A) C16A (C20A) C16A (C32A)
B10A
8,7 (26,1)
B16A (B32A)
6
Filling capcities,dimensions,weights,connections
Compressor volume Oil filling (l) 5)
Refrigerant volume R410A (kg)
Volume heating side (l)
Volume heat source side (l)
Weight of device, empty tank,
with housing (kg)
Weight of tank module, without housing (kg)
Weight of housing (kg)
Weight of hydraulic module, without housing (kg)
0.74
1.80
5.9
on demand
192
0.74
1.80
5.9
on demand
192
1.24
2.00
6.7
on demand
209
1.24
2.00
6.7
on demand
209
59
34
99
Connections: heat source / use
Dimensions W x H x D, mm
Volume domestic hot water tank, (l)
99
116
116
flat sealing
G 1¼ “a / G 1¼ “a
600 x 1850 x 650 (+ 35 mm connections)
170
G ¾“ i
At W10/W35 und ∆t=6K. 2) Tolerances as per EN 12900 and EN 14511 apply to the performance data listed.
70 % water + 30 % ethylen-glykol. 4) COP as per EN14511 5) Type: Ester oil ICI Emkarate RL 32-3MAF 6) standard in the 1x230 V
series.
1)
3)
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Technical data
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Technical data
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Technical data
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Technical data
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: +49 2323 9376 0, Fax: +49 2323 9376 99
Service: +49 2323 9376 350
E-Mail: info@waterkotte.de Internet: http://www.waterkotte.de
E-Mail: info@waterkotte.de Internet: http://www.waterkotte.de
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