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Summary of Contents for elco AEROTOP EVO (PLUS)
- Page 1 Installation, operation and maintenance manual AEROTOP EVO (PLUS) 1 / UK www.elco.net Art. No.420011332000—12/2023...
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Page 2: Table Of Contents
Contents Safety considerations ................6 Safety ....................... 6 Manual......................6 Risk situations ....................6 Intended Use....................6 Installation ...................... 6 Maintenance ....................6 Modification ....................6 Breakdown/Malfunction.................. 6 User training ....................6 Data update ....................6 Original instructions ..................6 Indications for the User ................ - Page 3 Contents Water filter ....................19 Non-return valve ..................19 Hydronic units and connection diagrams recommended ......20 Unit + pump ....................20 Operation sequence ..................21 Electrical connections ................22 Electrical data ....................22 Connections ....................22 Power supply network requirements ............22 Signals / data lines ..................
- Page 4 Contents Wires ......................44 Leak detection methods ................44 Removal and evacuation ................44 Charging operations ..................44 Dismantling ....................44 Labelling ......................45 Recovery ....................... 45 Transport, mark and storage ................ 45 Maintenance .................... 46 Safety......................46 General......................46 Inspections frequency ..................
- Page 5 Contents Single/multiple pump system ............... 53 Addressing ....................54 Remote ON-OFF ..................54 Start-up ......................54 Alarms......................54 Modbus ....................55 Communication specifications: RS - 485 ............55 5 / UK...
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Page 6: Basic Information
Basic Information Safety considerations Safety Installation Operate in compliance with safety regula- tions in force. Outdoor installation To carry out the operations use protection The positioning, hydraulic system, refriger- devices: ating, electrics and the ducting of the air gloves, goggles, helmet, headphones, pro- must be determined by the system design- tective knee pads. -
Page 7: Indications For The User
Indications for the User Keep this manual with the wiring diagram Serial number in an accessible place for the operator. It identifies uniquely each unit. Note the unit data label so you can provide Must be quoted when ordering spare them to the assistance canter in case of parts. -
Page 8: Information On Refrigerant Gas
Information on refrigerant gas WARNING This product contains fluorinated greenhouse gases covered by the Kyoto protocol. Do not discharge gas into air. Refrigerant characteristics Type of refrigerant Safety class (ISO 817) Quantity of refrigerant charged at the factory and tons of equivalent CO2: Size Refrigerant (Kg) Ton CO2 eq. -
Page 9: Accessories Supplied
Accessories supplied DHW tank temperature probe Taf1 DHW tank antifreeze probe Outlet water probe (pre-installed on the unit’s supply pipe) Probe well Transformer for keypad power supply Victaulic hydraulic pipe connection joints 9 / UK... -
Page 10: Before Installation
Before installation Reception WARNING Provide personnel with personal pro- You have to check before accepting the The unit may not be tilted more than 15° tective equipment suitable for the delivery: during transport. situation, such as helmet, gloves, acci- dent-prevention shoes, etc. - Page 11 Before installation Identify critical points during handling (disconnected routes, flights, steps, doors Protect the unit properly to prevent damage Lifting with balance Lifting with spacer bar Align the barycenter to the lifting point • Gradually bring the lifting belts under tension, making sure they are positioned correctly •...
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Page 12: Selecting The Installation Site
Selecting the installation site General the accumulation of snow must not Choose the installation place according to cause clogging of the coils Installation must be in accordance with the following criteria: local regulations. If they do not exist, fol- Limit vibration transmission: avoid installations in places subject to ... -
Page 13: Condensate Water
Selecting the installation site Drain pan Safety valve gas side Diameters of tray connections Option. The installer is responsible for evaluating The unit can be supplied with drain pans the opportunity of installing drain tubes, in Size GAS - Male under the coils. - Page 14 Selecting the installation site AEROTOP EVO 24 - 27 - 32 AEROTOP EVO PLUS 24 - 27 - 32 Compressor enclosure AEROTOP EVO Electrical panel 24 - 27 - 32 AEROTOP EVO PLUS Power input Inlet water connection Victaulic 1" 1/2 Outlet water connection Victaulic 1”...
- Page 15 Selecting the installation site AEROTOP EVO 48 - 54 - 65 AEROTOP EVO PLUS 48 - 54 - 65 Compressor enclosure AEROTOP EVO Electrical panel 48 - 54 - 65 AEROTOP EVO PLUS Power input Inlet water connection Victaulic 2" Outlet water connection Victaulic 2”...
- Page 16 Selecting the installation site AEROTOP EVO 79 - 88 - 105* AEROTOP EVO PLUS 79 - 88 Compressor enclosure AEROTOP EVO 79 - 88 - 105* Electrical panel AEROTOP EVO PLUS 79 - 88 Power input Inlet water connection Victaulic " Outlet water connection Victaulic 2”...
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Page 17: Water Connections
Water connections Hydraulic system The system must be drained before installing the new unit. The piping must be designed and manufac- Dirt can be removed only with a suitable water flow. tured to limit pressure drops as much as Particular attention must also be paid to “blind spots” where a lot of dirt can accumulate possible, i.e. -
Page 18: Anti-Freeze Solution
Water connections Risk of freezing Anti-freeze solution If the unit or the relative water connec- The use of an anti-freeze solution results in an increase in pressure drop. tions are subject to temperatures close to Make sure that the glycol type utilized is inhibited (not corrosive) and compatible with the 0°C: water circuit components. -
Page 19: Water Filter
Water connections Water filter Non-return valve Must be installed immediately in the water input of the unit, in a position that is easily Provide for the installation of non-return accessible for cleaning. valves (A) in the case of several units con- nected in parallel. -
Page 20: Unit + Pump
Water connections Victaulic fittings Victaulic connection joint. Supplied Fittings are to weld to the sys- tem pipe. It is not allowed to weld the system pipe with the Victaulic connection joint attached. The rubber gaskets might be irreparably damaged Hydraulically connection schematic Unit with pump heat pump exchanger antifreeze heater... -
Page 21: Operation Sequence
Water connections Victaulic fittings Operation sequence Remove the connection fitting supplied Before starting the unit pump: and use the Victaulic connection joint. 1. Close all vent valves in the high points of the unit hydraulic circuit Weld the fitting to the system pipe. ... -
Page 22: Electrical Connections
Electrical connections The characteristics of the electrical lines 7. Use the special holes on the bottom Signals / data lines must be determined by qualified electrical of the frame for the power line inlet. Do not exceed the maximum power al- personnel able to design electrical installa- Seal any residual openings to prevent lowed, which varies, according to the... -
Page 23: Controller Wiring Sections
Electrical connections Controller wiring sections 24-32 48-65 79-105 Max. cable section Cu (mm2) Power line inlet 23 / UK... - Page 24 Electrical connections Controller wiring sections 24 / UK...
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Page 25: Remote Control Of The Unit
Electrical connections Remote control of the unit With S5_3 ON, the unit is controlled remotely. The wired controller is disabled. ON/OFF status controlled by the On/Off input: • input ON = unit ON Heat/Cool mode controlled by the Heat Cool input: •... - Page 26 Electrical connections Connections performed by customer - unit with REMAUX 26 / UK...
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Page 27: Taf1 Probe
Electrical connections TW probe • Contact on APC board: CN26_HEAT1 Compressor running signal HL1 • The total system supply water flow con- KM1. trol probe is installed on the supply pipe Refer to the Service manual for • Connect the warning light as shown in configuration. - Page 28 Electrical connections APR board access Sizes 24-32 Sizes 48-65 28 / UK...
- Page 29 Electrical connections Domestic hot water In DHW production mode, the compressors Option. start only if the DHW storage tank temper- Components required: ature is above a minimum threshold (see • SV1 3-way valve table). • Taf1 temperature probe, domestic hot water antifreeze protection To prevent it from falling below the •...
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Page 30: Start-Up
Start-up Start-up The operations indicated should be performed by qualified technicians with specific training on the product. Upon request, the service centres can perform the start-up. The electric, hydraulic connections and the other work of the system are the responsibility of the installer. Please agree upon the start-up data with the service centre with sufficient advance. - Page 31 Start-up Start-up sequence For details refer to the different manual sections. Unit OFF power supply safety access suitable frame to withstand unit weight + people weight functional spaces air flow: correct return and supply (no bypass, no stratification) considered level to be reachable by snow considered main winds: there are deflectors, windbreaks, suitable anchor system lack of chimneys / corrosive atmospheres / pollutants structure integrity...
- Page 32 Start-up Start-up sequence For details refer to the different manual sections. Unit ON power supply compressor crankcase heaters operating at least since 8 hours off-load voltage measure phase sequence check pump manual start-up and flow check shut-off valve refrigerant circuit open unit ON load voltage measure verify the lack of bubbles in the liquid light (if applicable)
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Page 33: Electric Circuit
Start-up Refrigeration circuit Start-up report Check carefully the refrigerating cir- Identifying the operating objective cuit: the presence of oil stains can conditions is useful to control the unit over mean leakage caused by transporta- time. tion, movements or other). With unit at steady state, i.e. -
Page 34: Control
Control Panel Buttons Button Name Function UNLOCK UP DOWN MENU UP DOWN LEFT RIGHT ENTER ON OFF Returns to the previous level/page. BACK Lock/Unlock keys Switch On/Off Press Unit in modular configuration 34 / UK... - Page 35 Control Display Meaning ooling Heating Domestic hot water Controller Weekly timer active Fan usage value Pump in operation Backup electric heater in operation Manual antifreeze or defrosting in operation Remote control: the unit is set from the keypad to be controlled by a remote terminal or by a remote selector switch. SILENT MODE Button lock active...
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Page 36: Set Mode And Temperature
Control Set Date, Time, Language Menu MODE USER MENU SERVICE MENU PROJECT MENU In cooling mode with ext T < 15°C, the set point is forced to 10 °C (see Operation limits) USER MENU QUERY TIMER GENERAL SETTING DOUBLE SETPOINT Menu GENERAL SETTING MODE... -
Page 37: Silent Mode
Control Menu Menu MODE USER MENU SILENT SWITCH SERVICE MENU DHW SWITCH PROJECT MENU USER MENU SILENT SWITCH QUERY SELECT SILENT TIMER CURRENT SILENT GENERAL SETTING DOUBLE SETPOINT Menu Domestic hot water Option. SILENT SWITCH The unit is capable of handling domestic hot water production. DHW SWITCH A dedicated valve diverts the water flow from the system to the do- mestic hot water tank until the DHW set point set on the user inter-... - Page 38 Control STATE QUERY Querying variables The function displays some unit variables: operation status, 50 MW temperatures, alarm history. Menu MODE USER MENU QUERY SERVICE MENU STATE QUERY PROJECT MENU TEMP QUERY HISTORY ERRORS QUERY USER MENU QUERY TIMER TEMP QUERY GENERAL SETTING SELECT ADDRESS DOUBLE SETPOINT...
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Page 39: Timer
Control QUERY DAILY TIMER TIMER MODE Timer DAILY TIMER A daily or weekly schedule can be set. If the unit is controlled via remote ON-OFF or via Modbus, the tim- ers are disabled. SILENT MODE Menu MODE DAILY TIMER USER MENU SERVICE MENU PROJECT MENU USER MENU... -
Page 40: Unit Statuses
Unit statuses Code Description Code Description 0.xx unit address 31.xx temperature 1.xx nominal unit capacity (30/60/90 kW) 32.xx silent (1st digit: 0= night mode, 1= silent 2.xx number of units 33.xx reserved 3.xx correction 34.xx DC voltage A (reserved) 4.xx Mode (8: Off;... - Page 41 Control Alarms Description Code Alarm reset: switch the unit off and on again. reserved NOTE Before resetting an alarm, identify and remove the cause of the alarm. Repeated resets can cause irreversible damage. The unit is in protection mode in the follow- ing conditions: •...
- Page 42 Control Description Code Description Code Reserved Reserved Reserved valve B error antifreeze temperature in cooling mode valve C error protection voltage voltage and keypad MCE error 15Hz sequence pressure error Reserved sensor 42 / UK...
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Page 43: R32 Gas Safety Warnings
R32 gas safety warnings Area checks Before starting operations, the area sur- Electrical device checks Before working on systems containing flam- rounding the equipment must be inspected The reparation and maintenance of elec- mable refrigerants, perform safety checks to to guarantee the absence of flammables or tric components must include initial safe- reduce the risk of combustion to the mini- combustion risks. -
Page 44: Reparation Of Intrinsically Safe Components
R32 gas safety warnings Warning so the correct gas percentage (25% max) Make sure that the vacuum pump intake is must be verified. Leak detection fluids are not near ignition sources and that there is a Using silicone sealants may inhibit the suitable for most refrigerants, although suitable ventilation. -
Page 45: Labelling
R32 gas safety warnings The recovery procedure is monitored at all Transport, mark and storage Make sure enough tanks are used. times by skilled personnel; 1. Transport of equipment containing flam- All the tanks to be used are designated The recovery equipment and tanks mable refrigerants. -
Page 46: Maintenance
Maintenance Safety Inspections frequency Turn off the power to avoid electrical Operate in compliance with safety regula- Perform an inspection every 6 months risks or damages by lightning strikes. tions in force. minimum. To carry out the operations use protection With lower temperatures keep heaters The frequency, however, depends on the devices:... - Page 47 Maintenance Recommended periodical checks intervention frequency (months) corrosion panel fixing cleaning water filter cleaning water: quality, ph, weight of glycol (%) check the exchanger efficiency circulating check of the fixing and the insulation of the power lead check of the earthing cable electric panel cleaning capacity contactor status terminal closing, cable insulation integrity...
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Page 48: Compressor Crankcase Heater
Maintenance Flow Switch System drain Use a soft brush, vacuum dirt exhauster, • check operation The system must be drained only if neces- pressurised air jet or high-pressure washer. • remove incrustations from the blade sary. Keep the direction parallel to the fins to Do not drain the system periodically;... -
Page 49: Decommissioning
Decommissioning WEEE from private households: WEEE Warning originating from private households and WEEE which comes from commercial, Before performing any work, carefully read: industrial, institutional and other sources SAFETY WARNINGS FOR OPERATIONS ON which, because of its nature and quanti- UNITS CONTAINING R32 ty, is similar to that from private house- ... -
Page 50: Residual Risks
Residual risks General An incorrect fixing of the electric General risks In this section the most common situations components cover may lead to the Smell of burning, smoke or other signals are indicated, as these cannot be controlled entry of dust, water etc. inside and may of serious anomalies may indicate a situ- by the manufacturer and could be a source consequently electric shocks, damage... -
Page 51: Moving Parts
Residual risks When voltage is necessary for the circuit open the isolator on the attachment line of the unit itself, padlock it and display the appropriate warning sign. Moving parts Contact with the transmissions or with the fan aspiration can cause injuries. Prior to entering the inside of the unit open the isolater situated on the con-nection line of the unit itself, padlock and display the... -
Page 52: Unit In Modular Configuration
Unit in modular configuration Maximum number of connectable units: 16 Domestic hot water The system is completely controlled by the In a cascade system with DHW provision, Master unit. the system configuration must be as fol- Each module can be equipped with an iner- lows: tial system storage tank. -
Page 53: System With Reversed Return Connection
Unit in modular configuration Modular system connection diagram - addressing Single/multiple pump system Configure DIP switch S12-2 according to the type of system. MAX 16 UNITS Multiple water pumps A check valve is required for each unit in this configuration. Pump control is enabled on each unit MAX 4 UNITS MAX 4 UNITS... -
Page 54: Addressing
Unit in modular configuration At switch-on, when a load is requested, the Addressing Addressing controls units are switched on in sequence based Each connected module is identified by an Up to16 controls can be addressed, from 0 on their address, in numerical order. address, from 0 to 15: the Master unit is to 15;... -
Page 55: Modbus
Modbus Communication specifications: RS - 485 Protocol ModbusRTU: 9600, 8, N,1 Transmission speed 9600pbs Data bit 8 data bits Parity bit None parity Stop bit 1 stop bit Connections Connect on the back of the controller. Modular unit: connect the Modbus to the master unit port. Enabling SERVICE MENU →... - Page 56 Modbus Data Name Description Type R&W R&W R&W R&W RESERVED R&W mode R&W set point R&W Tws 2 R&W in cooling mode R&W Tws 2 R&W in heating mode R&W enable in cooling mode R&W R&W R&W OFFSET-C enable R&W in heating mode R&W R&W...
- Page 57 Modbus Data Name Descrition Type R&W dT5_ON R&W T_Heat1_Delay R&W dTw_Heat1_Off (TW_COOL DIFF/TW_HEAT_ R&W DIFF) R&W Ratio_Cool_First R&W Ratio_Heat_First R&W T_diff_pro R&W T_Frost R&W T_Defrost_in R&W T_Defrost_out R&W R&W T4_Heat1_On R&W Tw_Heat1_On R&W Tw_Heat1_Off R&W R&W T_Heat2_delay R&W dT5_Heat2_Off R&W T4_Heat2_On R&W R&W...
- Page 58 Modbus Data Name Description Type R&W type 5% step R&W percentage R&W offset R&W R&W DtTws R&W R&W FC Offset R&W FC Hyster R&W TWI_O ABNORMAL R&W R&W limit R&W R&W R&W R&W R&W 5 min step R&W R&W TW_COOL_DIFF R&W TW_HEAT_DIFF R&W...
- Page 59 Modbus Data Name Description Type R&W R&W R&W R&W R&W DHW enable R&W R&W DHW priority time R&W R&W time R&W time R&W R&W DHW mode R&W R&W R&W R&W R&W R&W R&W Time 59 / UK...
- Page 60 Modbus Data Name Description Type R&W RESERVED RESERVED RESERVED capacity power efficiency capacity power SG status EVU status mode RESERVED frequency 60 / UK...
- Page 61 Modbus Data Name Description Type EXVA EXVC SV8A SV8B SV2 state Pressure Code 61 / UK...
- Page 62 Modbus Data Name Description Type SV6 state Capacity control FCT status type Tsafe date RESERVED Taf2 62 / UK...
- Page 63 Modbus Data Name Description Type RESERVED TDSH TSSH TCSH ErrTypeGet ErrCodeGet LastErrTypeGet LastErrCodeGet RESERVED Address)*200 63 / UK...
- Page 64 Service: UK Importer ELCO HEATING SOLUTION LIMITED 3 Juniper West, Fenton Way Basildon, SS15 6SJ ELCO GmbH Hohenzollernstraße 31 D - 72379 Hechingen www.elco.net 64 / UK...
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