Winterwarm HPX Installation Manual
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Winterwarm HPX Installation Manual

Monoblock heat pump
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Installation manual
Monoblock Heat Pump
type HPX
Version V03

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Summary of Contents for Winterwarm HPX

  • Page 1 Installation manual Monoblock Heat Pump type HPX Version V03...

  • Page 2: Table Of Contents

    Content Introduction .................................. 4 Symbols used in this manual ..........................4 Warranty ................................4 Reporting malfunctions: ............................4 Disclaimer: ................................4 Safety instructions ................................ 4 Installation by qualified personnel: ........................4 Service and inspection ............................4 The functioning principle of the Heat Pump ....................... 10 Technical data ................................
  • Page 3 Checklist ................................22 Test run:................................23 Daily usage and maintenance: ............................ 24 General maintenance ............................24 Important for usage in the winter ........................24 Regaining refrigerant ............................24 Putting out of operation ............................ 25 9. Malfunctions ................................... 26 9. 1 Malfunction index ..............................26 9.2 Error code list ................................

  • Page 4: Introduction

    1 Introduction This manual is intended for the installer of electrical and mechanical appliances. This document contains instructions to use and maintain the Heat Pump. It is imperative to read the instructions in this document with care, to install the appliances functionally and safely.
  • Page 5 WARNING! If the power cord is damaged, it must be replaced by the manufacturer, an authorized service agent, or a qualified person to avoid risks. WARNING! The appliance has to be installed in accordance with the national wiring requirements. This product is a kind of comfort-air conditioning and cannot be installed at places where corrosive, explosive, and combustible elements or smog are present.
  • Page 6 Shut off the power supply The power supply has to be a The user cannot modify the before cleaning the device. dedicated circuit with RCD connec�ons of the power (Residual Current Device) and cord, without being given needs to have sufficient capacity. permission in advance.
  • Page 7 Do not step on, or place Never block the air intake and Keep compressed air anything on the appliance. outlet of the device. cylinders, gas botles, and such at at least 1 meter distance of the appliance. Otherwise falling danger of This could reduce efficiency or lead objects or people may occur.
  • Page 8 The appliance needs to be stored properly to prevent mechanical damage PAY ATTENTION The appliance is filled with the flammable gas R32. Read the user manual before using the appliance. There is a special refrigerant in the appliance to guarantee the functionality of the heat pump. This refrigerant is the fluoride R32, which is specially treated.
  • Page 9 Repairs and maintenance of electrical components include initial safety checks and inspection procedures of the components. If there is a defect that could jeopardize safety, no electrical power should be connected to the circuit until the defect is resolved. If the defect cannot be fixed immediately. An adequate temporary solution should be used, this should be reported to the owner of the device, so all parties involved are aware.

  • Page 10: The Functioning Principle Of The Heat Pump

    3 The functioning principle of the Heat Pump The air-to-water heat pump consists of an outdoor unit, an internal fan heat exchanger, and an internal expansion vessel. Functions: Cooling; Heating; Emergency operation; Forced operating mode; Venting the water system. 1 Cooling: in the cooling mode the refrigerant is condensed in the outdoor unit and evaporated in the heat exchanger.

  • Page 11: Technical Data

    4 Technical data 4.1 Table with data HPX06A HPX12A HPX16A Heating capacity * 12,0 15,7 Absorbed electrical power 1,11 2,49 3,57 5,41 4,82 4,40 SCOP ** 5,041 4,584 4,556 Energy classroom heating ** (811/2013/EU) A+++ A+++ A+++ Seasonal energy efficiency for room heating (ηs, h) ** 198,7 180,3 179,2...

  • Page 12: Temperature Limits

    4.3 Temperature Limits The device has limitations in regard to functioning well in different outdoor temperatures. Mode Outdoor Temperature (°C) Water Temperature (°C) Hea�ng -25 - 35 20 - 65 Cooling -15 - 48 5 - 25 The influence of environmental temperatures and the maximum water temperature: Note: The environmental and water temperature both influence the functioning of the device 4.4 Maximum and minimum water pressure...

  • Page 13: Installation Of The Heat Pump

    5 Installation of the Heat Pump 5.1 General instructions PAY ATTENTION ! • The installation of the unit has to be in accordance with national and local safety precautions. • The quality of the installation has a direct influence on the performance of the heat pump. The installation has to be conducted by professionals who are familiar with heat pump installations.

  • Page 14: Usage Of Rubber Grommets

    5.2.3 Usage of rubber grommets Water return Water supply Use the long rubber grommets to connect the wiring. Separates the power cable from the control cable. Tie up the rubber rings after finishing the wiring connection. 5.3 Closing water side 5.3.1 Installation scheme A) Anti-frost valve (2x with the heat pump, not supplied) B) Automatical venting (2x with inlet AND outlet, not supplied)

  • Page 15: Expansion Tank And Water Content

    C) Pressure meter: To check if there is sufficient water pressure in the system, install a pressure gauge. (The pressure cannot be digitally read from the thermostat) D) Expansion Valve: The heat pump is provided with a pressure safety valve that opens when the water pressure becomes too high.

  • Page 16: Available External Static Pressure On The Exhaust Pipe

    5.3.8 Available external static pressure on the exhaust pipe HPX06A HPX12A, HPX16A Notes: See the curve above for the maximum external static pressure. The water pump has a variable frequency. While operating the water pump will change the power based on the actual loading. 5.3.9 Requirements for water quality To prevent issues in the water circuit, the water has to meet the quality criteria below.

  • Page 17: Electric Connection

    5.4 Electric connection 5.4.1 General principles • Cables, wires, devices, and connectors that are used at the loca�on, have to comply with the applicable regula�ons and technical requirements. • Only installers with the right qualifica�ons are allowed to operate the wiring at the loca�on. •...

  • Page 18: Unit Type Hpx06A, 1-Phase 230V Connection

    5.4.4 Unit type HPX06A, 1-Phase 230V connection Connections XT3 Connections XT1 Connections XT4 Supply 230V AC 5.4.5 Model type HPX12A / HPX16A 3-Phase +N 400V connection Connections XT3 Connections XT1 Supply 3P+N, 400V AC 5.4.6 Connecting the communication cable In all cases, the communication between the heat pump, air heater, and the thermostat is based on a four-wire low- voltage connection (refer to the electrical diagram).

  • Page 19: Other Optional Connections

    Connect the 4-core cable to the terminal strip as shown above. 5.4.7 Other optional connections The device has more optional connections, besides the power cable and control cable. These are not required when a (hybrid) air heater is used. Below is a short description of the optional connections: XT3: Not applicable to (hybrid) air heaters XT4 &...

  • Page 20: Activities Related To The Refrigerant Circuit

    6 Activities related to the refrigerant circuit 6.1 General • Generally, NO actions have to be performed on the refrigerant circuit during the installation. There is no F- gasses certification requirement for the installation. • Actions on the refrigerant circuit can only be done by certified individuals. 6.1.1 Safe usage of flammable refrigerants 6.1.1.1 Qualification requirements for installation and maintenance...

  • Page 21: Filling And Draining The Refrigerant

    Filling and draining the refrigerant The device will be filled with refrigerant prior to delivery. A shortage or excess of refrigerant can lead to suboptimal functioning of the compressor or damage. When filling or draining refrigerant is necessary during the installation, for maintenance or other reasons, follow the steps below and the quantity mentioned on the rating plate.

  • Page 22: Commissioning

    requiring soldering is found, all refrigerant must be recovered or isolated (Using shut-off valves) in a part of the system away from the leak. Oxygen-free nitrogen has to be flushed through the system both before and during the soldering process. Use a suitable refrigerant leak detector to monitor the environment before and during PAY ATTENTION! use, ensuring that technicians can be well-informed of poten�al or actual leakage of flammable gas.

  • Page 23: Test Run

    7.2 Test run: Before starting the testing, check the following: The main power switch must be easily accessible so that in case of abnormal operation, the device can be quickly powered off. This can prevent damage to the device and ensure safety for individuals. Before starting up the device, it should be powered on for 8 hours.

  • Page 24: Daily Usage And Maintenance

    8 Daily usage and maintenance: 8.1 General maintenance To prevent damage to the device, all safety components are adjusted and sealed. Do not modify or remove them. During the ini�al start-up of the device or a�er a long period of inac�vity (more than 1 day) with the power cut off, it is necessary to preheat the device by applying power for at least 8 hours.

  • Page 25: Putting Out Of Operation

    Do not mix refrigerants in recovery equipment, especially not in cylinders. If compressors or compressor oil are being removed, ensure they are evacuated to an acceptable level to ensure no flammable refrigerant remains in the lubrica�ng oil. The evacua�on process should be carried out before returning the compressor to suppliers.

  • Page 26: Malfunctions

    9. Malfunctions 9. 1 Malfunction index Malfunctions Reasons Solutions The compressor does not start. An issue with the power supply or The phase sequence is reversed. Turn off and repair again. Find the cause and repair. the connection wire is loose. Replace the compressor.
  • Page 27 Code-indica�on Error name Origin of error Descrip�on on the control element ① The plug of the temperature sensor is not correctly It will be automa�cally cleared connected to the Outlet temperature sensor a�er the defect has been motherboard. error resolved. ②...
  • Page 28 Code-indica�on Error name Origin of error Descrip�on of the control element ①The plug of the communica�on cable is not correctly connected to the contact of the motherboard. ② The communica�on cable is defect. It will be restored as soon as the ③...
  • Page 29 Code-indica�on Error name Origin of error Descrip�on on the control element ① The plug of the temperature sensor is not correctly First sanitary (potable) water It will be automa�cally cleared connected to the contact on ② The resistance of the tank temperature sensor error a�er the defect has been the motherboard.
  • Page 30 Errors of the inverter: Display on segment Display on the wired Func�on Others display controller of the device Reset of the drive system Reset of the drive system Startup error of the Startup error of the compressor compressor Phase protec�on Phase protec�on Power protec�on of the Power protec�on of the...

  • Page 31: Flow Chart Troubleshooting

    9.3 Flow chart troubleshooting 9.3.1 Compressor high-pressure protection E1 Compressor high-pressure protection E1 Replace the high-pressure Is the high-pressure switch switch defective? Is the wiring of the high-pressure Replace the wiring switch loose? Is there a sufficient amount of Fill the system water in the system? Is the temperature sensor Install the temperature...

  • Page 32: Compressor Low-Pressure Protection E3

    9.3.2 Compressor Low-pressure protection E3 Compressor low pressure security E3 Is the low-pressure switch broken Replace or reconnect the low or is the wiring disconnected? pressure switch Check the ventilator Does the ventilator stop or turn the wrong way? Repair the leak and add Has the system leaked? refrigerant to the required quantity.

  • Page 33: Compressor Discharge Temperature Protection E4

    9.3.3 Compressor discharge temperature protection E4 Compressor discharge temperature protection E4 Does the discharge Replace the Is the resistance of the temperature reach 120°C? temperature sensor. sensor incorrect? Replace the motherboard of the outside unit. Is the electronic Replace the electronic expansion expansion valve valve broken?

  • Page 34: Temperature Sensor Error

    9.3.5 Temperature sensor error Temperature sensor error Is the plug of the temperature sensor Connect properly correctly placed in the socket? Replace the Is the resistance of the temperature sensor correct? temperature sensor Replace the motherboard 9.3.6 Communication error E6 Communication error E6 Is the communication of Install the wiring...

  • Page 35: Flow Chart Diagnosis Of The Pcb

    9.5 Flow chart diagnosis of the PCB 9.5.1 PFC-flashing E5 is displayed on the wired controller Monitoring Segment display of the screen motherboard PFC error Hc is displayed Inspect the motherboard 1 minute after powering off whether the bus voltage is lower than Is it wet, dirty or short-circuited Dry and clean...

  • Page 36: Ipm-Protection

    9.5.2 IPM-protection The reasons could be: • Loose screws of the IPM module • Damaged IPM module • Abnormal +15V power strip • Abnormal PFC-module • Wire connecting error with PFC • Wrong selection resistor RS1-RS3 on the PCB • Abnormal operation of the compressor •...

  • Page 37: Switching

    9.5.3 Switching Fuse(s) of outdoor unit have blows/ switched off Has the RCD swiched Is the switching capacity sufficient? Does the fuse/switch switch -off during start -up The residual current The system is abnormal. Install electric is too high. Check Check the wiring and coils fuses in the residual current...

  • Page 38: Abnormal Sound Of The Pfc-Inductor

    9.5.4 Abnormal sound of the PFC-inductor During normal operation, a continuous and monotonous sound of the inductor can be heard. An abnormal sound of the PFC-inductor could be discontinuity or an dissenting sound. This can be caused by: • PFC-failure •...

  • Page 39: Protection Against Overheating Of The Radiation

    9.5.5 Protection against overheating of the external coil E5 is displayed on the wired controller segment display of Monitoring the motherboard screen Protection against P8 is displayed temperatures that are too high. If the air outlet and return air Is the heat passages of the outdoor unit dissipation of the are blocked, the heat...

  • Page 40: Overvoltage Protection Of Dc-Bus

    9.5.6 Overvoltage protection of DC-bus E5 is displayed on the wired controller Segment display of the Monitoring motherboard screen Overvoltage protection of DC P8 is displayed Is the input voltage within the operating range (185~264VAC)? Does it happen while the compressor is operating? Does it occur during the Does it occur 6 times...

  • Page 41: Undervoltage Protection Of Dc-Bus

    9.5.7 Undervoltage protection of DC-bus E5 is displayed on the wired controller Protection Segment display of screen the motherboard No voltage PL is displayed protection Is the voltage within the range 185~264VAC? Does it happen while the compressor is operating? Has it occurred 6 times Does it occur when the compressor starts?

  • Page 42: Electrical Wiring Scheme

    10 Electrical wiring scheme 10.1 Control board HPX06A / HPX12A / HPX16A Screen Introduction printing AC-L Live power wire Neutral power wire To ground E-heating of the water tank E-heater 1 E-heater 2 Other heating by 230VAC External water pump Reserved Reserved 2-way valve 1 is normally open...
  • Page 43 Screen Introduction printing Water pump of the water reservoir Reserved External 3-way valve 1 Reserved Electrical three-way valve 2 open Electrical three-way valve 2 closed CN18 Built-in water pump signal (PWM) CN19 Backup water pump signal (PWM) -field supply CN15 20K temperature sensor (inlet water) CN15 20K temperature sensor (outlet water)
  • Page 44 Screen printing Introduction AC-L L power supply Neutral wire of the power supply PWR1 310V supply 310V direct current of the drive Fuse 4-way valve VA-1 E-heating chassis HEAT Electrical heating tape 1-pins: fan supply; 3-pins: fan GND; 4-pins: +15V; DC-MOTOR 5-pins: control signal;...
  • Page 45 For the HPX06A Screen printing Introduction AC-L L-OUT Live input of the filter board N-OUT Neutral line input of the filter board L1-1 To PFC inductor brown cable L1-2 To white wire PFC-inductor L2-1 To yellow wire PFC-inductor L2-2 To blue wire PFC-inductor COMP Wiring board (3-pin)(DT-66BO1W-03)(variable frequency) COMM...
  • Page 46 For the models HPX06A, HPX012A, HPX16A Screen Introduction printing Connection to the compressor phase-W Connection to the compressor phase-U Connection to the compressor phase-V Connection to the inverter board (entrance) T-2. S-1. Connection to the inverter board (entrance) T-1. Connector to the filter L1-F Connector to the filter L2-F Connector to the filter L3-F Comm1...
  • Page 47 HPX06A Screen printing Introduction AC-L Live supply wire of motherboard Neutral supply wire of motherboard L-OUT Live line output of the filter board (to the drive and main boards) N-OUT Neutral line output of the filter board (to the drive board) N-OUT1 Output neutral line L-OUT1...
  • Page 48 For the models HPX12A / HPX16A, Zeefdruk Inleiding AC-L1 Entrance side phase L1 of the entire unit AC-L2 Entrance side phase L2 of the entire unit AC-L3 Entrance side phase L3 of the entire unit Entrance side neutral line of the entire unit L1-F Connect to the power input of the drive card L2-F...

  • Page 49: Disassembly Of The Device

    11 Disassembly of the device Note: First, turn off the power supply and remove the refrigerant from the device. Procedure Illustration HPX06A Remove the mounting bolts, top cover, front panel, and right panel. Pg. 49...
  • Page 50 Note: First, turn off the power supply and remove the refrigerant from the device. Procedure Illustration HPX06A Remove the mounting bolts, side panel, connector panel, and support. (upright column) Remove the mounting bolts and the outer protective cover. Remove the mounting bolts and the cover of the electrical box.
  • Page 51 Note: First, turn off the power supply and remove the refrigerant from the device. Procedure Illustration HPX06A Desolder the connection points of the 4-way valve, and remove the pipes of the 4-way valve. Note: When desoldering the connection, make sure to cover the solder joints with a damp cloth to prevent damage at high temperatures.
  • Page 52 Note: First, turn off the power supply and remove the refrigerant from the device. Procedure Illustration HPX06A Remove the mounting bolts and then remove the fan. Remove the mounting bolts of the motor and motor support, and then move them. Remove the mounting bolts and then separate the condenser from the base.
  • Page 53 Note: First, turn off the power supply and remove the refrigerant from the device Procedure Illustration HPX12A – HPX16A Remove the top panel, front panel, and right panel. Remove the mounting nuts, then the back panel, connection panel, and standing frame. Remove the mounting nuts, then the front grille.
  • Page 54 Note: first, turn off the power supply and remove the refrigerant from the device Procedure Illustration HPX12A – HPX16A Remove the covers of both the electrical box and the inductor box. Remove the electrical box and the inductor box. Remove the mounting bolts, desolder the connections between the gas/liquid lines of the plate heat exchanger and the cooling system, and then remove the water system.
  • Page 55 Note: First, turn off the power supply and remove the refrigerant from the device Procedure Illustration HPX12A – HPX16A Remove the suction line • Loosen the bolts of the gas valve. • desolder the line connected to the gas valve. •...

  • Page 56: Recycling The Device

    Note: First, turn off the power supply and remove the refrigerant from the device. Procedure Illustration HPX12A – HPX16A Remove the mounting bolts and motor support nuts, then remove the motor and motor support. Separate the condenser from the base by removing the attachment bolts.

  • Page 57: Declaration Of Conformity

    13 Declaration of conformity Declaration of conformity Winterwarm Heating Solutions B.V. Olden Goorweg 1 7108 AE Winterswijk The Netherlands Declares that Heat pump types: HPX06A, HPX12A, HPX16A Are in accordance with the essential requirements of the relevant EU directives being:...

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