AIT Hydraulic Station User manual

UK
83059300gUK
Accessories for
heat pumps
Operating Manual
Hydraulic Station

2Subject to change without notice | 83059300gUK | ait-deutschland GmbH
Table of contents
1 About this operating manual ...................... 3
1.1 Validity....................................................... 3
1.2 Reference documents............................... 3
1.3 Symbols and markings.............................. 3
1.4 Contact...................................................... 4
2 Safety ............................................................... 4
2.1 Intended use ............................................. 4
  ............................ 4
2.3 Personal protective equipment ................. 4
2.4 Residual risks............................................ 4
2.5 Avoid damage to property......................... 5
3 Operation and care....................................... 5
3.1 Energy and environmentally conscious
operation ................................................... 5
3.2 Maintenance.............................................. 5
4 Scope of supply............................................. 6
4.1 Accessories............................................... 6
4.2 Components of the device ........................ 6
5 Transport, installation and assembly ....... 7
5.1 Unpacking and transport........................... 7
5.2 Making transport easier ............................ 7
5.3 Carrying the device and transporting
with handcart............................................. 7
5.4 Installation................................................. 8
5.5 Installation / hydraulic connection to the
heating circuit and the domestic hot water ... 8
5.6 Safety module ........................................... 9
5.7 Expansion vessel ...................................... 9
5.8 Hydraulic connection for the
domestic hot water tank ............................ 9
6 Electrical installation..................................... 9
7 Installing the control device.......................11
  ...................... 12
8.1 Heating water quality .............................. 12
 
domestic hot water charging circuit......... 12
 
the domestic hot water tank .................... 13
9 Insulate hydraulic connections ................ 14
 ................................ 14
11 Commissioning ............................................ 14
12 Faults.............................................................. 14
12.1 Unlock the safety temperature limiter ..... 14
13 Dismantling and Disposal......................... 15
13.1 Dismantling ............................................. 15
13.2 Disposal and Recycling........................... 15
Technical data / Scope of supply............ 16
HSV ................................................................ 16
HSDV .............................................................. 18
Free pressing ............................................... 20
HSV 9M1/3 ....................................................... 20
HSDV 9M1/3..................................................... 20
HSV 12M3, HSV 12.1M3 .................................. 20
HSDV 12M3, HSDV 12.1M3 ............................. 20
Dimensioned drawings .............................. 21
HS(D)V 9M1/3 .................................................. 21
HS(D)V 12M3 ................................................... 22
HS(D)V 12.1M3 ................................................. 23
Installation plans.......................................... 24
HS(D)V 9M1/3 .................................................. 24
HS(D)V 12M3, HS(D)V 12.1M3......................... 25
Terminal diagrams ...................................... 26
HSV ................................................................ 26
HSDV .............................................................. 27
Terminal diagram, mains connection
heat pump 1~230V
+ electric heating element 3~400V ......... 28
Terminal diagram, mains connection
heat pump 1~230V
+ electric heating element 1~230V ......... 29
Terminal diagram, mains connection
heat pump 3~400V
+ electric heating element 3~400V ......... 30
Circuit diagrams........................................... 31
HSV ................................................................ 31
HSDV .............................................................. 33

3Subject to change without notice | 83059300gUK | ait-deutschland GmbH
1 About this operating manual
This operating manual is part of the device.
Before working on or with the device, read the op-
erating manual carefully and follow it for all activi-
ties at all times, especially the warnings and safe-
ty instructions.
Keep the operating manual to hand at the de-
vice and hand over to the new owner if the device
changes hands.
If you have any questions or anything is unclear,
ask the local partner of the manufacturer or the
factory's customer service.
Note and follow all reference documents.
1.1 Validity
This operating manual exclusively refers to the device

1.2 Reference documents
The following documents contain additional informa-
tion to this operating manual:
Planning & design manual, hydraulic integration
Operating manual of the heating and heat pump
controller
Brief description of the heat pump controller
Operating manual of the expansion board (acces-
sories)
Log book
Heat pump manual
1.3 Symbols and markings

Symbol Meaning
Safety-relevant information.
Warning of physical injuries.
DANGER Indicates imminent danger resulting
in severe injuries or death.
WARNING Indicates a potentially dangerous
situation, which can result in severe
injuries or death.
CAUTION Indicates a potentially dangerous
situation, which can result in
moderate or minor injuries.
IMPORTANT Indicates a potentially dangerous
situation, which can result in
property damage.
Symbols in the document
Symbol Meaning

Information for the owner/operator
Requirement for action
Single step action prompt
1., 2., 3., …Numbered step within a multi-step
action prompt. Keep to the given
order.
Additional information, e.g. a tip on
making work easier, information on
standards
Reference to further information
elsewhere in the operating manual
or in another document
Listing

4Subject to change without notice | 83059300gUK | ait-deutschland GmbH
1.4 Contact
Addresses for purchasing accessories, for service
cases or for answers to questions about the device
and this operating manual can be found on the internet
and are kept up-to-date:
www.ait-deutschland.eu
2 Safety
         
condition and only use it as intended, safely and aware
of the hazards, and follow this operating manual.
2.1 Intended use
The device is solely intended for the following func-
tions:
Heating
Domestic hot water preparation
Proper use includes complying with the operating
conditions ( „Technical data / Scope of sup-
ply“, from page 16) and the operating manu-
al and noting and following the reference docu-
ments.
When using the local regulations note: laws,
standards, guidelines, directives.
All other uses of the device are not as intended.
2.2 
The operating manuals supplied with the product are
intended for all users of the product.
The operation of the product via the heating and heat
pump control and work on the product which is intend-
ed for end customers / operators is suitable for all age
groups of persons who are able to understand the ac-
tivities and the resulting consequences and can carry
out the necessary activities.
Children and adults who are not experienced in han-
dling the product and do not understand the neces-
sary activities and the resulting consequences must
be instructed and, if necessary, supervised by persons
experienced in handling the product and who are re-
sponsible for safety.
Children must not play with the product.

All instructional information in this operating manual is

        
the work on the device safety and correctly. Interfer-
-
ing injuries and damage to property.
Ensure that the personnel is familiar with the lo-
cal regulations, especially those on safe and haz-
ard-aware working.
 
only to carry out work on the electrics and elec-
tronics.
        
other work on the system, e.g.
Heating installer
Plumbing installer
Refrigeration system installer (maintenance
work)
During the warranty and guarantee period, service
work and repairs may only be carried out by personnel
authorised by the manufacturer.
2.3 Personal protective equipment
There is a risk of cutting your hands on sharp edges of
the device.
Wear cut-resistant protective gloves during trans-
port.
2.4 Residual risks
Electric shock
Components in the device are energised with
life-threatening voltage. Before opening the device
panelling:
Disconnect the device from power supply.
Protect the device against being switched back
on again.
Existing earthing connections within housings or on
mounting plates must not be altered. If this should ne-
vertheless be necessary in the course of repair or as-
sembly work:
Restore earthing connections to their original con-
dition after completion of the work.

5Subject to change without notice | 83059300gUK | ait-deutschland GmbH
2.5 Avoid damage to property
Improper action
Requirements for minimum scale and corrosion dam-
age in hot water heating systems:
Proper planning, design and commissioning
Closed system with regard to corrosion
Integration of an adequately dimensioned pres-
sure maintaining device
Use of demineralised heating water (VE water) or
water corresponding to the VDI 2035 norm
Regular servicing and maintenance
If a system is not planned, designed, started up and
operated according to the given requirements, there is
a risk that the following damage and faults will occur:
Malfunctions and the failure of components, e.g.
pumps, valves
Internal and external leaks, e.g. from heat ex-
changers
Cross-section reduction and blockages in compo-
nents, e.g. heat exchanger, pipes, pumps
Material fatigue
Gas bubbles and gas cushion formation (cavita-
tion)
 󰀨
coatings, deposits, and associated noises, e.g.

Note and follow the information in this operating
manual for all work on and with the device.

water in the heating circuit
󰀩
heat generator and the heating components depend
decisively on the quality of the heating water.
-
ter, calcium precipitates as scale. Lime scale deposits
form on the heat transfer surfaces of the heating. The
󰀩-
es, the heat exchangers will be damaged.
Fill the system with deionised heating water
(VE water) or with water corresponding to the VDI
2035 norm only (low-salt operation of the system).
3 Operation and care
NOTE
The device is operated via the control panel
of the heating and heat pump controller
( operating manual of the heating and
heat pump controller).
3.1 Energy and environmentally
conscious operation
The generally accepted requirements for energy con-
scious and environmentally conscious operation of a
heating system also apply to use of a heat pump. The
most important measures include:
 
No unnecessarily high domestic hot water tem-
perature (note and follow local regulations)
Do not open windows with just a gap or tilt open
(continuous ventilation), but instead open wide for
a short time (shock ventilation)
Always ensure that the controller settings are cor-
rect
3.2 Maintenance
Wipe down the outside of the device only using a
damp cloth or cloth with mild cleaning product (wash-
ing up liquid, neutral cleaning product). Do not use any
harsh, abrasive, acid or chlorine-based cleaning prod-
ucts.

6Subject to change without notice | 83059300gUK | ait-deutschland GmbH
4 Scope of supply
Example of scope of supply arrangement
Example HS(D)V 9M1/3
1 Compact device (domestic hot water tank and
󰀨
2 Accompanying parts package: safety module,
pump ball valves, outdoor temperature sensor,
adjustable feet
3 Accompanying parts package: control panel for
the heating and heat pump controller
1. Inspect the delivery for outwardly visible signs of
damage.
2. Inspect the scope of supply for completeness.
Any defects or incorrect deliveries must be report-
ed immediately.
4.1 Accessories
The following accessories are available for the device
through the manufacturer's local partner:
Expansion circuit printed board with various addi-
tional functions
Room control panel for controlling the main func-
tions from the living room
Electrical connection kit
4.2 Components of the device
Example HS(D)V 9M1/3
 󰀨

HS(D)V 12…)
 󰀨
3 Heating circuit recirculating pump (HUP)
4 Domestic hot water tank
 
6 Electric heating element behind shielding
panel
7 Switchover valve domestic hot water
8 Heating circuit safety module (insulated)
9 Protection anode
10 Controller
11 Switch box
12 Expansion tank
󰀨
󰀨󰀨
15 Feet for adjusting screws

7Subject to change without notice | 83059300gUK | ait-deutschland GmbH
5 Transport, installation and
assembly
5.1 Unpacking and transport
Notes on safe transport
The device is heavy ( „Technical data / Scope of
supply“, from page 16). There is a risk of injuries or
damage to property if the device falls or overturns.
There is a risk of cutting your hands on sharp edges of
the device.
Wear cut resistant protective gloves.
The hydraulic connections are not designed for me-
chanical loads.
Do not lift or transport the device by the hydraulic
connections.
Transport the device preferably with a pallet truck, al-
ternatively with a handcart or by carrying.
Transport with a pallet truck
Transport the device to the place of installation
packaged and secured on a wooden pallet.
Unpacking
1. -
age the device.
2. Dispose of the transport and packaging material
in an environmentally friendly way and in accord-
ance with local regulations.
3.         
front panel at the place of installation.
If the device is to be carried, then it is recommended
that the wooden pallet is not removed yet.
5.2 Making transport easier
In order to make the transport simpler and easier, the
whole hydraulic system(including the controller with
switch box) can be unscrewed beforehand.
The hydraulic system is fastened to the tank with 3
hexagonal bolts.
Beispiel HS(D)V 9M1/3
1 4 union nuts, which must be loosened when
unscrewing
2 3 hexagonal bolts
First loosen the union nuts (①) on the pipework to the
tank, then the 3 hexagonal bolts (②) and then remove
the whole hydraulic system from the tank.
5.3 Carrying the device and
transporting with handcart
Carrying the hydraulic station
In order to make it easier to carry, a T-piece with two

outlet. It is recommended that the wooden pallet is on-
ly removed after carrying is complete.
Carry the hydraulic station to the installation site
with 3 – 4 people.

8Subject to change without notice | 83059300gUK | ait-deutschland GmbH
Transporting the hydraulic station with a
handcart
1. Load the hydraulic station with the underside of
the device on the handcart.
2. Secure the hydraulic station to the handcart with
lashing straps.
3. Transport the hydraulic station to the installation
site.
5.4 Installation
Installation site
IMPORTANT
Only ever install the device inside buildings.
The installation area must be frost-free and dry. It must

„Installation plans“, from page 24 and „Dimen-
sioned drawings“, from page 21, for the respec-
tive model
1. Place the device on a stable and horizontal sur-
face, preferably decoupled from structure-borne
noise.
2. Tilt the device slowly and carefully to one side.
3. Secure the tilted device to ensure that it cannot tip
back to its initial position.
4. Fit the adjusting screws to all 3 feet.
Screw-in the adjusting feet
5. Tilt the device slowly and carefully back to its ini-
tial position.
6. Level out the three adjusting screws.
7. If the hydraulic system was dismantled for trans-
port reasons, then it must be screwed back into
place on the tank!
5.5 Installation / hydraulic connection
to the heating circuit and the
domestic hot water
NOTE
Before connection to the heating system, the

„Dimensioned drawings“, from page 21
IMPORTANT
Damage to the copper pipes due to unacceptable
loading!
Secure all connections against twisting.
Cross-sections and lengths of the pipes for the
heating circuit are adequately dimensioned. In do-
ing so, ensure that the connection pipework be-
tween the heat pump and hydraulic station are also
taken into account.
Freely pressing the recirculating pump produces
at least the minimum throughput required for the
device type ( “Free pressing”, page 20).


Insert the vent at the highest point of the heating
circuit.
Lift up the hood at the front of the hydraulic sta-
tion.

9Subject to change without notice | 83059300gUK | ait-deutschland GmbH
1. There are 3 grooves located on the left and right
on the inside of the hood. There are 3 correspond-
ing studs on the tower housing to lock the hood.
2. This enables it to be dismantled and re-assem-
bled with a single manual action.
5.6 Safety module
The safety module for the heating circuit is in the ex-
tra box.
Install the safety module at the connection provided
on the top of the device.
The safety discharge of the safety valve must be dis-
charged into the drain via a funnel waste trap in accord-
ance with the respective valid standards, guidelines and
directives.
5.7 Expansion vessel
The expansion vessel for the heating circuit is integrated.
Always inspect whether the size of the expansion ves-
sel is large enough for the system. If necessary, an ad-
ditional expansion vessel must be installed on site in
accordance with the relevant valid standards.
NOTE
The admission pressure of the expansion
vessel must be adjusted to the system (ap-
-
sure) in accordance with calculation accord-
ing to the relevant standards (EN 12828).
5.8 Hydraulic connection for the
domestic hot water tank
Connect the domestic hot water tank according to DIN
1988 and DIN 4753 Part 1 (or the standards and direc-
tives applicable locally).
The working overpressure cited on the rating plate
must not be exceeded. Install a pressure reducer if re-
quired.
The sensor for the domestic hot water preparation is
already connected in the switch box.
IMPORTANT
The electrical conductivity of the domestic hot wa-
ter must be > 100 µS/cm and must lie within the
drinkable water quality limits.
6 Electrical installation
6.1 Connect the electrical cables
IMPORTANT
Irreparable damage to the compressor due to

 
the compressor load infeed.
Basic information on the electrical connection
       
company may apply to electrical connections
Fit the power supply for the heat pump with an
all-pole circuit breaker with at least 3 mm contact
spacing (per IEC 60947-2)
Note the level of the tripping current („Technical
data / Scope of supply“, from page 16))
Comply with the electromagnetic compatibility
regulations (EMC regulations)
Lay unshielded power supply cables and shielded
󰀩
Maximum line length: 30m
Cable extension details see heat pump manual

10 Subject to change without notice | 83059300gUK | ait-deutschland GmbH
5. Carry out electrical connections in accordance
with the terminal diagram.
„Terminal diagram“ for the respective model, from
page 26
1 Contactor
2 Control panel
3 Bus cable connection
4 Electrical switch box
5 Strain relief
The hydraulic station is connected on site to the sub-
distribution according to the following scheme:
5
1 Heat pump
2 Load Compressor
3 Bus (shielded)
4 Control voltage (for dual heat pump only)
5 Hydraulic station
6 Heating element load line
7 Control voltage
8 Load Compressor
9 Sub-distribution
Establish the electrical connections between
the heat pump and the hydraulic station
1. Route the two plug-in connections of the load and
bus cables from the hydraulic station to the plug-
in points on the heat pump.
NOTE.
For dual output-controlled heat pumps, the
lines (8 m) are already connected to the heat
pump.
2. Couple the connections together.
3. Fit cover for plug-in connections.
6.2 Electrical connection
The electrical connection is established via the switch
box.
1. Strip the sheathing of all cables to the external
loads before laying in the cable gland of the con-
trol box.
2. Feed the cable on the rear of the hydraulic station
through the cable gland into the switch box.
3. Open the switch box in the device.
Only slightly undo the top two screws of the cov-
er plate. Remove the remaining screws. Unhook
cover panel.
4. Feed the control and sensor cable as well as
the cable for the EVU blocking time through the
glands on the rear of the device and into the interi-
or of the device. Lay the cables through the cable
gland to the terminals in the switch box.