Aeromax KHP0041 Installation And Maintenance Manual

Air source heat pump

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Model numbers:

KHP0041: 4kW Heat Pump

Model numers:

KHP0038: 6kW Heat Pump

KHP0038: 6kw Heat Pump

KHP0039: 8kW Heat Pump

KHP0039: 8kw Heat Pump

KHP0040: 12kW Heat Pump

KHP0040: 12kw Heat Pump

KHP0042: 15kW Heat Pump

Air Source Heat Pump

Installation and Maintenance Manual

Air Source heat Pump

Installation Manual

A9317D

Table of Contents

Summary of Contents for Aeromax KHP0041

Page 1: Installation Manual
Air Source heat Pump Air Source Heat Pump Installation and Maintenance Manual Installation Manual Model numbers: KHP0041: 4kW Heat Pump Model numers: KHP0038: 6kW Heat Pump KHP0038: 6kw Heat Pump KHP0039: 8kW Heat Pump KHP0039: 8kw Heat Pump KHP0040: 12kW Heat Pump...
Page 3: Table Of Contents
Spare Part List POWER WIRING Rating Tables Maintenance. FLUSHING WATER AND AIR CHECKING FOR WATER LEAKS CONFIGURING & CHECKING THE SYSTEM Code Description KHP0041 AEROMAX PLUS 4KW KHP0038 AEROMAX PLUS 6KW KHP0039 AEROMAX PLUS 8KW KHP0040 AEROMAX PLUS 12KW KHP0042...
Page 4: R-410A - General Info
Introduction The information in this manual is to provide general Please note: Kingspan Renewables do not accept any assistance in the selection of equipment. The responsibility for matters of specification, design or responsibility for the specification of the equipment must...
Page 5: Unit Protection Devices
Unit protection devices Introduction Check List The following check list has been prepared to assist you in Radiator System Circuit understanding the differences from other types of heating • As the Aeromax Plus generates lower temperatures systems you may have installed and help to understand than a conventional boiler the radiators should have and comply with all of the technical details contained been designed to suit the lower mean temperature.
Page 6: Safety Procedures
Safety procedures Important safety information is displayed on the product and in this Manual. Please read this installation manual carefully before installing the unit. It contains further important instructions for proper installation. Explanation of illustrated marks Indicates prohibited items. Indicates mandatory items. Indicates cautions (including danger/warnings).
Page 7: Unit Installation
200mm above the usual snow level or alternatively to use the outdoor unit wall mounting bracket kit. See Kingspan optional extras such as the “snow feet” (Anti vibration foot KHP0044 ) recommended for exposed areas to help create an air gap under the unit.
Page 8: Dimensions And Clearances 8
Disconnect the mains power supply prior to any disposal centre or to the original equipment dealer maintenance operations or prior to handling any for proper environmentally compatible disposal. internal parts of the unit. Dimensions and Clearances weight KHP0041 KHP0038 KHP0039 1363 KHP0040 1363 KHP0042 Minimum installation clearances in mm are shown in fig.
Page 9: Dimensions And Clearances
Dimensions and Clearances 1000 1500 2000...
Page 10: Installation Pack
Installation Before installation, check strength and levelness of the If the outdoor unit is installed in a very windy place, base so that abnormal noise is not generated. According protect the fan with a wind protection screen and check to the dimensions and clearances, fix the base firmly that it works correctly.
Page 11 Foundation Specification Foundation bolt M10 (3/8”) Thickness of concrete 120mm Length of bolt 70mm Weight-bearing capacity 320kg...
Page 12: Water Connections
Water connections Water Connections (Fig. 8/9/11) Make the plate heat exchanger hydraulic connections with System cleaning and Water Characteristics the necessary components, using material which will In the case of a new installation, or cleaning the guarantee that the screwed joints are leak proof. The circuit, it is necessary to perform a preventive typical hydraulic circuit diagram shows a typical water cleaning of the system.
Page 13 Integrated water circuit - Safety Devices 1 Automatic valve with air vent 2 Flow switch 3 Pressure relief valve (300kPa, outlet 1/2’) 4 Temperature probe Isolating valves 3-way valve System f ilter Hot water cylinder Expansion vessel with PRV & Gauge (Robokit)* Heating system Flush &...
Page 14 30AWH004X 4 kW 6 kW 30AWH006X A (l/s) 30AWH012X 8 kW 12 kW & 15 kW 30AWH008X...
Page 15 Installation % Inhibited Propyl- ene Glycol Freezing time (*) -4 °C -9 °C -15 °C -23°C Correction Capacity 0,996 0,991 0,983 0,974 Factors Absorbed power 0,990 0,978 0,964 1,008 Loss of head 1,003 1,010 1,020 1,033 (*) Note: Temperature values are indicative. Always refer to the temperatures indicated for the specific product used TABLE TO USE FOR CALCULATING THE WATER CONTENT IN THE SYSTEM Installed Unit...
Page 16 = Pre-charge Pressure (Bar) = Max System Pressure (Bar) Cylinder Installation for Domestic Hot Water We recommend the Kingspan Albion Aerocyl is used as it has a heat pump specific coil fitted. Note... If the Aerocyl is used in conjunction with the 3 port valve supplied with the Aeromax plus there is no requirement for the additional 2 port valve.
Page 17 Water connections (Typical Schematic for Radiator System)
Page 18 Water connections (Typical Schematic for Radiator System)
Page 19 Water connections (Typical Schematic for Radiator System)
Page 20 Electrical connections (Fig. 13) All field electrical connections are the responsibility of the installer. WARNING Make water connections before electrical connections. Make ground connection prior to any other electrical connections. Unit Aeromax Plus KHP041 KHP0038 KHP0039 KHP0040 KHP0042 12kW 15kW Power Supply V - ph - Hz 230 - 1 - 50...
Page 21 Electrical connections...
Page 22: Way Valve
(NTC 2 wire, 3kΩ @ 25°C, Kingspan Part Number KHP0009). Connect the terminals of the probe between PINS 23 and 24 of the terminal strip (see Fig. 13).
Page 23 Auxiliary accessories connection Signal for requesting an External Heat Source or Dehumidification Between PINS 4 and N of the terminal strip (see Fig. IMPORTANT NOTICE : 13),there is an output (1ph ~ 230V, 2A max) that can be In case of SHW activation (pins 13-15 closed) heat pump programmed using the remote User Comfort Interface (see will turn on and backup heater will turn off.
Page 24: System Test
System test Inverter board alarm codes KHP0040 12kW unit only (Fig. 14) Before a check, confirm each bit of the DIP switch is set Faults of the inverter can be diagnosed by LED indications to OFF position. on the cycle control P.C. board of the outdoor unit. Utilize them for various checks.
Page 25 System test Inverter board alarm codes (only for KHP0042 15kW unit) (Fig. 14) The error which is generating at present and the latest c) If there is an error, any of LED D800 to D804 goes error (Latest error information including present) can be on.
Page 26 Refrigerant Diagram and Unit Protect Devices GMC Board Alarm Codes (Fig. 14) There is an LED on the GMC board that displays any board Example: error 23: LED off for 4 seconds. 2 flashes at a errors. The error code can be identified from the flashing frequency of 1Hz.
Page 27 A: 4 way valve B: DC Rotary Compressor C: BPHE D: Pulse Motor Valve E: Distributor F: Fan G: Heat Exchanger HTT: High Temperature Thermostat T1: TS sensor T2: TD sensor T3: TR sensor T4: TE sensor T5: TO sensor Ta: EWT sensor Tb: LWT sensor Type of Safety Device...
Page 28 Additional Systems: Twin Zone System. Water connections...
Page 29 Additional Systems: Twin Zone System. Wiring Diagram...
Page 30 Additional Systems: Bi-Valent Alternative System (Boiler). Water connections...
Page 31 Additional Systems: Bi-Valent Alternative System (Boiler). Wiring Diagram...
Page 32 Additional Systems: Bi-Valent Parallel System (In-line Electric Heater) Water connections...
Page 33 Additional Systems: Bi-Valent Parallel System (In-line Electric Heater) Wiring Diagram...
Page 34 Additional Systems: Bi-Valent Retrofit System (S-Plan Boiler) Water connections...
Page 35 Additional Systems: Bi-Valent Retrofit System (S-Plan Boiler) Wiring Diagram...
Page 36: Day Hot Water Programmer
Installation Pack 7 day hot water programmer Please see page 43 for full instructions Programable room stat Please see page 55 for full instructions 2 x 750mm flexible hoses including 90° elbow, pre-insulated Used to connect flow & return pipes to heat pump and reduce vibration 1 x system filter Drawing: Design parameters:...
Page 37 Installation Pack System Antifreeze / Inhibitor - Clear • Protects against frost damage from -14°C to -34°C • Protects against corrosion, limescale and bacterial contamination • Non-toxic • Compatible with all metals and materials commonly found in heat Application Fluid Plus is a concentrated heat transfer fluid capable of frost protection from -14°C to -34°C especially formulated for use in Heat Pumps.
Page 38 Installation Pack W Plan diverter valve (heat pump specific) Operating voltage 230VAC Switch current rating 3 (1) A Switch action Type 1B Max temperature 45°C Enclosure rating IP40 Pollution situation Degree 2 Ball pressure temp 75°C Open/close time 30/10 sec Rated impulse voltage 2.5K Cord attachment...
Page 39: Technical Specification
Installation Pack Diagnostic Indicator Read the following instructions before starting the installation. This product is a Diagnostic Indicator for Aeromax Plus heat pump models. It indicates the alarm and power status of the Aeromax Plus unit. It must be connected to the Aeromax Plus unit for correct operation. Technical specification Dimensions 120mm (w) x 80mm (h) x 55mm (d)
Page 40 Installation Pack Immersion Heater Controller Read the following instructions before starting the installation. This product is an Immersion Heater Controller for Aeromax Plus heat pump systems. It is installed to control the operation of the immersion heater to sanitise the Domestic Hot Water cylinder to prevent Legionella growth.
Page 41: Optional Installation Accessories
Filling station C0814 filling station. The Kingspan Flushing & filling station aids the installer when commissioning the heating system. It can be connected directly to the flush and fill port supplied in the installers pack which in turn is then filled with the Kingspan antifreeze / inhibitor concentrate.
Page 42 Optional Installation Accessories External Temperature Sensor KHP0009 Ø 4mm B036502H01 B036502H01 2x FROH2R Ø 4mm 0.5 mm (max 50m) C W G Y 23 24 1 21 22 3 6 7 8 2 û û û û û û û û...
Page 43 7 day hot water programmer Installation & User Instructions +1HR override +1HR MAN override RESET DAY/HO Mode SELECT Index User Installation What is a programmer? Product specification Your timeswitch Installation Preset programmes – Wiring – Before you start – DIL switch settings –...
Page 44 7 day hot water programmer Installation Ÿ Remove wallplate from unit by unscrewing the two Ÿ For wiring connections refer to the diagrams. screws on the bottom edge of the unit. Ÿ TS715-Si models are double insulated and do not Ÿ...
Page 45 7 day hot water programmer Advanced Programming Options To enter advanced programming press PROG, + and DAY/HOL together and hold for 5 seconds. Option 1 - (3 or 2 On/Off’s per day) Use + or - to change between 3 and 2 on/off ’s each day. Option 2 - (Disable or enable auto time change) Option 2 - (Disable or enable auto time change) Press NEXT, then use + or - change between auto time...
Page 46 7 day hot water programmer Copy Functions Explained To use the AB copy function – press the PROG button: AB Copy: The AB copy function is available in 5+2 mode only and only if activated in the Advanced 1.This will show the “ A” days, with all the days selected. Programming setting.
Page 47 7 day hot water programmer Your timeswitch The TS715-Si allows you to switch your system on and off at times that suit you. You can programme up to 3 separate ON/OFF times per day. Preset Programmes Your TS715-Si comes ready programmed with a set If you want to change any of these settings, you can do so of operating times which often suit most people.
Page 48 7 day hot water programmer Setting the correct Time and Day These settings are made during manufacture and only DAY/HOL need to be made in the unlikely event that the unit has lost the settings. Setting the Date Press and hold PROG for 5 seconds to display year. Use the + or - buttons to set the correct year.
Page 49 7 day hot water programmer 7 day hot water programmer Programming the ON/OFF Times in 5/2 day mode 1. Press PROG once until SET ON TIME appears at the top of the display and MOTUWETHFR appears at the bottom of the display. Use the + or - buttons to set the time you would like your system to first come on in the morning (Event 1).
Page 50 7 day hot water programmer Programming the ON/OFF Times in 7 day mode 1. Press PROG once until SET ON TIME appears at the top of the display. Note the current day is displayed. Press the DAY/ HOL button until the required day is displayed.
Page 51 7 day hot water programmer Programming the ON/OFF Times in 24 hour mode 1. Press PROG once until SET ON TIME appears at the top of the display. Use the + OR - buttons to set the time you want your system to first come on in the morning (Event 1).
Page 52 7 day hot water programmer Temporary override buttons Sometimes you may need to change the way you use your heating temporarily, i.e. due to unusually cold weather. The TS715 Si has two convenient overrides which can be selected without affecting the set programme.
Page 53 7 day hot water programmer Changing clocks forward & back This is handled automatically. Should the installer have turned off Automatic Time Change then follow the instructions below. Open the flap on the front of the unit to reveal the programming buttons.
Page 54 7 day hot water programmer Making a Full Reset If it is necessary to fully reset the unit, including the date and time, follow the instructions below. 1. Press and hold the +1HR and MAN buttons on the left hand side of the product. 2.
Page 55 Programmable room stat Installation & User Instructions Index Installation Instructions User Instructions Product Specification What is a Programmable Room Thermostat Installation Preset programmes Cable Access and Wiring Setting Date and Time Installer Advanced Programming Options Changing Preset Programmes User overrides Advanced User Programming Options Overview of Installer Selectable Features Setting References...
Page 56 Programmable room stat Installation • First, remove the wallplate from the back of the unit. • From the top left hand corner of the wallplate, there must be clearances of at least 15mm to the right, 15mm to the left, 30mm above and 100mm below in order to mount the plug-in module.
Page 57 Programmable room stat Please Note: Some existing thermostats will have a Neutral and/or Earth wire connected. These are not required by the battery powered versions of the TP5000 Si and must NOT be connected to any battery powered TP5000 Si terminals. Instead they should be made electrically safe and coiled in the recess at the back of the TP5000 Si.
Page 58 Programable room stat Installer advanced programming options TP5000 Si incorporates a number of advanced features which can be set by the user. These are accessed via a User Advanced Programming Mode, please refer to User Advanced Programming in the user instructions for details (see page 67).
Page 59 Programmable room stat Option 34 - Select On/Off Chrono-proportional Option 35 - Set integration time (Option 34 set to 3, 6, 9 or 12) (seek advice prior to adjusting) This allows the thermostat to be set to This allows the thermostat to be set to run in This adjusts the integration time of run in On/Off mode or for a chrono- the PI algorithm to increase control...
Page 60 Programmable room stat Option 71 - Random start rules (24V/230 Volt models only) Option 72 - Owner site reference number This enables a random start on pow- This enables multi-site owners er-up following a power cut to reduce to store a site reference load on the electrical network.
Page 61 Programmable room stat What is a programmable room thermostat? ... an explanation for householders The best way to do this is to set low temperatures first, say 18°C, and then turn them up by one degree each A programmable room thermostat is both a programmer day until you are comfortable with the temperatures.
Page 62 Programmable room stat Weekend (Sat-Sun) Weekdays (Mon-Fri) Event Time Temp. °C Event Time Temp. °C 06:30 07:30 08:30 09:30 11:30 11:30 13:30 13:30 16:30 16:30 22:30 22:30 Note: these are also times for Note: these are also times for Block “A” programmes Block “B”...
Page 63 Programmable room stat Setting the correct time After setting the date press PROG to display the time. The time display will flash on and off. Use the + and - buttons to set the correct time (press and hold to change in 10 min. increments). Setting the correct day The day of the week is set automatically.
Page 64 Programmable room stat Changing the preset programmes in 5/2 day mode For Weekends Press PROG until the first preset time and temperature (Event 1 Days SAT, SUN) appears in display. Repeat steps b, c, & d above to programme the remaining weekend events.
Page 65 Programmable room stat Setting the correct time a) Press PROG until the first preset time and temperature (Event 1 for d) Press PROG to move to the next preset time and Programme A) appears in display. temperature (Event 2). b) Use the + and - buttons to adjust the TIME (press and e) Repeat steps b, c, &...
Page 66 Programmable room stat To change time display between 12 hour and 24 Press ‡ and + together to toggle between 12 and 24 hour To change between °C and ° F scaling Press ˆ and - together to toggle between °C and ° F temperature scaling.
Page 67 Programmable room stat Optimum start control (OSC) Your thermostat includes an optional optimum start A full description of this and how to enable it and control. This feature allows you to set the time at which set it up is given in User Advanced Programming, you require a room temperature by.
Page 68 Programmable room stat Option 11 - Start-up method Option 12 - Optimum start control pre-heat setting (Option 11 set to 1) Your thermostat can start up the Press + until Option 12 is displayed, system in three different ways. use ‡ & ˆ to select required Press + until Option 11 is setting (only active if Option 11 displayed, use ‡...
Page 69 Programmable room stat Temperature range limitation This allows the installer to programme both upper and lower temperature limits. It may limit the upper and lower temperature that you are able to set on the thermostat. Temperature override limitation This allows the installer to limit the number of degrees that you can override the programmed temperature by, it also allows the installer to set rules regarding how long a temperature override will remain in place.
Page 70 Programmable room stat Settings Reference Note to installers: Please use this table to record changes to default settings. Installer Settings Option Description Installer Set Value Set upper limit of temperature range Set lower limit of temperature range Enable Off at lower limit Enable On at upper limit Select On/Off or Chrono-proportional Set Integration Time...
Page 71: Spare Part List
Spare Part List KHP0041 - 4kW, KHP0038 - 6kW, KHP0039 - 8kW...
Page 72 Spare Part List Pos. Description Note Base pan assy Front panel Ass. front side panel Ass. rear side panel Front service cover Pillar Ass. top cover Fan guard grille Fan motor Motor nut Propeller fan Orifice Handle Condenser coil assy Coil guard net Compressor (DA111A1F-20F1) Klixon...
Page 73 Spare Part List KHP0040 - 12kW, KHP0042 - 15kW...
Page 74 Spare Part List Pos. Description Note Base pan assy Front panel Ass. front side panel Ass. rear side panel Front service cover Pillar Ass. top cover Fan guard grille Fan motor Motor nut Propeller fan Orifice Handle Condenser coil assy Coil guard net Compressor (DA420A3F-21M) Klixon...
Page 75 Rating Tables 115% 105% 100% 90% 80% 70% 60% 50% 40% 30% 15% Hz CAPACITY 115% 105% 100% 90% 80% 70% 60% 50% 40% 30% 15% Hz 4 kW 1.86 1.87 1.87 4 kW Unit 0.81 0.59 0.37 Unit -10 2.33 2.41 2.44 2.46 2.5...
Page 76 Rating Tables 115% 105% 100% 90% 80% 70% 60% 50% 40% 30% 15% Hz CAPACITY 115% 105% 100% 90% 80% 70% 60% 50% 40% 30% 15% Hz 6 kW 1.76 1.77 1.77 6 kW Unit 0.99 0.72 0.45 Unit -10 2.21 2.29 2.31 2.33 2.36 2.4...
Page 77 Rating Tables 125% 105% 100% 90% 80% 70% 50% 40% 30% 15% Hz CAPACITY 125% 105% 100% 90% 80% 70% 50% 40% 30% 15% Hz 8 kW 2.03 2.04 2.06 2.06 2.06 8 kW Unit 1.91 1.57 1.23 0.9 0.56 Unit -10 2.07 2.47...
Page 78 Rating Tables 115% 105% 100% 85% 65% 45% 25% Hz CAPACITY 115% 105% 100% 85% 25% Hz 12 kW 1.48 1.48 12 kW -20 0 2.41 Unit Unit -10 2.26 2.27 2.28 2.29 2.31 2.31 2.31 -10 7.28 6.68 6.44 5.49 3.12 1.95...
Page 79 Rating Tables 115% 110% 100% 85% 65% 50% 35% 15% Hz CAPACITY 115% 110% 100% 85% 35% 15% Hz 15 kW 1.92 1.93 1.94 15 kW 3.05 2.12 1.26 Unit Unit -10 2.33 2.35 2.36 2.39 2.4 2.41 2.42 2.42 -10 8.44 7.89 7.42...
Page 80 ENGINEERS Maintenance Sheet Customer Name Service Engineers Name Address Company Tel No Site Number Tel No Date of Inspection Model No. Serial No. SYSTEM AND INSTALLATION STATUS NOTES INSTALLATION LOCATION MAINTENANCE AND ACCESS TO REMOVE COVERS SPACE AVAILABLE FOR AIR FLOW STANDARD OF PIPEWORK STANDARD OF INSULATION STANDARD OF ELECTRICAL INSTALLATION...
Page 81: Maintenance Checklist
Commissioning Maintenance Checklist The Aeromax plus must be maintained on an annual Inside the Heat Pump basis. The basic requirements are: Check all electrical connections for tightness Visual inspection for either oil or water leaks External checks Check operation of unit with cover still removed Visually inspect all connecting pipework for any signs of leaks Cylinder...
Page 82 Danfoss FP715 Hot Water programmer fitted* Cylinder Thermostat fitted* Danfoss TP5000 room stat fitted* Kingspan diagnostic indicator fitted*† Kingspan Advanced Controller (NUI) fitted (Optional).*† Commissioning System flushed with cleanser* System checked for leaks* Antifreeze added to system… concentration level. *...
Page 83 Notes...
Page 84 KINGSPAN ENVIRONMENTAL Wakefield Office Tadman Street, Wakefield West Yorkshire WF1 5QU T 0845 2 6 00 258 F 0845 2 60 02 59 sales@kingspansolar.co.uk www.kingspansolar.co.uk Portadown Office 180 Gilford Road, Portadown Armagh BT63 5LF T 028 3836 4444 F 028 3836 4445...

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