Table of Contents
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Model numers:
Model numers:
KHP0041: 4kW Heat Pump
KHP0038: 6kW Heat Pump
KHP00: 6kw Heat Pump
KHP0039: 8kW Heat Pump
KHP00 : 8kw Heat Pump
KHP0040: 12kW Heat Pump
KHP00: 12kw Heat Pump
KHP0042: 15kW Heat Pump
Air Source Heat Pump
Installation and Maintenance Manual
Air Source heat Pump
Installation Manual
A9317A
A9317C
6HSW 2010
Ver 1.2b
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Chapters
Table of Contents
Related Manuals for Kingspan KHP0041
Summary of Contents for Kingspan KHP0041
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Page 1: Installation Manual
Air Source heat Pump Air Source Heat Pump Installation and Maintenance Manual Installation Manual Model numers: Model numers: KHP0041: 4kW Heat Pump KHP0038: 6kW Heat Pump KHP00: 6kw Heat Pump KHP0039: 8kW Heat Pump KHP00 : 8kw Heat Pump KHP0040: 12kW Heat Pump... -
Page 3: Table Of Contents
Rating Tables POWER WIRING Pressure Loss Curves Maintenace. FLUSHING WATER AND AIR CHECKING FOR WATER LEAKS CONFIGURING AND 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 assistance in the selection of equipment. The responsibility any responsibility for matters of specification, design for the specification of the equipment must however... -
Page 5: Check List
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 systems you may have installed and help to understand and conventional boiler the radiators should have been comply with all of the technical details contained within this 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: Electrical Connections
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
Disconnect the mains power supply prior to any disposal centre or to the original equipment dealer for maintenance operations or prior to handling any proper environmentally compatible disposal. internal parts of the unit. Dimensions and Clearances weight KHP0041 KHP0038 KHP0039 KHP0040 1363 1363 KHP0042 Mimimum installation clearances in mm are shown in fig.2 (single installation) and fig. -
Page 9: Dimensions And Clearances
Dimensions and Clearances 1000 1000 1500 2000... -
Page 10: Installation & Technical Data
Installation Before installation, check strength and levelness of the base If the outdoor unit is installed in a very windy place, protect so that abnormal sound does not generate. According to the fan with a wind protection screen and check that it the dimensions and clearances, fix the base firmly with the works correctly. - Page 11 M10 (3/8”) Thickness of concrete 120mm Length of bolt 70mm Weight-bearing capacity 320kg...
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Page 12: Water Connections
Water connections Water Connections (Fig. 8/9) Make the plate heat exchanger hydraulic connections System cleaning and Water Characteristics with the necessary components, using material which will In the case of a new installation, or cleaning the circuit, guarantee that the screwed joints are leakproof. The typical it is necessary to perform a preventive cleaning of the hydraulic circuit diagram shows a typical water circuit system.In order to guarantee the good operation of the... - Page 13 Air flow requirements NOTE If you intend to install the heat pump in a custom built enclosure, you must adhere to the airflow data in the NB: Kingspan do not offer a design service for this type of application. Model Rating KHP0041...
- Page 14 Installation Monopropylene Glycol -4 °C -9 °C -15 °C -23 °C Correction Capacity 0,996 0,991 0,983 0,974 Absorbed power 0,990 0,978 0,964 1,008 Loss of head 1,003 1,010 1,020 1,033 Installed Unit ..... Unit content (*) ..... Pipe content (**) .....
- Page 15 Ppre = Pre-charge Pressure (Bar) Pmax = 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 16 Water connections (Typical Schematic for Radiator System)
- Page 17 Water connections (Typical Schematic for Radiator System)
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Page 18: Electrical Connections
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 19 Electrical connections - Single Zone (B) DIA...
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Page 20: Connection Of Auxiliary Accessories
(NTC 2 wire, non-representative reading of the external temperature 3kΩ @ 25°C, Kingspan Part Number KHP0009). Connect by the probe positioned on the machine, an additional the terminals of the probe between PINS 23 and 24 of the... - Page 21 Auxiliary accessories connection Signal for requesting an External Heat Source or Dehumidification IMPORTANT NOTICE : 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.
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Page 22: System Test
System test Inverter board alarm codes KHP0040 12kW unit (Fig. 12) 11Troubles of the inverter can be diagnosed by LED Before a check, confirm each bit of the DIP switch is set to indications on the cycle control P.C. board of the outdoorunit. - Page 23 System test Inverter board alarm codes (only for KHP0042) (Fig. 12) The error which is generating at present and the latest c) If there is an error, any of LED D800 to D804 goes on. error (Latest error information including present) can be (Display 1) confirmed by lighting LED D800 to D804 on the outdoor d) When pushing the pushdown button switch SW800 for...
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Page 24: Unit Protection Devices
Refrigerant Diagram and Unit Protect Devices GMC Board Alarm Codes (Fig. 12) 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 25 A: 4 way valve B: DC Rotary Compressor C: BPHE D: Pulse Motor Valve E: Distributor 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 Operating Condition...
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Page 26: Installation Pack
Installation Pack 7 day hot water programmer Please see page 42 for full instructions Programable room stat Please see page 54 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 27 Installation Pack System Antifreeze / Inhibitor - Clear Application in Heat Pumps. Instructions for use Dilute before use using mains water. In order to ensure adequate corrosion and biocidal protection, the minimum ‘in-use’ protection according to the table below. Concentration -14°C -22°C -34°C...
- Page 28 Installation Pack W Plan diverter valve (heat pump specific) Operating voltage 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 Solder 2 crimp joints...
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Page 29: 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 30: Optional Installation Accessories
KHP0050 Aeromax Plus filling station The Kingspan Aeromax Plus 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 31 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 X = unsuitable location...
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Page 32: Day Hot Water Programmer
7 day hot water programmer Installation & User Instructions +1HR override +1HR MAN override DAY/HOL RESET Mode SELECT Index User Installation What is a programmer? Product specifi cation Your timeswitch Installation Preset programmes Wiring Before you start DIL switch settings AM/PM or 24hr display Advanced Programming Options Setting the Time and Day... -
Page 33: Installation
7 day hot water programmer Installation on the bottom edge of the unit. TS715-Si models are double insulated and do not require an earth connection, however a parking terminal is be clearances of at least 140 mm to the right, 15mm to the provided on the wallplate. - Page 34 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. 3 on/off...
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Page 35: What Is A Programmer
7 day hot water programmer Copy Functions Explained AB Copy: The AB copy function is available in 5+2 mode To use the AB copy function – press the PROG button: only and only if activated in the Advanced Programming 1. This will show the “A” days, with all the days selected. setting. -
Page 36: Your Timeswitch
7 day hot water programmer Your timeswitch The TS715-Si allows you to switch your system on and off at times that suit you. day. Preset Programmes Your TS715-Si comes ready programmed with a set of If you want to change any of these settings, you can do so operatingtimes which often suit most people. -
Page 37: Setting The Time And Day
7 day hot water programmer Setting the correct Time and Day These settings are made during anufacture and only need DAY/HOL 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 38 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 DAY/HOL display. Use the + or - buttons to set the time you would like your system to fi rst come on in the morning (Event 1).
- Page 39 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 DAY/HOL of the display. Note the current day is displayed. Press the DAY/ HOL button until the required day is displayed. Use the + or - buttons to set the time you want your system to fi rst come on in the morning (Event 1).
- Page 40 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 DAY/HOL of the display. Use the + OR - buttons to set the time you want your system to fi rst come on in the morning (Event 1).
- Page 41 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. +1HR +1HR = pressing this button when the unit is in AUTO or +1HR...
- Page 42 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 fl ap on the front of the unit to reveal the programming buttons.
- Page 43 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. +1HR 1. Press and hold the +1HR and MAN buttons on the left +1HR hand side of the product.
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Page 44: Programable Room Stat
Programable room stat Installation & User Instructions Index Installation Instructions User Instructions Product Specifi cation 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 Setting References Please Note:... - Page 45 Programable room stat Installation be clearances of at least 15mm to the right, 15mm to the left, 30mm above and 100mm below in order to mount the sunlight. plug-in module. from draughts or heat sources such as radiators, open fi res or direct sunlight.
- Page 46 Programable 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 47 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 66).
- Page 48 Programable room stat Option 34 - Select On/Off or 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 run in On/Off mode or for a chrono- This adjusts the integration time of proportional cycle rate to be selected.
- Page 49 Programable 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 50 Programable room stat What is a programmable room thermostat? ... an explanation for householders The best way to do this is to set low temperatures fi rst, 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 51 Programable room stat Weekend (Sat-Sun) 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 52 Programable room stat Setting the correct time After setting the date press PROG to display the time. The time display will fl ash on and off . Use the + and - buttons to set the correct ime (press and hold to change in 10 min.
- Page 53 Programable room stat Changing the preset programmes in 5/2 day mode Press PROG until the fi rst 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 54 Programable room stat Setting the correct time a) Press PROG until the fi rst 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 hold e) Repeat steps b, c, &...
- Page 55 Programable room stat To change time display between 12 hour and 24 clock. To change between °C and °F scaling clock. Thermostat mode a) A constant temperature of between 5-30°C can be selected if required. This can provide frost protection for away from the programmed frost protection temperature periods away from home, it can also be used to provide to another value.
- Page 56 Programable room stat Optimum start control (OSC) Your thermostat includes an optional optimum start control. A full description of this and how to enable it and set it This feature allows you to set the time at which you require a up is given in User Advanced Programming, steps 12 &...
- Page 57 Programable 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 system in three diff erent Press + until Option 12 is displayed, ways. Press + until Option 11 is setting (only active if Option 11 required setting.
- Page 58 Programable 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 59 Programable 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...
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Page 60: Spare Part List
Spare Part List KHP0041 - 4kW, KHP0038 - 6kW, KHP0039 - 8kW... - Page 61 Spare Part List Pos. Description Note Base pan assy Ass. front side panel Ass. rear side panel Pillar Ass. top cover Motor nut Propeller fan Orifice Handle Condenser coil assy Coil guard net Klixon Klixon holder Cushion rubber Suction accumulator Liquid receiver /4 way valve PMV liquid assy...
- Page 62 Spare Part List KHP0040 - 12kW, KHP0042 - 15kW...
- Page 63 Spare Part List Pos. Description Note Base pan assy Ass. front side panel Ass. rear side panel Pillar Ass. top cover Motor nut Propeller fan Orifice Handle Condenser coil assy Coil guard net Klixon Klixon holder Cushion rubber Suction accumulator Liquid receiver 4 way valve PMV liquid assy...
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Page 64: Rating Tables
Rating Tables CAPACITY 1.86 1.87 1.87 4kW Unit 0.81 0.59 0.37 Unit 2.33 2.41 2.44 2.46 2.50 2.53 2.56 2.59 2.60 2.61 2.61 "EWT- 2.67 2.64 2.62 2.49 2.26 1.97 1.67 1.37 1.08 0.78 0.49 "EWT- 2.53 2.62 2.65 2.68 2.71 2.75 2.78... - Page 65 Rating Tables CAPACITY 1.76 1.77 1.77 6kW Unit 0.99 0.72 0.45 Unit 2.21 2.29 2.31 2.33 2.36 2.40 2.43 2.45 2.47 2.47 2.47 "EWT- 3.26 3.22 3.20 3.04 2.76 2.40 2.04 1.68 1.32 0.95 0.60 "EWT- 2.40 2.48 2.51 2.53 2.57 2.60 2.64...
- Page 66 Rating Tables CAPACITY 2.03 2.04 2.06 2.06 2.06 8kW Unit 1.91 1.57 1.23 0.90 0.56 Unit 2.07 2.30 2.47 2.53 2.55 2.59 2.61 2.63 2.64 2.64 "EWT- 3.98 3.93 3.90 3.36 2.93 2.48 2.04 1.60 1.16 0.73 "EWT- 2.21 2.45 2.63 2.69 2.72...
- Page 67 Rating Tables CAPACITY 12kW 1.48 1.48 12kW 2.41 1.50 Unit Unit 2.26 2.27 2.28 2.29 2.31 2.31 2.31 7.28 6.68 6.44 5.49 4.30 3.12 1.95 "EWT-LWT "EWT-LWT 2.50 2.52 2.52 2.54 2.56 2.56 2.56 7.85 7.20 6.94 5.92 4.64 3.37 2.10 30-35"...
- Page 68 Rating Tables CAPACITY 15kW 1.92 1.93 1.94 15kW 3.05 2.12 1.26 Unit Unit 2.33 2.35 2.36 2.39 2.40 2.41 2.42 2.42 8.44 7.89 7.42 6.20 5.03 3.88 2.75 1.63 "EWT-LWT "EWT-LWT 2.47 2.49 2.50 2.53 2.55 2.56 2.56 2.57 9.10 8.50 8.00 6.68...
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Page 69: Pressure Loss Curves
Pressure Loss Curves 4kW Unit 6kW Unit 30AWH015H 8kW Unit 12kW & 15kW Unit 4kW Unit 6kW Unit 8kW Unit 12kW & 15kW Unit... -
Page 70: Maintenace
Commissioning Maintenance Checklist The Aeromax plus must be maintained on and annual Inside the Heat Pump basis. The basic requirements are: Check all electrical connections for tighness Visual inspection for eitrher 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 71 Link wire installed between terminals 3 & 7 on outdoor unit* 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 72 ENGINEERS FORMS 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 ACCESS TO REMOVE ELECTRICAL COVERS CHECK AIR CHARGE IS IN EXPANSION VESSELS PRESSURISE PRIMARY CIRCUIT TO APPROXIMATELY 1.50 BAR POWER SOURCE (v)