Index Safety ................................4 General ..................................4 Intended use .................................. 4 Explanation of symbols ..............................5 Personnel requirements ..............................6 Special dangers ................................6 Standards and Regulations ........................9 Standards and Regulations ............................9 Transport, Packaging, Storage ........................ 12 Safety notes for transport............................. 12 Inspection of the delivery .............................
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Index Operation startup ............................57 Safety during startup ..............................57 Inspection before startup ............................. 57 Startup ..................................58 Setting the controller ..............................60 Parameterization ................................. 61 Startup protocol ................................61 Maintenance ............................... 62 Maintenance ................................62 Components relevant to safety ............................ 63 Work activities to be performed ...........................
1. Safety ThermiStar L .. SP 01/03/10 Safety General The assembly, startup and maintenance instructions are addressed to technicians of professional heating companies. Contains important information for safe handling of the device. Compliance with all specified safety information and handling instructions is the prerequisite for safe working.
1. Safety ThermiStar L .. SP 01/03/10 Explanation of symbols This sections provides an overview of all important safety aspects for optimal personal protection as well as for safe and troublefree operation. The handling instructions and safety notes specified in these instructions must be followed to prevent accidents, personal injuries and property damages.
1. Safety ThermiStar L .. SP 01/03/10 Personnel requirements WARNING! Danger to life if not sufficiently qualified! Improper handling leads to considerable personal injuries and property damages. Therefore: - Assembly, startup and maintenance work, repairs or modifications of the set fuel amounts may only be done by a heating and/or air conditioning pro- fessional.
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1. Safety ThermiStar L .. SP 01/03/10 Electrical current DANGER! Danger of life through electric current! Touching live parts presents an immediate danger to life. Damages to the insulation or individual components can present a danger to life. Therefore: - In case of damaged insulation, immediately cut off the power supply and initiate the repair.
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1. Safety ThermiStar L .. SP 01/03/10 CAUTION! Risk of injury due to refrigerant! Refrigerant is corrosive and causes cold burns upon contact with skin. Therefore: - Wear chemical-resistant protective gloves when handling refrigerant at any time. - Wear protective glasses to avoid contact with eyes.
2. Standards and Regulations ThermiStar L .. SP 01/03/10 Standards and Regulations Standards and Regulations The following standards and regulations must be observed with the installation and operation of the heating system. Standards Publication Standards Title date Heating systems in buildings, safety DIN EN 06.2003...
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2. Standards and Regulations ThermiStar L .. SP 01/03/10 Stipulations The erection and operation of the heating system requires compliance with the technical building supervision rules as well as other legal stipulations of the individual countries. Publication Stipulations Title date...
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2. Standards and Regulations ThermiStar L .. SP 01/03/10 Additional Standards / Regulations for Switzerland Assembly, startup and maintenance may only be performed by certified installation companies. Work on electrical system components may only be performed by a licensed electrician.
3. Transport, Packaging, Storage ThermiStar L .. SP 01/03/10 Transport, Packaging, Storage Safety notes for transport CAUTION! Damage through improper transport! Significant property damage may be incurred by improper transport. Therefore: - Be careful when unloading packaging items upon delivery as well as during in-plant transport and obey the symbols on the packaging.
3. Transport, Packaging, Storage ThermiStar L .. SP 01/03/10 Notes on storage The shaft of the boiler pump may seize during extended storage. This is not a defect. Please see the chapter "Pump control" on page Error! Bookmark not defined..
RVS 61.843 and control unit AVS 37.294 Heating circulation pump (up to L 28) Connector for additional electric heater 6.0 kW From ThermiStar L 10 SP with soft-start control Module for thawing the split evaporator via hot-gas bypass con- trols...
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4. General ThermiStar L .. SP 01/03/10 Control unit QAA 78 94.88147-5021 Radio-controlled control unit optional use as control unit, service unit or room unit. Setting of all parameters in the RVS controller, range of radio connection approx. 30 m Radio module AVS 13.399/201...
5. Technical Data ThermiStar L .. SP 01/03/10 Technical Data Dimensions and connection ratings Connections at rear wall of heat pump Sk09-6200-121 Stand: 06.11.09 Sk09-6200-023_a Stand: 06.11.09 Fig. 1:Connections at rear wall of heat pump L05 to L15 Fig. 2:Connections at rear wall of heat pump L19 to L41...
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5. Technical Data ThermiStar L .. SP 01/03/10 Erection measurements and dimensions, split evaporator for ThermiStar L .. SP Fig. 3: Erection measurements and dimensions, split evaporator for ThermiStar L .. SP Legend for Fig. 3: ThermiStar … SP Abbr.
5. Technical Data ThermiStar L .. SP 01/03/10 Type plate Fig. 4: Sample type plate...
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5. Technical Data ThermiStar L .. SP 01/03/10 Legend for Fig. 4: Abbr. Meaning Type Part number / Item number Country of destination Serial number Refrigerant Refrigerant capacity Output A2/W35 Output B0/W35 Output W10/W35 Output W7/W35 Rated thermal output max. positive operating pressure max.
5. Technical Data ThermiStar L .. SP 01/03/10 Electrical data Wiring diagram for ThermiStar L 05 SP - L 07 SP with expansion set up to 7 kW Sk09-6200-018_c Stand: 09.02.2010 Fig. 5: Wiring diagram for ThermiStar L 05 SP - L 07 SP with expansion set up to 7 kW...
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5. Technical Data ThermiStar L .. SP 01/03/10 Legend for Fig. 5: Abbr. Meaning Abbr. Meaning Refrigerant temperature liquid - When using fault current circuit breakers, Condensor pump observe separate neutral leads for normal Performance limit and special tariff! Motor...
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5. Technical Data ThermiStar L .. SP 01/03/10 Wiring diagram for ThermiStar L 10 SP - L 19 SP with expansion set 10-20 kW Sk09-6200-019_c Stand: 09.02.2010 Fig. 6: Wiring diagram for ThermiStar L 10 SP - L 19 SP with expansion set 10-20 kW...
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5. Technical Data ThermiStar L .. SP 01/03/10 Legend for Fig. 6: Abbr. Meaning Abbr. Meaning Performance limit - When using fault current circuit breakers, observe separate neutral leads for normal Motor and special tariff! Condenser motor - Observe identical phase potential of the...
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5. Technical Data ThermiStar L .. SP 01/03/10 Wiring diagram for ThermiStar L 28 SP - L 41 SP with expansion set >25 kW Sk09-6200-020_c Stand: 09.02.2010 Fig. 7: Wiring diagram for ThermiStar L 28 SP - L 41 SP with expansion set >25 kW...
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5. Technical Data ThermiStar L .. SP 01/03/10 Legend for Fig. 7: Abbr. Meaning Abbr. Meaning Refrigerant temperature liquid - When using fault current circuit breakers, observe separate neutral leads for normal Condensor pump and special tariff! Performance limit - Observe identical phase potential of the...
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5. Technical Data ThermiStar L .. SP 01/03/10 Sensor positions 49.0 42.2 42.3 48.1 48.0 Fig. 8: Sensor positions Legend for Fig. 8: Descrip- terminal Meaning tion RVS 61 Temperature sensor Sensor heat pump flow 42.2 Sensor heat pump return 42.3...
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5. Technical Data ThermiStar L .. SP 01/03/10 Legend for Fig. 9: Abbr. Meaning Abbr. Meaning Outside temperature sensor Multifunctional sensor input 4 MFE4 connector k, terminals M, B9 (functions see MFE1) connector x, terminals M, BX4 Service tool OCI 700...
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5. Technical Data ThermiStar L .. SP 01/03/10 Electrical controller data Rated voltage AC 230 V (± 10%) Rated frequency 50/60 Hz Max. power consumption 11 VA Input (Controller) Fuse protection of supply lines max. 10 AT Wire gauge 1 wire: 1.0 mm - 1.5 mm...
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5. Technical Data ThermiStar L .. SP 01/03/10 2-wire connection, not interchangeable Max. line length Basic unit - peripheral unit 200 m Max. total line length 400 m (Max. cable capacity: 60 nF) Min. wire gauge 0.5 mm Interfaces Cu cable 1.5 mm2, 2-wire, not interchangeable...
6. Assembly ThermiStar L .. SP 01/03/10 Assembly Safety during assembly WARNING! Risk of injury due to improper assembly! Improper assembly leads to serious personal injuries and property damages. Therefore: - The assembly and startup must be performed by an authorized heating and/or air conditioning profes- sional.
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6. Assembly ThermiStar L .. SP 01/03/10 WARNING! Risk of life through fire! Easily flammable materials or liquids can catch fire. Therefore: - Do not use or store explosive or easily flammable substances (i.e. fuel, paints, paper, wood) in the area where the device is installed.
6. Assembly ThermiStar L .. SP 01/03/10 Assembly tools The assembly and maintenance of the heating system requires standard tools from the field of heating installations, cooling installa- tion technology, as well as water systems installations. Assembly information CAUTION! Environmental damage through substances...
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6. Assembly ThermiStar L .. SP 01/03/10 Refrigerant The safety datasheet concerning refrigerant R 410A is available for download at www.mhg.de\Download\Sicherheitsdatenblätter. NOTE! In case of emergencies, ring the telephone number below: +44(0)208 762 83 22 [CareChem 24] (Europe) WARNING! Danger of life through lack of oxygen! Vapors of the refrigerant R 410A are heavier than air and may cause suffocation by displacing oxygen.
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6. Assembly ThermiStar L .. SP 01/03/10 Welding work NOTE! If any welding work is scheduled on the refrigerant line, a protective gas (i.e. nitrogen) will need to be passed through the pipe in order to prevent scale formation. Scale and other contamination can impair the proper operation of the device leading to disor- ders.
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6. Assembly ThermiStar L .. SP 01/03/10 CAUTION! Environmental damage due to improper assembly of the refrigerant line! Refrigerant and compressor oil can leak! Therefore: - Only use tools recommended for work on cooling devices: Bending pliers, pipe cutters, countersink...
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6. Assembly ThermiStar L .. SP 01/03/10 NOTE! Ball valves must remain shut (delivery condition)! Fig. 10: Connection split evaporator Legend for Fig. 10: Abbr. Meaning Fluid line Suction gas line Hot-gas line Sensor cable heat source evaporation...
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6. Assembly ThermiStar L .. SP 01/03/10 Installation of the heat pump The heat pump is delivered standing on a wooden pallet. Remove the foil/packaging and install the heating pump in accor- dance with the following steps. Fig. 12: Heating pump without enclosure Fig.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 14: Pre-assemble the enclosure ass seen in the image prior to installing the hydraulic and cooling lines. CAUTION! Water damage through condensation or humidity in the air! Extremely low temperatures at the refrigerant lines lead to condensation or humidity in the air and can cause water damage.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 15: Place the counter nut into the insulation and screw in the cable gland.
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6. Assembly ThermiStar L .. SP 01/03/10 Connection of split evaporator with heat pump CAUTION! Risk of injury due to refrigerant! Refrigerant is corrosive and causes cold burns upon contact with skin. Therefore: - Wear chemical-resistant protective gloves when handling refrigerant at any time.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 16: Heat pump connections Legend for Fig. 16: Abbr. Meaning Fluid line Suction gas line Hot-gas line Evacuate the suction, liquid and hot-gas lines. Connect the devices to the Schrader valves for evacuation (see Fig. 10).
6. Assembly ThermiStar L .. SP 01/03/10 Hydraulic connection Requirements on the heating water To prevent corrosion damages in the heating system, heating water in potable quality must be used under consideration of the requirements according to VDI guideline 2035 "Preventing damages in warm water heating systems".
6. Assembly ThermiStar L .. SP 01/03/10 Electrical connection DANGER! Danger of life through electric current! Contact with live components represents a risk to life. Activated electrical components can perform uncontrolled movements and cause serious injuries. Therefore: - Make sure that all electrical parts are without current.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 19: Electrical connection Legend for terminal diagram electrics board: The electrical connection is made according to the wiring diagram in chapter 5.4. The circuit protection in the distributor (meter cabinet) must be made with a 3-pole power circuit breaker (C-characteristics) according to the output ratings of the heat pump.
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6. Assembly ThermiStar L .. SP 01/03/10 Highly reliable spring clips are used as connection terminals. The clips are opened with the appropriate included tool (e.g. small screw driver) which is inserted in the respective square opening and is then moved in the direction away from the lead intake opening.
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6. Assembly ThermiStar L .. SP 01/03/10 Enclosure assembly Fig. 22: Snap the catches of the side panel of the enclosure into the rear panel. Fig. 23: Fix side panels on the rear panel of the enclosure.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 24: Insert the spring plates in the side enclosures. Fig. 25: Snap the front panel onto the catches of the side panel.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 26: Screw the closing journals into the lid of the enclosure. Fig. 27: Position the lid. Fig. 28: Insert the bracket.
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6. Assembly ThermiStar L .. SP 01/03/10 Fig. 29: Screw in the upper wing nut of the bracket. Fig. 30: Screw in the lower wing nut of the bracket. Fig. 31: Reach through the opening of the bracket to remove the...
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6. Assembly ThermiStar L .. SP 01/03/10 Motor control unitRSHL 4818 for ThermiStar L 10 bis L 19 Fig. 32: Operational diagram RSHL 4818 Legend for Fig. 32: Abbr. Meaning LED indication Push button Setting to 1 Current settings Multiplier/Current Limit...
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6. Assembly ThermiStar L .. SP 01/03/10 Status LED in- dications Flashing Green Power OFF Not available Power ON Yellow Idle / Setup Ramping* Bypass ON Internal overheat Motor overheat alarm* alarm Phase sequence Not available Phase loss alarm alarm*...
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6. Assembly ThermiStar L .. SP 01/03/10 Motor control unitRSHR 4025 for ThermiStar L 28 Fig. 33: Operational diagram RSHR 4025 Legend for Fig. 33: Abbr. Meaning Set warm-up time to value 1 Set cool-off time to value 0 Set warm-up torque to 25%...
7. Operation startup ThermiStar L .. SP 01/03/10 Operation startup Safety during startup WARNING! Risk of injury due to improper operation! Improper operation leads to serious personal injuries or property damages. Therefore: - Installation and assembly must be performed by a heating systems dealer.
7. Operation startup ThermiStar L .. SP 01/03/10 Startup NOTE! The customer / owner of the system must be present when starting up the system. A startup protocol must be established on site. NOTE! For operators of equipment containing 3 kg or more...
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7. Operation startup ThermiStar L .. SP 01/03/10 Pump control Circulating pump control Unscrew pump stopper and turn pump shaft as illustrated below. Screw pump stopper back in Caution: Collect drops Fig. 34: Remove pump stopper Switching on the device Once the proper installation verification and testing has been com- pleted, the power can be switched on.
7. Operation startup ThermiStar L .. SP 01/03/10 Setting the controller Control unit AVS 37 Fig. 35: Control unit AVS 37 Legend for Fig. 35: Abbr. Meaning Select drinking water mode Service connector for BSB data BUS Exit settings Select heating mode...
7. Operation startup ThermiStar L .. SP 01/03/10 Parameterization At this point, MHG refers to the Assembly-Operation-Maintenance manual RVS 61.843 / AVS 37.. / QAA 75.. / QAA 78.. (Part No. 98.18803-6105) The factory parameters can be taken from the table on the pages 86-87.
8. Maintenance ThermiStar L .. SP 01/03/10 Maintenance Maintenance NOTE! The respective regulations and guidelines of the country of destination must be complied with! NOTE! Depending on the refrigerant dosage, the system op- erator must have the system inspected at least every 12 months.
8. Maintenance ThermiStar L .. SP 01/03/10 Components relevant to safety To ensure the long-term availability and safety of heat generators and components and to meet the requirements of the EU guideline 2002/91/EG, the following components must be replaced after they have reached the nominal service life, specified by the manufacturer in terms of time or switching cycles.
8. Maintenance ThermiStar L .. SP 01/03/10 Work activities to be performed CAUTION! Risk of injury due to refrigerant! Refrigerant is corrosive and causes cold burns upon contact with skin. Therefore: - Wear chemical-resistant protective gloves when handling refrigerant at any time.
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8. Maintenance ThermiStar L .. SP 01/03/10 Confirm the work activities performed in the following maintenance protocol with an X or a . Maintenance activities Description Done Document amount and type of refrigerant used Document any amounts of refrigerant refills...
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8. Maintenance ThermiStar L .. SP 01/03/10 Disassembly of the control unit NOTE! Loosen the catches with a screwdriver. Ensure that the catches are not broken off when dismantling the control unit. Fig. 36: Insert a screw driver according to the above illustration...
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8. Maintenance ThermiStar L .. SP 01/03/10 Fig. 38: Remove the control unit from the bracket. Fig. 39: Reach the control unit through the opening of the bracket an d store inside.
9. Troubleshooting ThermiStar L .. SP 01/03/10 Troubleshooting Troubleshooting Faults and their removal If while the heat pump is running the heat discharge is suddenly interrupted (e.g. by a stopped heating circulation pump or closed valves), the high pressure safety limiter in the heat pump may be triggered (due to the thermal inertia of the system).
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9. Troubleshooting ThermiStar L .. SP 01/03/10 Troubleshooting Fault Cause Remedy Defect on input Ventilator(s) is/are not running Check fuse, check relay side Check control signal 0-10 V (LP fault) Condenser dirty/iced over Clean condenser, initiate thawing; check temperatures on condenser...
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9. Troubleshooting ThermiStar L .. SP 01/03/10 Fault Cause Remedy Failure of a phase Check supply line of 3-phase current Fault in compres- sor motor, com- Mechanical failure due to lack of lubrication Request factory service pressor overload Winding protection defective...
10. Warranty ThermiStar L .. SP 01/03/10 Warranty 10.1 Warranty Limit of liability All specifications and information in these installation instructions were compiled under consideration of the applicable standards and regulations, the state of technology as well as our experience and insights of many years.
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10. Warranty ThermiStar L .. SP 01/03/10 Warranty The ThermiStar heat pump by MHG renders its perfect function only when installed and started professionally. Warranty conditions of MHG can be taken from the warranty certificate. Spart parts NOTE! Use only original MHG spare parts in case of...
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10. Warranty ThermiStar L .. SP 01/03/10 2. Wearing parts Wearing parts are such parts which must be replaced several times within the scope of service life while the product is used as intended (e.g. during maintenance). 3. Auxiliary materials Auxiliary materials are required with the repair and maintenance of devices.
10. Warranty ThermiStar L .. SP 01/03/10 10.2 Manufacturer Certificate / EU Design Conformity Declaration Manufacturer Certificate Buchholz, 27.05.2009 MHG Heiztechnik GmbH hereby certifies the following for the heat pumps listed below: The heat pumps are equipped with different safety circuit devices for pressure limitation in the refrigerant cycle in compliance with DIN 32733.
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10. Warranty ThermiStar L .. SP 01/03/10 EU Design Conformity Declaration According to EG Machine Guideline Buchholz, 27.05.2009 MHG Heiztechnik GmbH hereby declares that the ThermiStar heat pumps comply with the following EU guidelines and standards: EU Guideline Standard Machine guideline...
ThermiStar L .. SP 01/03/10 10.3 Proof of Service Maintenance protocol Heat Pump ThermiStar L .. SP / LZ .. SP Customer: Maintenance contract/Customer No.: The following work was carried out on your heating system in the context of your yearly maintenance:...
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10. Warranty ThermiStar L .. SP 01/03/10 1. Maintenance 2. Maintenance Amount of Amount of refrigerant refrigerant refilled refilled Amount of Amount of refrigerant refrigerant retrieved retrieved Electric meter Electric meter reading reading Heat meter Heat meter reading reading Leak-tightness...
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10. Warranty ThermiStar L .. SP 01/03/10 3. Maintenance 4. Maintenance Amount of Amount of refrigerant refrigerant refilled refilled Amount of Amount of refrigerant refrigerant retrieved retrieved Electric meter Electric meter reading reading Heat meter Heat meter reading reading Leak-tightness...
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10. Warranty ThermiStar L .. SP 01/03/10 5. Maintenance 6. Maintenance Amount of Amount of refrigerant refrigerant refilled refilled Amount of Amount of refrigerant refrigerant retrieved retrieved Electric meter Electric meter reading reading Heat meter Heat meter reading reading Leak-tightness...
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10. Warranty ThermiStar L .. SP 01/03/10 7. Maintenance 7. Maintenance Amount of Amount of refrigerant refrigerant refilled refilled Amount of Amount of refrigerant refrigerant retrieved retrieved Electric meter Electric meter reading reading Heat meter Heat meter reading reading Leak-tightness...
11.1 Hydraulic diagrams NOTE! The hydraulic scheme serves as an installation suggestion (without claim to completeness). Addi- tional parts required must be provided by the customer/contractor. Air/Water heat pump ThermiStar L with change-over valve heating/warm water 41.0 43.0 64.0 42.2 22.0...
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11. Hydraulic diagrams ThermiStar L .. SP 01/03/10 Components Component Type Part number Remark 98.30000-6324 L 05 SP L 07 SP 98.30000-6326 L 10 SP Included in scope of delivery: 98.30000-6328 L 13 SP Controller RVS 61.843 98.30000-6330 MHG ThermiStar L L 15 SP 98.30000-6332...
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42.2 22.0 43.0 48.0 42.3 49.0 48.1 Fig. 42: Sk09-6200/022 Air/Water heat pump ThermiStar L with change-over valve heating/warm water and buffer reservoir Legend for Fig. 42: Abbr. Meaning Abbr. Meaning Ventilator 1 Filter 22.0 Sensor outside 1 (terminal B9) Fluid line 41.0...
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11. Hydraulic diagrams ThermiStar L .. SP 01/03/10 Components Component Type Part number Remark 98.30000-6324 L 05 SP L 07 SP 98.30000-6326 L 10 SP Included in scope of delivery: 98.30000-6328 L 13 SP Controller RVS 61.843 98.30000-6330 MHG ThermiStar L L 15 SP 98.30000-6332...
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11. Hydraulic diagrams ThermiStar L .. SP 01/03/10 Factory parameterization Setting value Control User Function / Default value L 19 - L 34 - line level L 05 - 15 561-566 Timer setting 4 Monday 05:00 – 21:00 561-566 Timer setting 4 Tuesday 05:00 –...
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11. Hydraulic diagrams ThermiStar L .. SP 01/03/10 Setting value Control User Function / Default value L 19 - L 34 - line level L 05 - 15 Sensor input BX2 None ¦ Buffer reservoir sensor B4 ¦ Buffer reservoir sensor B41 ¦...
Hot surfaces ................ 7 Wearing parts.............. 63, 74 Welding work ..............36 Wiring diagram for ThermiStar L 05 SP – L 07 SP .... 22 Wiring diagram for ThermiStar L 10 SP - L 19 SP .... 24 Installation clearances ............33 Wiring diagram for ThermiStar L 28 SP - L 41 SP ....
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