Aereco CONNECT WP120 User manual

CONNECT WP120 / CONNECT WP130
v2017.2
TECHNICAL MANUAL
INSTALLATION AND MAINTENANCE INSTRUCTIONS

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Dear customer,
We would like to thank you for choosing an Aereco product. It is a product based on
many years’ experience and careful project studies, and has been manufactured
using high-quality materials and the latest technology.
Furthermore, the CE designation guarantees that the units meets the requirements of
the EU Machinery Directive with regard to safety. The quality
level is continually monitored and Aereco products therefore represent safety,
quality and reliability.
Data may be changed at any time and without obligation to give notice if this serves
to improve the product.
Thank you again.
Aereco GmbH
Aereco reserves the right to make changes at any time to improve the product without being obliged to
make such changes to units already manufactured, delivered or in production.

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Table of contents
1. GENERAL INFORMATION .................................................................................................................5
RETAINING DOCUMENTS..........................................................................................................5
SAFETY INFORMATION AND INSTALLATION REQUIREMENTS..............................................5
WARRANTY.................................................................................................................................5
2. UNIT DESCRIPTION...........................................................................................................................7
PLINTH AND LOAD-BEARING CONSTRUCTION.......................................................................7
UNIT DIMENSIONS .....................................................................................................................7
2.2.1. HOUSING DIMENSIONS......................................................................................................7
2.2.2. POSITION OF THE VIBRATION DAMPERS.........................................................................8
2.2.3. POSITION OF THE MEDIA CONNECTIONS........................................................................8
COMPONENTS............................................................................................................................9
2.3.1. REFRIGERANT CIRCUIT COMPONENTS...........................................................................9
2.3.2. WATER CIRCUIT COMPONENTS........................................................................................9
2.3.3. CONTROL AND SAFETY COMPONENTS.........................................................................10
TECHNICAL DATA.....................................................................................................................12
HEAT PUMP CIRCUIT AND WATER CIRCUIT..........................................................................13
3. RECEIVING AND MOVING THE UNIT..............................................................................................14
4. INTEGRATION IN THE BUILDING HEATING SYSTEM....................................................................16
RECOMMENDATION AND SYSTEM DIAGRAM WITH AWN STRATIFIED STORAGE ............16
SETTINGS FOR USE WITH STRATIFIED STORAGE...............................................................17
SETTINGS FOR USE WITHOUT STRATIFIED STORAGE .......................................................17
SETTING THE EXPANSION VESSEL .......................................................................................18
INTEGRATION WARNINGS ......................................................................................................19
5. OPERATING RANGE AND OPERATING LIMITS.............................................................................20
REQUIREMENTS FOR SOURCE AND SINK MEDIA................................................................21
OPERATING WITH ANTIFREEZE.............................................................................................21
5.2.1. ETHYLENE GLYCOL SOLUTIONS.....................................................................................21
5.2.2. PROPYLENE GLYCOL SOLUTIONS..................................................................................21
7. INSTALLATION.................................................................................................................................22
ON-SITE INSTALLATION REQUIREMENTS.............................................................................22
INDIVIDUAL STEPS TO BE COMPLETED DURING INSTALLATION.......................................22
7. MAINTENANCE AND SERVICE .......................................................................................................23
EXTRAORDINARY MAINTENANCE..........................................................................................23
REGULAR MAINTENANCE.......................................................................................................24
8. STANDARDS AND GUIDELINES .....................................................................................................26
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Product designation: Connect WP120 / Connect WP130
Type: Inverter-controlled, source-controlled brine/water heat pump
Application purpose: For exhaust air heat recovery in conjunction with Aereco AWN Basic
products for exhaust air conveyance with an air/brine heat exchanger
Document version: 2017.2

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1. GENERAL INFORMATION
The units have been manufactured in accordance with technical standards and recognised safety
regulations. They have been developed to recover heat from exhaust air systems and to heat heating and
domestic hot water, and are to be used for these purposes. Any contractual and extra-contractual liability of
the company for damage to persons, animals or property as a result of installation, adjustment and
maintenance errors or improper use shall be excluded. Any use not expressly stated in this manual shall
not be permitted.
RETAINING DOCUMENTS
These instructions, together with all other documents, are to be given to the unit operator, who assumes
responsibility for retaining these documents and shall ensure that they are available if required. Please
read through the handbook provided carefully.
All works are to be carried out by specialist personnel in accordance with the provisions in force applicable
to each country.
The CONTROL CONSOLE OPERATING INSTRUCTIONS and the
ELECTRICAL CIRCUIT DIAGRAMS are included with the unit.
Give the instructions and all supplementary documentation to the unit’s user, who assumes responsibility
for retaining these instructions so that they are always available if required.
SAFETY INFORMATION AND INSTALLATION REQUIREMENTS
The unit must be installed by an approved specialist in compliance with the national legislation in force in
the country of destination. Aereco shall not accept any liability for damage resulting from non-compliance
with these instructions.
The unit must be installed so that maintenance and/or repair work can be carried out.
Before starting any work, it is necessary to READ THE INSTRUCTIONS CAREFULLY AND TO
UNDERTAKE SAFETY CHECKS TO PREVENT ANY RISK. All
authorised personnel must be familiar with the work steps and risk that may occur when starting
installation work on the unit.
WARRANTY
The unit warranty shall not cover the cost of motor ladders, scaffolding or other lifting systems which may
be necessary to provide the services covered by the warranty. Give the following installation instructions
and all supplementary documentation to the unit’s user, who assumes responsibility for retaining these
instructions so that they are always available if required. READ THESE INSTRUCTIONS CAREFULLY.
The unit must be installed by trained personnel in compliance with the national legislation in force in the
country of destination.
It must be installed so that maintenance and/or repair work can be carried out. The warranty shall become
void if work is carried out on the unit contrary to the instructions given here or in any other way without
professional care.
No changes may be made to the unit as this may result in hazards and the manufacturer
cannot be held liable for any damage caused.
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TYPE PLATE
The heat pump is labelled with a technical type plate.
Caution
If the type plate or other elements that safely identify the product are changed,
removed or go missing, installation and maintenance work will be more difficult.
INTRODUCTION
The Connect WP is a water-cooled heat pump that uses R410A refrigerant. This interior unit has a
hermetic cooling circuit with an inverter rotary piston compressor, as well as a unit- and source-side
plate heat exchanger. It is therefore perfectly designed to use waste heat from exhaust fans and offers
the following benefits in particular:
Highly efficient
These units have been optimised for waste heat utilisation, whereby high levels of efficiency can
be achieved.
Connections
All power and water connections are in the upper section of the unit, which makes installation and
maintenance easier. By reducing the required space, the unit can also be positioned in minimal free
space.
Quiet The Connect WP units stand out given their quiet operation. The careful sound insulation of the
unit using sound-absorbing material means the Connect WP series can be used in plant rooms.
Area of application
The exhaust air heat can be fed back to the building by the heat pump via a domestic hot water
preheating stage and a return flow boost on the heating side. Combining these two heat sinks
guarantees that as much heat is removed as possible and offers the opportunity to provide heat all
year round. The Connect WP output is adjusted automatically to the heat quantity of the exhaust
air.

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2. UNIT DESCRIPTION
The Connect WP is a water-cooled heat pump that uses R410A refrigerant. This interior unit has a
hermetic cooling circuit with an inverter rotary piston compressor, as well as a unit- and source-side plate
heat exchanger. It is a single-circuit unit. A water filter, differential pressure controller and safety valve are
all installed on the sink- and source-side as standard. Microprocessor-controlled regulation including LCD
display allows the unit to be operated easily via the user menu.
PLINTH AND LOAD-BEARING CONSTRUCTION
Consisting of elements made from hot-dipped galvanised sheet steel of the appropriate strength. All
components feature a weather-resistant polyester powder coating (RAL 9002). During the design phase, it
was ensured that all interior components are easily accessible. All housing plates are coated with sound-
absorbing material of the appropriate thickness. The power and water connections are all located at the
top of the unit. This makes them easily accessible for installation and maintenance work, and very little
technical space is required given their space-saving layout.
UNIT DIMENSIONS
2.2.1. HOUSING DIMENSIONS
Connect WP 120 Connect WP 130
WP
Dimensions without pallet (mm)
Dimensions with Euro pallet (mm)
Sizes
A
B
C
A1
B1
C1
120
976
605
603
1120
800
1200
130
1126
605
773
1120
800
1200
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2.2.2. POSITION OF THE VIBRATION DAMPERS
To prevent structure-borne sound from being transferred to the installation surface, it can be helpful to fit
the unit with vibration dampers. The intended fixing points are shown on the schematic.
Connect WP 120 Connect WP 130
2.2.3. POSITION OF THE MEDIA CONNECTIONS
Connect WP 120 Connect WP 130
Connect
AWN connection side (brine)
Heating circuit connection side (hot
water)
Connection
no.
1
2
3
4
All sizes
Outlet 1 1/4” IG
Inlet 1 1/4” IG
Outlet 1 1/4” IG
Inlet 1 1/4” IG
Connections 5 and 6 are not used.
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COMPONENTS
2.3.1. REFRIGERANT CIRCUIT COMPONENTS
COMPRESSOR
A hermetic inverter rotary piston compressor that is highly efficient and uses an energy-saving DC electric
motor. Mounted on elastic vibration-damping compensators.
COMPRESSOR INVERTER MODULE
The inverter module infinitely controls the compressor speed using the sensor-controlled power
specification on the system controller. This means the compressor motor is continually monitored and
protected from damage.
CONDENSER
Featuring a plate structure (stainless steel, 1.4401). Featuring closed cellular insulation material on the
outside to minimise heat loss.
EVAPORATOR
Featuring a plate structure (stainless steel, 1.4401). Featuring closed cellular insulation material on the
outside to minimise heat loss and to prevent condensate formation.
REFRIGERANT COLLECTOR
A refrigerant collector ensures a bubble-free liquid upstream of the expansion valve in all performance
ranges.
FILTER DRYER
A hermetic-mechanical filter dryer with cartridges made of ceramic and hygroscopic material retains
impurities and any traces of moisture present in the cooling circuit.
THERMOSTATIC EXPANSION VALVE
The mechanical expansion valve with external pressure compensation regulates the gas flow to the
evaporator depending on the thermal load to ensure the intake gas overheats to a sufficient degree.
REFRIGERANT SIGHT GLASS WITH HUMIDITY INDICATOR
Used to check the refrigerant fill level and any possible humidity in the cooling circuit.
2.3.2. WATER CIRCUIT COMPONENTS
SINK CIRCUIT (HOT
WATER)
SOURCE CIRCUIT
(AWN BRINE
CIRCUIT)
WATER FILTER
A steel filter net prevents the heat exchangers from clogging.
DIFFERENTIAL PRESSURE CONTROLLER
A differential pressure sensor allows continuous
water circulation to be controlled in the AWN heat
exchanger circuit. In the event of a fault, the
cooling circuit is switched off.
SAFETY VALVE (6 BAR)
In the event of pressure faults in the brine and heating water pipes, a safety valve is triggered and
excess pressure is released. This can be connected to a drain on site.

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BRINE CIRCUIT EXPANSION VESSEL
For the brine circuit, an expansion vessel
(membrane type) is already integrated in the
heat pump and pre-filled with nitrogen. The
expansion vessel must be adapted to the
existing system pressure during commissioning.
VENTILATION VALVE
Used to manually vent the system.
DRAIN COCKS
To drain the system (heating water circuit and brine circuit), drain lines with cocks are provided at the
lowest points of the two heat exchangers for service and decommissioning purposes.
BUFFER CHARGE PUMP
A hot water feed pump provides an available
external feed pressure to overcome pressure
losses outside the heat pump in the heating circuit
between the heat pump and the hot water buffer.
The feed volume of this high-efficiency energy-
efficiency pump is adjusted by the electronic
system control by means of a PWM signal.
AWN PUMP
A brine feed pump provides an available external
feed pressure to overcome pressure losses
outside the heat pump in the brine circuit between
the heat pump and the AWN module. This high-
efficiency energy-efficient pump must be adjusted
to the respective hydraulic losses during
commissioning. Instructions on how to do this are
also included with the unit.
HEAT METER VOLUME MEASURING UNIT
A heat meter determines the volume flow of the
heating water in the heat pump and its temperature
at the heat pump heating water outlet. An
additional temperature sensor is fitted at the
heating water inlet. The respective measurement
data is transferred to the unit control system. The
quantity of heat discharged is calculated from the
volume flow and the temperature difference.
2.3.3. CONTROL AND SAFETY COMPONENTS
LOW-PRESSURE PRESSURE SWITCH
This device fixed on the low-pressure side of the cooling circuit stops the compressor from running if the
normal operating pressure range is undershot.
HIGH-PRESSURE PRESSURE SWITCH
This device fixed on the high-pressure side of the cooling circuit stops the compressor from running if the
normal operating pressure range is overshot.
ELECTRONIC CONTROL AND SWITCH PANEL
The heat pump is equipped with a power switch and control cabinet according to standard EN 60204-
1/IEC 204-1, including:
•Door lock disconnect switch
•Circuit breaker or motor protection switch for compressors
•Terminals for connecting the external temperature sensors
•Terminals for connecting external components such as heating circuit pump or heating circuit mixer
•Terminals for boiler/heating resistors alarm signal input,
•Terminals for external WP release by the AWN
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ELECTRONIC CONTROL UVR 1611
The unit control panel allows plant operating parameters to be adjusted quickly and intuitively. The display
shows various indications of the operating mode, set parameters and any alarms triggered. All standard
settings and any changes are saved in the controller control panel.
After a power failure, the unit is able to restart automatically and retains the original settings.
Some accesses are password-protected and are only available for technical customer service. The
electronics also include a range of protection algorithms to prevent damage to key plant components.
Further information can be found in the operating instructions for the UVR module.
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TECHNICAL DATA
PERFORMANCE DATA
Connect WP120
Connect WP130
Nominal heat output/COP A20/W35
6.06 kW / 5.66
13.62 kW / 5.33
A20/W35 modulation output range
3.25-8.62 kW
4.83-22.28 kW
Modulation range of exhaust air volume flow
(effective)
480-1,800 m³/h
1,250-4,500 m³/h
Exhaust minimum volume flow (effective)
480 m³/h
1,250 m³/h
Max. electrical power consumption
2.25 kW
6.2 kW
Max. flow temperature
55°C
55°C
Housing radiation sound output
52 dB(A)
58 dB(A)
Sound pressure level at 3 m distance
31 dB(A)
33 dB(A)
BRINE CIRCUIT
Brine circuit water volume flow
1,340 l/h
2,760 l/h
Available external feed pressure
52 kPa
48 kPa
Medium
Ethylene glycol 35%
Ethylene glycol
35%
Flow/return connections
1 ¼” IG
1 ¼” IG
HEATING CIRCUIT
Heating circuit water volume flow (max.)
1,805 l/h
3,155 l/h
Available external feed pressure
48 kPa
42 kPa
Medium
Hot water
Hot water
Flow/return connections
1 ¼” IG
1 ¼” IG
COOLING CIRCUIT DATA
Refrigerant
R410A
R410A
Refrigerant fill level
1.6 kg
2.39 kg
Compressor type
Inverter rotary piston
Inverter rotary
piston
Max. system pressure
42 bar
42 bar
ELECTRICAL DATA
Maximum power consumption
10.2 A
Power supply
cable connection
Main switch
230 V /1/ 50 Hz
3G2.5 mm² (max.
cable length 20 m)
25 A
DIMENSIONS
Height (A)
0.976 m
1.13 m
Width (B)
0.605 m
0.6 m
Depth (C)
0.603 m
0.77 m
Net weight
95 kg
140 kg
All data for exhaust air at 20°C and 50% rel. humidity.
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HEAT PUMP CIRCUIT AND WATER CIRCUIT
Key
CP Compressor
CN Condenser
DL Refrigerant sight glass
EV Evaporator
FD Filter dryer
FM Water filter
PD Differential pressure switch for brine circuit flow
monitoring PH Heating circuit charge pump
PS Brine circuit pump
VE Brine circuit membrane expansion vessel
VSA Pressure relief valve
VT Expansion valve
WMZ Heat meter volume measuring unit FTS
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Heat
sink
Connect WP120/130

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3. RECEIVING AND MOVING THE UNIT
The unit is shipped ex works wrapped in foil. Before moving the unit, the load capacity of the hoists used
must be checked. The unit may only be moved by qualified and suitably equipped personnel.
HANDLING THE UNIT:
If belt lifting is to be used, place protective parts between the belt and the housing to prevent damage to
the structure. All coverings must be firmly secured before handling the unit. Before lifting, the specific
weight must be checked on the technical type plate. Use all specified lifting points and only these points.
Use ropes of the same length in accordance with the regulations. Use a spacer that complies with the
regulations (not included). Handle the unit carefully and without jerking.
CHOOSING THE INSTALLATION SITE
The units are subjected to a final inspection at the factory and only need to be connected to the
electricity and water supply at the installation site.
Before the unit is installed, its installation location must be agreed with the customer, and the following
points must be observed:
The supporting surface must be able to withstand the weight of the unit.
The safety distances between the units and other devices or building elements must be strictly
observed.
The device must be installed by a technician in accordance with the applicable national laws of
the country of use.
The technically required minimum clearances must be provided in order to allow work to be carried
out for REGULAR AND EXTRAORDINARY MAINTENANCE.
It should be noted that the refrigeration unit may transmit vibrations during operation; it is
therefore recommended that the vibration damping brackets are attached to the base in
accordance with the installation diagram.
When securing the unit, check carefully that it is balanced.
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3.3. MINIMUM SPACE REQUIREMENT
CAUTION!
& It is strictly forbidden to stay below the elevated unit.
& The units must NOT be stacked.
& The unit must be installed in such a way that maintenance and/or repair operations are possible.
& The drawings are for illustrative purposes only.
& The specified technical minimum distances must be observed; height and rear side must be designed
according to the type of installation and the installation site.
& The device must be installed in a technical room or a room with at least
one drain.
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Aereco GmbH - Robert-Bosch-Sir. 9 - 65719 Hofheim-Wallau - GERMANY I Tel: [phone] - www.aereco.de

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4. INTEGRATION IN THE BUILDING HEATING SYSTEM
To best use the Connect WP exhaust air heat pump, we recommend hydraulically integrating it into the
building heating system as shown in the system diagrams below. The device always operates in the
optimum power range and with the highest efficiency. Seasonal changes in heating and hot water
requirements are automatically recorded and adjusted. Due to this type of integration of the system, the
building heating technology remains virtually unaffected.
RECOMMENDATION AND SYSTEM DIAGRAM WITH AWN STRATIFIED STORAGE
To integrate an AWN in the heat supply of a building, Aereco recommends a combination with a stratified
storage tank with discharge system and preheating stage for domestic hot water (DHW). This enables both
an increase in the return flow of the heating circuit during the heating period and support for hot water
preparation throughout the year. As a result, the heat sink available to the AWN is maximised, as are
running times and contribution margins.
With this concept, it is not necessary to communicate with the components in the rest of the heating
system. An independent controller measures the temperature in the upper section of the stratified tank (S1)
and the heating water return (S2) in the heating circuit installed on site. The controller takes these
measured variables into account and controls the discharge pump (P) so that the heating water return flow
is always increased (S1 > S2).
DW preheating is automatically ensured by passing through a stainless-steel coil in the stratified storage
tank. The cold water (CW) is thus heated and then enters the water heater. Due to the small volume in the
preheating, this stage can be designed as a purely continuous system. A DW storage tank with an internal
heating water coil (storage system) would be considerably less efficient for preheating.
The heating water pump integrated in the exhaust air heat pump constantly pumps the heat via the heating
water into the stratified storage tank, where a simplified diagram is shown for use with central heating and
hot water preparation. In the case of deviating concepts, it is possible and necessary to appropriately adapt
the integration logic.
The respective concrete dimensioning and implementation only results from an individual viewpoint. This
drawing is to be understood as a non-binding planning proposal and does not replace any execution planning.
The shut-off and safety devices required for professional installation are not included.
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SETTINGS FOR USE WITH STRATIFIED STORAGE
If the Connect WP is integrated into the building heating system according to the above recommendation
(see concept sketch 4.1), the factory settings do not have to be adjusted. Only the following steps need
to be taken:
-Attach the temperature sensor to the lower part of the buffer tank and connect it to input terminal
6 (see circuit diagram).
-Ensure the buffer tank discharge pump (“P” in concept sketch 4.1) is regulated as described
above.
SETTINGS FOR USE WITHOUT STRATIFIED STORAGE
Deviating from the recommended system diagram (4.1), the unit can also be used in conjunction with
separate heating and domestic hot water storage tanks. The addition of an outdoor temperature sensor
enables dynamic temperature control of the treated water and thus increases the energy efficiency of the
system in this integration variant. In this case, the following steps must be carried out:
-Remove the cable bridge on input terminal 16
-Fit an outdoor temperature sensor to input terminal 12 (see circuit diagram)
-Attach the temperature sensor to the lower part of the buffer tank and connect it to input terminal 6
(see circuit diagram)
-Attach sensor 4 to the domestic hot water storage tank (see circuit diagram)
-Assemble and install the 3-way switch-over valves for switching between heating and domestic hot
water preparation (see circuit diagram)
-Set the value for the outlet temperature during hot water preparation to the desired setpoint (see
UVR module instructions)
-Set the desired heating curve for the heating backup (see UVR module instructions)
-Set the desired hot water temperature (see UVR module instructions). The
corresponding circuit diagrams are included with the respective unit.
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10.2
SETTING THE EXPANSION VESSEL
The standard value for the preload pressure
of the expansion vessel is 1.5 bar, the
maximum value is 6 bar.
Adjust the vessel according to the maximum
difference in height (H) of the consumption
point (see figure) according to the following
formula:
psetting[bar] = H[m] + 0.3
If, for example, the value of the height
difference H equals 20 m, the setting value
of the vessel is 2.3 bar.
If the setting value obtained by the calculation
is less than 1.5 bar (i.e. for H < 12.25), the
standard setting must be retained. For height
differences of over 55 m, a special solution
must be
determined. The pressure relief valve and expansion vessel are not designed for this purpose.
Key Hmax Ensure that the highest consumption point does not exceed the height
difference of 55 metres.
Hmin Ensure that the lowest consumption point can withstand the total
pressure at this point.
Reference operating conditions:
Max. water temp. = 60°C,
Min. water temp. = 15°C
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INTEGRATION WARNINGS
CAUTION
Based on expertise, the selection and installation of components outside the unit is the responsibility of
the installer, who must work in accordance with good engineering practice and the regulations in force in
the country of destination.
CAUTION
The connecting pipes to the machinery must be adequately dimensioned for the actual water flow required
by the system when in operation. The water flow at the heat exchanger must always be constant. In
particular, pressure loss values must be subjected to the correction factors specified under 0 for the glycol
content present.
CAUTION
Clean the unit thoroughly before connecting it. This cleaning allows any possible residues, such as
welding beads, secretions, rust or other impurities, to be removed from the pipes. These substances
may otherwise accumulate inside the unit and lead to the unit malfunctioning.
CAUTION
The connecting lines must be adequately supported so that their weight does not burden the unit.
CAUTION
In the event of system downtime, the water contained in the heat exchanger may freeze and cause
irreparable damage to the source-side heat exchanger (AWN circuit). To avoid the danger of freezing,
there are three possible solutions:
1. Fully draining the water from the unit.
2. Operating with glycolised water, with a glycol content selected according to the minimum external
temperature.
3. Using resistors. In this case, the resistors must always be live whenever there is the possibility of
frost (machine in standby mode).
CAUTION
If the AWN fan fails (loss of power or fault), ensure that the heat pump also switches off. Otherwise the
system may be damaged. For this purpose, a release signal must be transmitted from the AWN to the
Connect WP via a potential-free contact (see below).
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5. OPERATING RANGE AND OPERATING LIMITS
In its standard configuration, the unit is not suitable for installation in a salty environment. The operating
limits refer to a temperature difference at the evaporator and at the condenser of �t = 5°C. Whenever the
unit is to be operated outside the operating range, we recommend that you contact our technical service
department beforehand.
For further information, please refer to the table of power ratings and power consumption deviating from the
nominal value in the corresponding chapter.
Heating mode operating ranges
70
60
50
40
30
20 2 4 6 8 10 12 14 16 18
Water outlet temperature
to the AWN / °C
When operating under full load, the Connect WP provides hot water up to 60°C. An efficiency limit is pre-
programmed at the factory, which switches off the heat pump at a buffer memory temperature of 45°C
(bottom). This can be adapted on site or during commissioning. This is particularly suitable for operation
with own electricity (e.g. from photovoltaics). Please refer to the technical documentation for further
details.
20
Heating circuit water outlet
temperature / °C