WATERKOTTE EcoTouch DS 5027 Ai Planning And Installation Manual
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WATERKOTTE EcoTouch DS 5027 Ai Planning And Installation Manual

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Planning and installation

EcoTouch DS 5027 Ai

Heating System

WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: 0049/(0)2323/9376-0, Fax: 0049/(0)2323/9376-99, E-Mail: info@waterkotte.de
Internet: http://www.waterkotte.de
Z20555 / 2005/06/10

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Summary of Contents for WATERKOTTE EcoTouch DS 5027 Ai

  • Page 1: Planning And Installation

    Planning and installation EcoTouch DS 5027 Ai Heating System WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne Tel.: 0049/(0)2323/9376-0, Fax: 0049/(0)2323/9376-99, E-Mail: info@waterkotte.de Internet: http://www.waterkotte.de Z20555 / 2005/06/10...
  • Page 2 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. 2 / 60 2005/06/10 Copyright ...

  • Page 3: Table Of Contents

    Overview (unit opened) ....................12 Components and installation ....................13 Heating system EcoTouch DS 5027 Ai ................13 Installation ........................13 4.2.1 Heat pump system series EcoTouch DS 5027 Ai ..........13 4.2.2 Heat pump module ..................... 13 Electrical equipment ......................14 4.3.1 Electrical resistance heating ................
  • Page 4 Installation instructions for external sensor ............... 33 8.3.1 Cabeling ......................33 Electrical connections ...................... 34 8.4.1 EcoTouch DS 5027 Ai (3x 400 V) ............... 34 8.4.2 EcoTouch DS 5027 Ai (1x 230 V) ............... 35 8.4.3 Connectors ......................36 8.4.4 Controller WWPR 2 .....................
  • Page 5 (GWP) of 1975. Do not release refrigerant R134a into the atmosphere: R134a is a greenhouse gas according to Kyoto Protocol and has a global warming potential (GWP) of 1300. 5 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 6: Safety

    Safety 1 Safety 1.1 Intended use Your WATERKOTTE heat pump is used for space heating and cooling, and domestic water heating. Project planning of the heat source system must be performed in compli- ance with the technical information provided by WATERKOTTE for layout of heat source systems.

  • Page 7: Modifications And Repairs 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 rel- evant usage and safety requirements.

  • Page 8: Specific Types Of Hazards

     Risk of chemical burns when skin comes in direct contact with lubricant leak.  Electronic components can be damaged by electrostatic processes. 8 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 9: Operator's Duty Of Care

    1.5 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.

  • Page 10: Functional Principle Of Heat Pump

     heating system EcoTouch DS 5027 Ai  domestic hot water tank Driving energy Energy output Heat source Low temperature Heat pump Figure 1: Energy share when using a geothermal energy pump 10 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 11: Product Description

    Product description 3 Product description 3.1 Overview (connected device) Figure 2 : Heating system EcoTouch DS 5027 Ai ON / OFF switch Control panel (electronic heat pump controller) 11 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 12: Overview (Unit Opened)

    Product description 3.2 Overview (unit opened) Figure 3: EcoTouch DS 5027 Ai (Top view, opened) Safety group with manometer: relief valve, bleeder Connecting terminal 12 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 13: Components And Installation

    Sound insulation ensures low noise emissions. 4.2 Installation 4.2.1 Heat pump system series EcoTouch DS 5027 Ai Funtions: Heat pump, domestic hot water heating system, electrical re- sistance heating for startup and standby, regulation and electrical control, touch display with Easy-Con Software, smartphone control via Easy-Con Mobile software, diagnosis system.

  • Page 14: Electrical Equipment

    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 operat- ed with WATERKOTTE compact heat pumps according to technical guide- lines of WATERKOTTE Wärmepumpen GmbH.

  • Page 15: Sensors

    External wall sensor in accessories kit, reference room sensor and hot water sensor (optional). 4.4.4 COP-Counter A WATERKOTTE COP counter is already integrated in the heat pump con- trol. For additional information, please refer to operating manual for heat pump control. 4.5 Options Domestic hot water: thermo storage/charging storage (heating side), pota- ble water heater, temperature sensor, three way valve.

  • Page 16: Model Ecotouch Ds 5027Ai Nc

    Components and installation 4.6 Model EcoTouch DS 5027Ai NC The model EcoTouch DS 5027 Ai NC is a variant of series EcoTouch DS 5027 Ai with the option of natural cooling, while maintaining all basic fea- tures. Natural cooling means an expansion of thermal comfort to the sum- mer months.

  • Page 17: Model Ecotouch Ds 5027Ai Rc

    Components and installation 4.7 Model EcoTouch DS 5027Ai RC The model EcoTouch DS 5027 Ai RC is a variant of series EcoTouch DS 5027 Ai with the option of active cooling, while maintaining all basic fea- tures. Active cooling means an expansion of thermal comfort to the sum-...

  • Page 18: Transport

     Please also read chapter "General safety information” Figure 4: Dimensions DS 5027 Ai (without packaging) 18 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 19: Transport To Installation Site

    Transport 5.1 Transport to installation site Units of the EcoTouch DS 5027 Ai series are delivered ready-to-connect with sepa-rate metal cladding. For transport purposes, the metal cladding and the heat pump are delivered in one carton on a palette. During transport it must be ensured that appropriate means of transport are used (lift truck, transport rollers, handcart).

  • Page 20: Installation

    10 mm thick rubber mat. Acoustics in in- stallation rooms with rigid walls can noticeably increase operating noise. Counter measure: acoustic insulation of one of the opposite wall or ceiling surfaces. 20 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 21: Creating The Foundation And Installing Heat Pump

    Insulation material (3 layer, polyurethan rubber) Supporting subsurface Insulation material Screed Concrete plinth 6.2.2 Dimensions concrete plinth (mm): Plinth Width Depth High EcoTouch 850 mm 700 mm 150 mm DS 5027Ai 21 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 22: Installation Of The Housing

    So you can’t damage the retaining bolts (see Figure).  The removal tool is driven with moderate force, by hand, into the gap between the front and side panel. 22 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 23: Installation And Connection

    Designation for inlet and out- let must be observed. When there is danger of frost, add antifreeze to pro- tect against formation of ice. 23 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 24 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. A circulation pump is installed at heating side.

  • Page 25: Heat Pump With Underfloor Heating

    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 (P11108).  If the formation of deposits is to be expected (e.g. strong contamination) based on water quality, cleaning must be performed in regular intervals.

  • Page 26: Connection To Heat Source

    PE-pipe20x2) 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.
  • Page 27 Flow rate T 4K m³/h 25/1-7 25/1-7 25/1-7 Pump (class A) 25/1-7 25/1-8 25/1-8 25/1-8 25/1-8 Residual head T 5K * medium circle (15% Ethylen-Glykol and 85% water) 27 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 28: Water Glycol Systems

    7.3.1 Water glycol systems Since the EcoTouch DS 5027 Ai 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).
  • Page 29 The above values are reference values which can vary under certain operat- ing conditions. If you have any questions, please call us at: (+49) (0) 2323 93760. 29 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 30: Flow Monitoring

    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! 30 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 31: Electrical Work

     All connections performed directly at the plug connections of the relay circuit board must be established with flexible lines; if necessary, inter- mediate terminals must be used.. 31 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 32: Electrical Heat Generator For Startup And Standby

    Due to safety reasons, a label placed on the controller cover must refer to the temporary solution, i.e. „Electrical heat generator temporarily activated“. 32 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 33: Parallel Operation: Heat Pump And Electrical Heat Generator

    The cable for the electric wiring can be passed through the openings to the upper rear wall of the heat pump. The cables are fixed by means of strain relief and cable glands. 33 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 34: Electrical Connections

    Electrical work 8.4 Electrical connections 8.4.1 EcoTouch DS 5027 Ai (3x 400 V) 34 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 35: Ecotouch Ds 5027 Ai (1X 230 V)

    Electrical work 8.4.2 EcoTouch DS 5027 Ai (1x 230 V) 35 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 36: Connectors

    Electrical work 8.4.3 Connectors 36 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 37: Controller Wwpr 2

    NO11 – Multifunctional exit NO11 – Sortie multifonction NO12 – Stetiges Kühlsignal NO12 – Continuous cooling signal NO12 – Signal rafraîchissement constant NO13 – NO13 – NO13 – 37 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 38: Pipe & Instrumentation Flow Chart/Measurement & Control Technology

    Pipe & instrumentation flow chart/measurement & control technology 9 Pipe & instrumentation flow chart/measurement & control technology EcoTouch DS 5027Ai and EcoTouch DS 5027Ai NC EcoTouch DS 5027Ai RC 38 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 39 Fully hermetic, scroll Condenser Steel plate pack, copper soldered Refrigerant inspection glass Refrigerant filter Expansion valve Electronical Evaporator Plate pack, copper soldered Filter dryer 4-way magnetic valve 39 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 40: Hydraulic Diagramms Ds 5027Ai & Ds 5027Ai Nc / Rc

    10 Hydraulic diagramms DS 5027Ai & DS 5027Ai NC / RC Heat pump EcoTouch DS 5027Ai and EcoTouch DS 5027Ai RC Heat pump EcoTouch DS 5027Ai NC 40 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 41 (heat source) circulation pump (heat source) expansion tank (heat source) 2-way motor ball valve (heating) heat exchanger (natural cooling) 2-way motor ball valve (heat source) 41 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 42: Commissioning

    Before operation, check if all plates, fuses and other protective devices are properly installed Do not touch switch with wet hands. This poses a risk of electric shock. 42 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 43: Initial Start-Up Of Machine

    Figure 7: ON / OFF switch (see pointing 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.

  • Page 44: Control Of Entire Operation

    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. 44 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 45: Turning Heat Pump Off

    Turn OFF the main switch of heat pump. Turn OFF LS switch: Compressor, control voltage and electrical heating el- ement. 11.5 Taking heat pump out of operation for extended period - see 11.4 - 45 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 46: Troubleshooting

     Overheating of motor winding; possible causes: Failure of a phase, me- chanical failure due to lack of lubrication, lack of refrigerant, defects in refrigerant regulation, operation with incorrect refrigerant, excessive temperature of pressurised gas. 46 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 47: Safety Measures

    13.3 Refrigerator oil Use only the specified oil type (ester oil ICI Emkarate RL 32-3MAF); non- compliance will result in exclusion of warranty and certainly cause mal- functions. 47 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 48: Maintenance And Care

     Check setting of control.  Leak test: The statutory inspection intervals depend on the refrigerant volume. For more information, see the heat pump logbook. 48 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 49: Connection Diagrams

    Connection diagrams 15 Connection diagrams 49 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 50 Connection diagrams 50 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 51 Connection diagrams 51 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 52 Connection diagrams 52 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 53 Connection diagrams 53 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 54 Connection diagrams 54 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 55 Connection diagrams 55 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 56: Description Of The Parts In The Connection Diagram

    (heating and cooling) 2nd heat generator non-return valve regulating valve dirt trap motor-powered switch valve 56 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 57 (swimming pool) multiple-ply filter for poolwater cleaning poolwater - desinfection system ph – value control- and adjustment system poolwater – drain poolwater circulation pump 57 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

  • Page 58: Technical Data

    Technical Data 16 Technical Data Performance table EcoTouch DS 5027 Ai, DS 5027_Ai_NC und DS 5027_Ai_RC, with R410A, with A-class Pump 5008.5Ai_A 5010.5Ai_A 5012.5Ai _ A 5014.5Ai _ A 5017.5Ai _ A 5020.5Ai _ A 5023.5Ai _ A 5027.5Ai _ A Groundwater source heating 1.2/8.0...
  • Page 59 Technical Data 59 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.
  • Page 60 Technical Data WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne Tel.: 0049/(0)2323/9376-0, Fax: 0049/(0)2323/9376-99 Service: 0049/(0)2323/9376-350 E-Mail: info@waterkotte.de, Internet: http://www.waterkotte.de 60 / 60 2005/06/10 Copyright  2013 by: WATERKOTTE GmbH. Subject to changes.

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