alphainnoTec WWC H/X Series User manual

UK
Water/Water-Heat Pumps
Compact
83050700fUK – Translation into English of the original German operating manual
Operating Manual
WWC H/X – series
WWC X – series

2Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Please read rst
This operating manual provides important information
on handling the unit. It is an integral part of the product
and must be stored so that it is accessible in the immedi-
ate vicinity of the unit. It must remain available through-
out the unit's entire service life. It must be handed over
to subsequent owners or users of the unit.
Read the operating manual before starting any work on
or with the unit. Especially the chapter on safety. Follow
all instructions in full and unreservedly.
It is possible that this operating manual may contain
instructions that seem incomprehensible or unclear. In
the event of any questions or if any details are unclear,
contact the factory customer service department or the
manufacturer's local partner.
Since this operating manual was written for several
different models of the unit, always comply with the
parameters for the respective model.
This operating manual is intended only for persons
assigned to work on or with the unit. Treat all constitu-
ent parts condentially. They are protected by copy-
right. They may not be reproduced, transmitted, copied,
stored in electronic systems or translated into another
language, either wholly or in part, without the express
written permission of the manufacturer.
Symbols
The following symbols are used in the operating manual.
They have the following meaning:
Information for uers.
Information or instructions for qualied
technicians.
DANGER!
Indicates imminent danger, which results
in severe injuries or death.
WARNING!
Indicates a potentially dangerous situa-
tion, which could result in severe injuries
or death.
CAUTION!
Indicates a potentially dangerous situation
that could result in moderate or slight
injuries.
IMPORTANT
Indicates a potentially dangerous situation, which
could result in property damage.
NOTE.
Emphasized information.
€ENERGY SAVING TIP
Indicates advice, which helps to save energy, raw
materials and costs.
Reference to other sections of the operating
manual.
Reference to other documents of the manufac-
turer.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Contents
INFORMATION FOR USERS AND QUALIFIED
PERSONNEL
PLEASE READ FIRST..................................................................2
SYMBOLS .....................................................................................2
INTENDED USE..........................................................................4
DISCLAIMER................................................................................4
EC CONFORMITY .....................................................................4
SAFETY .........................................................................................4
CUSTOMER SERVICE ................................................................5
WARRANTY / GUARANTEE ....................................................5
DISPOSAL ....................................................................................5
OPERATING PRINCIPLE OF HEATPUMPS ..........................5
AREA OF USE AND
HEAT SOURCE REQUIREMENTS.....................................6
HEAT METERING.......................................................................7
OPE R ATI ON ................................................................................7
CARE OF THE UNIT..................................................................7
MAINTENANCE OF THE UNIT ..............................................7
Cleaning and flushing unit components.............................7
MALFUNCTIONS.......................................................................8
INSTRUCTIONS FOR QUALIFIED TECHNICIANS
SCOPE OF DELIVERY ................................................................8
Main components..................................................................9
INSTALLATION ..........................................................................9
Installation room...................................................................9
Transport to installation location....................................10
Installation............................................................................10
INSTALLING THE HYDRAULIC CONNECTIONS ...........12
Safety assembly ...................................................................13
Expansion vessel .................................................................13
DOMESTIC WATER HEATING..............................................14
DOMESTIC HOT WATER TANK ..........................................14
ELECTRICAL CONNECTION WORK .................................14
FLUSHING AND FILLING THE SYSTEM .............................16
Water quality of the fill and make-up water in
water heating systems according to VDI 2035 ........16
Flush and fill the heating circuit and
the domestic hot water tank ......................................17
BLEEDING..................................................................................18
INSULATING THE
HYDRAULIC CONNECTIONS .......................................19
INSTALLING THE CONTROL PANEL .................................19
INSTALLATION AND REMOVAL OFTHESCREEN .........20
SET THE OVERFLOW VALVE.................................................21
PUMP SETTINGS FOR
WWC 220HX AND WWC 280X.............................22
COMMISSIONING ...................................................................22
Safety temperature limiter................................................23
DISMANTLING .........................................................................23
TECHNICAL DATA / SCOPE OF DELIVERY
WWC 100H/X – WWC 220H/X ....................................24
WWC 280X – WWC 440X..............................................26
PERFORMANCE CURVES
Heating capacity/COP / Power consumption /
Heat pump pressure loss
WWC 100H/X ....................................................................28
WWC 130H/X ....................................................................29
WWC 160H/X ....................................................................30
WWC 190H/X ....................................................................31
WWC 220H/X ....................................................................32
WWC 280X.........................................................................33
WWC 440X.........................................................................34
DIMENSIONAL DRAWINGS AND INSTALLATION PLANS
WWC 100H/X – WWC 220H/X
Dimensional drawings ........................................................35
Installation plan ...................................................................36
WWC 280X
Dimensional drawings ........................................................37
WWC 440X
Dimensional drawings ........................................................38
WWC 280X – WWC 440X
Installation plan ...................................................................39
HYDRAULIC INTEGRATION
WWC 100H/X – WWC 220H/X
Default ................................................................................. 40
Separate buffer tank...........................................................41
WWC 280X – WWC 440X
Default ..................................................................................42
Separate buffer tank...........................................................43
Legend Hydraulic integration........................................... 44
TERMINAL DIAGRAMS
WWC 100H/X – WWC 220H/X ....................................45
WWC 280X – WWC 440X..............................................46
CIRCUIT DIAGRAMS
WWC 100H/X ....................................................................47
WWC 130H/X – 220H/X..................................................50
WWC 280X.........................................................................53
WWC 440X.........................................................................56
EC DECLARATION OF CONFORMITY..............................59

4Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Intended use
The unit is only to be used for its intended purpose. This
means:
•for heating.
•for domestic water heating.
The unit may be operated only within its technical
parameters.
Overview “Technical data / scope of delivery”.
NOTE.
Notify the responsible power supply company of
the use of a heat pump or heat pump system.
Disclaimer
The manufacturer is not liable for any damage or losses
resulting from use of the unit which is not its intended
use.
The manufacturer's liability also expires:
•if work is carried out on the unit and its compo-
nents contrary to the instructions in this operat-
ing manual.
•if work is improperly carried out on the unit and
its components.
•if work is carried out on the unit which is not
described in this operating manual, and this work
has not been explicitly approved by the manufac-
turer in writing.
•if the unit or components in the unit have been
altered, modied or removed without the explicit
written consent of the manufacturer.
EC conformity
The unit bears the CE marking.
EC Declaration of Conformity
Safety
The unit is safe to operate for its intended use. The con-
struction and design of the unit conform to current state
of the art standards, all relevant DIN/VDE regulations
and all relevant safety regulations.
Every person who carries out work on the unit must
have read and understood the operating manual before
starting any work. This also applies if the person con-
cerned has already worked with such a unit or a similar
unit or has been trained by the manufacturer.
Every person who carries out work on the unit must
comply with the relevant local accident prevention and
safety regulations. This especially applies to the wearing
of personal protective clothing.
DANGER!
Risk of fatal electric shock!
All electrical connection work must be
carried out by qualied electricians only.
Before opening the unit, safely disconnect
the system from the power supply and
prevent it from being switched back on!
WARNING!
Only qualied personnel (trained heat-
ing, refrigerating system and refrigerant
engineers and electricians) may carry out
work on the unit and its components.
WARNING!
Note and follow safety stickers on and in
the unit.
WARNING!
Unit contains refrigerant!
Leaking refrigerant could result in per-
sonal injury and environmental damage.
Therefore:
– Switch off system.
– Thoroughly ventilate installation
room.
– Notify the manufacturer’s authorised
service centre.
IMPORTANT
For safety reasons:
Never disconnect the unit from the power sup-
ply, unless the unit is being opened.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
IMPORTANT
Only install the heat pump indoors.
Dimensioned drawing and installation plan for
the respective unit model.
Customer service
For technical assistance, please contact your qualied
technician or the manufacturer’s local service partner.
For a current list and additional partners of the manufac-
turer, please visit
DE: www.alpha-innotec.de
EU: www.alpha-innotec.com
Warranty / Guarantee
For warranty and guarantee provisions, please refer to
your purchase documents.
NOTE.
Please contact your dealer about all matters
concerning warranties and guarantees.
Disposal
When withdrawing the old unit from service, always
comply with the relevant local laws, guidelines, direc-
tives and standards concerning the recovery, recycling
and disposal of the operating materials and components
of refrigerating units.
“Dismantling”.
Operating principle of
heatpumps
Heat pumps operate on the same principle as a refriger-
ator: same technology, only with reversed benets. The
refrigerator extracts heat from foods, which is released
into the room through ns on the back.
The heat pump extracts heat from our environment:
air, earth or ground water. The extracted heat is condi-
tioned in the unit and supplied to the heating water. Even
when it is extremely cold outside, the heat pump draws
enough heat to heat a house.
Example: drawing of a brine/water heat pump with oor
heating:
4/4= usable energy
approx.
3/4= environmental energy
approx.
1⁄4= external
electrical energy

6Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Area of use and
heat source requirements
Taking into consideration the ambient conditions, limits
of use and the relevant regulations, every heat pump can
be used in new or existing heating systems.
“Technical data / scope of delivery” overview,
WATER TEMPERATURE / WATER QUANTITY
The water in the extraction well of the heat source
system must have a minimum temperature of 7 °C all
year round and may not exceed a temperature of 25°C.
Depending on the heat output required or its cooling
capacity as a relevant variable for dimensioning the heat
source, a minimum water rate is required, which must
be provided by the heat source as a continuous output.
Before installing the water/water heat pump, a pump test
should/must be carried out for at least 12 hours with
verication of a quasi-constantly lowered water table
(persistence) in order to provide information about
the quantity of water available. For efcient operation
of the well, during the initial start-up the nominal ow
rate must be adjusted on the heat source side. Any
appropriate components, which enable balancing are
to be installed in the pipe network here. The material
of the components used must be chosen according to
the water quality. The necessary ow rate (heat source
water rate) must meet the heat pump's requirements.
“Technical data/scope of supply” overview.
WATER QUALITY
In Germany the well must be designed and built to DIN
4021 and VDI 4640 (in other countries according to the
corresponding regulations). Wells may only be drilled
and built by drilling companies with a permit in accord-
ance with DVGW W120. The water quality of the heat
source is dened as normal groundwater. Ensure that
the suction and return pipe always extends below the
water level by sufcient depth, to ensure that oxygen
is not added to the water (risk of iron oxide deposits).
Please discuss the problem of iron oxide deposits with
your well builder. During the planning the quality of the
groundwater should be checked in advance as well as
possible (e.g. by asking the competent water authority
or searching for data on existing adjacent wells) and sub-
sequently veried by water analysis in the built produc-
tion well. The following table helps to assess the water
quality.
IMPORTANT
A water analysis and pump test must be carried
out before installing the water/water heat pump.
NOTE:
Water analyses are prepared by water test labo-
ratories. Initial information about possible use of
groundwater is available from your local water
management authority. A pump test provides
information as to whether a sufcient quantity
/ rate of water is available to cover the require-
ments for the heating output of your unit. The
minimum groundwater ow rate must at least be
available as a continuous output.
“Technical data/scope of supply” overview,
“Heat source ow rate” section.
EVALUATION OF THE WATER ANALYSIS
Water constituents - minimum requirement. The water
should be analysed in advance for the test values listed
below (table). An important criterion to be used for
taking water samples is the DVGW Standard, Technical
Notices, Leaet W 112 and use of the technical rules
listed in it (DIN, EN and ISO standards).
Designation Limit
pH value > 6.8
Iron level < 0.2 mg / l
Manganese level < 0.1 mg / l
Chloride level < 300 mg / l
Free chlorine level < 3 mg / l
Turbidit y none
Technical freedom
from sand
< 0,1 ml sand per
10 l pumped water
IMPORTANT
If a value does not conform to the value listed
in the table, a water/water heat pump may not
be used. Direct operation of the unit in conjunc-
tion with surface water, wastewater, industrial
wastewater or mixtures of water and alkali solu-
tions, acids or chlorine is also not allowed.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Heat metering
In addition to proof of the system's efciency, the
EEWaermeG (German law on renewable energy heat)
also requires heat metering (referred to in the follow-
ing as WME). The WME is mandatory for air/water heat
pumps. For brine/ water and water/water heat pumps, a
WME must be installed for ow temperatures ≥ 35 °C.
The WME must record the total thermal energy output
(heating and domestic hot water) in the building. In the
case of heat pumps with heat metering the analysis is
carried out via the controller. This displays the thermal
energy output into the heating system in kWh.
NOTE.
Unit variants with or without heat metering are
available.
Operation
ENERGY SAVING USE OF THE HEAT PUMP HEATING
By deciding to purchase a heat pump or a heat pump sys-
tem you are making a long-term contribution to protect-
ing the environment through low emissions and reduced
primary energy use.
You can operate and control the heat pump system with
the control panel of the heating and heat pump control-
ler.
NOTE.
Make sure that the control settings are correct.
Operating manual of the heating and heat pump
controller.
To ensure that your heat pump or heat pump system
operates efciently and in an environmentally friendly
way in heating mode, please pay particular attention to
the following:
€ENERGY SAVING TIP
Avoid unnecessarily high ow temperatures.
The lower the ow temperature on the heating
water side the more efcient the system.
€ENERGY SAVING TIP
Preferably use purge ventilation. Compared to
continuously open windows, this form of ventila-
tion (fully opening windows for a short period,
two to three times a day) reduces energy con-
sumption and your heating bill.
Care of the unit
You can clean the outer surfaces of the unit with a damp
cloth and proprietary household cleaning products.
Do not use cleaning or care products that contain abra-
sives, acids and/or chlorine. Such products would irrepa-
rably damage the surfaces and could also cause technical
damage to the unit.
Maintenance of the unit
The cooling circuit of the heat pump requires no regu-
lar maintenance.
According to EU regulation (EC) 517/2014, leak
inspections and maintenance of a log book are required
by law for certain heat pumps!
Log book for heat pumps, Section “Information
on use of the log book”.
The components of the heating circuit and the heat
source (valves, expansion vessels, circulation pumps, l-
ters, dirt traps) should be tested and cleaned as needed,
however, at least annually, by qualied personnel (heat-
ing or refrigerating system tters).
It is best to arrange a maintenance agreement with a
heating installation company. The company will arrange
the necessary regular maintenance work.
CLEANING AND FLUSHING UNIT COMPONENTS
CAUTION!
Unit components may be cleaned and
ushed only by customer service person-
nel authorised by the manufacturer. Use
only liquids recommended by the manu-
facturer.
After ushing the condenser with chemi-
cal cleaning agent, any residues must be
neutralised and the system intensively
ushed with water. Always note and follow
the technical data of the respective heat
exchanger manufacturer.

8Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Malfunctions
In the event of a malfunction, you can detect the cause
of the malfunction via the diagnostics program of the
heating and heat pump controller.
Operating manual of the heating and heat pump
controller.
WARNING!
Only customer service personnel author-
ised by the manufacturer may carry out
service and repair work on the compo-
nents of the unit.
Note that no fault is displayed if the safety temperature
limiter on the electric heating element has triggered
(depending on model).
“Commissioning”, “Safety temperature limiter”
section.
Scope of delivery
Example layout of the scope of delivery:
1 Compact unit with hermetic compressor, all
safety-relevant components for refrigeration
circuit monitoring, installed sensors for
recording the hot gas, heating water ow and
return temperature, sensors for monitoring
the heat source temperature, ow monitors
for monitoring the water ow rate
2 Screen
3 Safety assembly for the heating circuit
4 Separate package (size 1: one box; size 2: two
boxes) with control panel, external tempera-
ture sensor, dirt trap, Sylomer strips, seals
5 Vibration isolators for the heat-
ing circuit and for the heat source
6 Expansion vessel for the heat-
ing circuit with cap valve
Complete the following rst:
Check the delivery for outwardly visible signs of
damage…
Check to make sure that the delivery is complete…
Any defects or incorrect deliveries must be
reported immediately.
NOTE.
Note the unit model.
“Technical data / scope of delivery” overview.

9
Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
FUNCTIONALLY NECESSARY ACCESSORIES
IMPORTANT
Only use the manufacturer's original accessories.
If the unit is to be used for heating water, a 3-way switch-
ing valve must be installed. This is not included with the
unit and must be ordered separately.
MAIN COMPONENTS
1 evaporator
2 compressor
3 condenser
Installation
The following applies to all work to be done:
NOTE.
Always comply with the relevant local accident
prevention regulations, statutory regulations,
guidelines and directives.
NOTE.
Note the sound information for the respective
model.
“Technical data / Scope of delivery” overview,
“Sound” section.
INSTALLATION ROOM
ATTENTION
Install the heat pump only indoors.
The installation room must be frost-free and
dry.
WARNING!
Please note and follow the respective
relevant local standards, directives and
regulations applicable, especially the
minimum volume necessary depending
on the refrigerant capacity of the relevant
heat pump system (EN 378-1).
Refrigerant Limit
R 134a 0.25 kg/m³
R 404A 0.48 kg/m³
R 407C 0.31 kg/m³
R 410A 0.44 kg/m³
Overview “Technical data / scope of delivery”,
“General unit data” section.
Minimum volume = Refrigerant capacity [kg]
Limit [kg/m³]
NOTE.
If several heat pumps of the same type are instal-
led, only one heat pump must be considered.
If several heat pumps of different types are in-
stalled, the heat pump with the largest refrige-
rant capacity must be considered.

10 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
TRANSPORT TO INSTALLATION LOCATION
Always comply with the following safety information
during transport:
WARNING!
Several people are required to transport
the unit. Take into account the weight of
the unit.
“Technical data / Scope of delivery” overview,
“General unit data” section,
CAUTION!
Wear safety gloves.
WARNING!
The unit can tilt and tip over when being
removed from the wooden pallet and dur-
ing transport. This can result in personal
injury and damage to the unit.
– Take suitable precautions to prevent
the risk of tipping over.
IMPORTANT
Never use components and hydraulic connec-
tions on the unit for transport purposes.
IMPORTANT
Do not tilt the unit more than a maximum of 45°
(in any direction).
To prevent transport damage, you should transport the
unit to its nal place of installation in its packed condi-
tion (on the wooden pallet with packaging) using a pallet
truck.
If it is not possible to transport the unit to the nal instal-
lation location using a pallet truck, you can also transport
the heat pump on a handcart.
Before transporting with a handcart, we recommend
removing the front panel in order to reduce the weight
of the unit.
Remove packaging and set extra box aside (will be
needed later on!)...
Remove angle bracket, transport and packaging
material from the unit…
Dispose of angle bracket, transport and packaging
material properly and in an ecologically compatible
way...
Lift unit from the pallet…
Remove front panel of unit...
•
To do so, loosen the quick-release screws. Turn
through 90° to the left…
•
Lift front panel and set aside in a safe place.
Push handcart under the rear side of the unit.
IMPORTANT
If the handcart is pushed under the unit at the
rear panel, ensure you do not damage any con-
nections during transport.
IMPORTANT
Transport with a handcart on the front side of
the unit is not permitted.
IMPORTANT
Do not tilt the unit more than a maximum of 45°
(in any direction).
INSTALLATION
CAUTION!
Several people are required to install the
unit.
NOTE.
Take into account the size of the unit.
“Technical data / Scope of delivery” overview,
“General unit data” section.
NOTE.
Always refer to and follow the installation plan
for the respective model. Note the size and
minimum clearances.
Installation plan for the respective model.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Proceed as follows at the installation location:
If you have no already done so, remove angle
bracket, transport and packaging material from the
unit. Set the extra box to the side and lift the unit
from the wooden pallet...
“Transport to installation location”.
Dispose of angle bracket, transport and packaging
material properly and in an ecologically compatible
way...
Set unit on a stable, solid and level, preferably
sound-insulated surface. Ensure that the oor is
designed for the weight of the heat pump...
Set up the unit so that the switchbox side (= opera-
tor side) is accessible at all times...
“Technical data/Scope of delivery” overview,
“General unit data” section.
Use the Sylomer strips supplied to level out any
minor unevenness.
The Sylomer strips give the heat pump additional
stability. They absorb sound and vibrations transfer
to the oor.
Place the Sylomer strips under the heat pump as fol-
lows:
•
Tilt the unit to one side, slowly and carefully...
Secure unit in raised tilted position so that it cannot
accidentally tip back into the original position.
IMPORTANT
Do not tilt the unit more than a maximum of 45°
(in any direction).
CAUTION!
Hands and ngers could be crushed during
the following work!
•
Position a Sylomer strip under the unit, ush with
the respective outer edge...
•
Slowly and carefully tilt the unit back into its initial
position.
Repeat steps •to •for the remaining sides
of the unit.
Position Sylomer strips at right angles to each other,
end-to-end:
Front side of unit (= operator side)

12 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Installing the hydraulic
connections
NOTE.
All materials used in the heat source circuit
(pipes, connections, sealing material…) must be
corrosion resistant and suitable for the ground-
water quality. Use suitable plastics or stainless
steel.
IMPORTANT
Connect the unit to the heating circuit accord-
ing to the hydraulic diagram for the respective
model.
“Hydraulic connection” instructions.
IMPORTANT
The heat source system must be designed
according to the specications of the planning
manual.
Planning manual and “Hydraulic connection”
documents.
NOTE.
Check to make sure that the cross-section and
lengths of the pipes for the heating circuit are
adequately dimensioned. The free compression
of the circulation pumps must be able to deliver
at least the minimum throughput required for
your model.
“Technical data /Scope of delivery” overview,
“Heat source” and “Heating circuit” sections.
NOTE:
Check whether the cross-sections and lengths
of the heat source pipes are adequately dimen-
sioned.
NOTE:
The heat source pump must be designed as a
constant speed pump. It must at least produce
the minimum throughput required for your unit
model. The heat source pump must be designed
by performing a pipe network calculation.
“Technical data/Scope of delivery” overview,
“Heat source” sections..
IMPORTANT
Please note that the designed heat source pump
may only be used within its pump characteristic
curve!
IMPORTANT
When installing the connections, always secure
the connections on the unit against twisting, in
order to prevent damage to the copper pipes
inside the unit.
NOTE:
Install the dirt trap included in the scope of
delivery in the well shaft (heat source inlet)
The connections for the heating circuit or the heat
source are located at the rear of the unit:
For position of the connections, please refer
to the dimensioned drawing for the respective
model.
Install shut-off devices for the heating water outlet
(ow) and heating water inlet (return) on the heat
pump side…
Install shut-off devices for the heat source inlet and
heat source outlet on the heat pump side…
NOTE.
By installing the shut-off devices, the evaporator
and condenser of the heat pump can be ushed,
if necessary.
Thoroughly ush the heating circuit and heat source
circuit before connecting to the unit…
NOTE.
Dirt and deposits in the heating circuit and heat
source can cause malfunctions.
Connect the xed pipes of the heating circuit with
the corresponding connections at the rear of the
unit. Use vibration isolators and elbow unions (size
2 only)…
Vibration isolators must be installed to prevent
structurally borne sound transfer to the xed pip-
ing.
Vibration isolators for the heating circuit are
included with the unit; they have a zinced mesh and
are marked in colour.

13
Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Connect the xed piping of the heat source with
the relevant connections at the rear of the unit. Use
vibration isolators and elbow unions (size 2 only)…
Vibration isolators must be installed to prevent
structurally borne sound transfer to the xed pip-
ing.
Vibration isolators for the heat source are included
with the unit and have a stainless steel mesh.
Lay vibration isolators in the quadrant, as shown by way
of example in the following sketch:
Straight or extended hose laying of the vibration isola-
tors is not permitted.
SAFETY ASSEMBLY
You must install the safety assembly for the heating
circuit. The safety assembly for the heating circuit is
included in the extra box.
The discharge from the heating water safety valve must
be drained according to the relevant standards and regu-
lations. Discharging the safety valve discharge into the
sewers is allowed only if fed via a a funnel siphon, which
must be accessible at all times.
The connection for the safety assembly is located on the
outside at the top rear of the unit.
1 Heating circuit safety
assembly connection
EXPANSION VESSEL
The expansion vessel for the heating circuit and the cor-
responding cap valve are included in the scope of deliv-
ery. They must both be integrated in the heating circuit
on site in compliance with the relevant standards, guide-
lines and directives.
IMPORTANT
In conjunction with a multi-functional and/or
buffer tank with volume >200 l, always install an
additional, adequately-dimensioned expansion
vessel.

14 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Domestic water heating
If the unit is to be used for domestic water heating, a
3-way changeover valve must be installed. This is not
included with the unit and must be ordered separately.
IMPORTANT
Only use the manufacturer’s original accessories.
Domestic water heating with the heat pump requires an
additional heating water circuit (parallel) to the heating
circuit. When connecting, make sure that the domestic
hot water charge is not fed through a buffer tank in the
heating circuit.
“Hydraulic connection” documents.
Domestic hot water tank
If the heat pump is to be used for domestic water heat-
ing, you must integrate special domestic hot water tanks
in the heat pump system. Choose a storage volume so
that the required quantity of domestic hot water is avail-
able even during a power failure.
NOTE:
The heat exchanger surface of the domestic hot
water tank must be dimensioned so that the
heating output of the heat pump is transferred
with minimum spread.
You can choose a domestic hot water tank from our
product range. They are optimally matched to your heat
pump.
NOTE:
Integrate the domestic hot water tank in the
heat pump system as shown in the hydraulic dia-
gram for your system.
“Hydraulic connection” documents.
Electrical connection work
The following applies to all work to be done:
DANGER!
Risk of fatal electric shock!
All electrical connection work must be
carried out by qualied electricians only.
Before opening the unit, safely disconnect
the system from the power supply and
prevent it from being switched back on!
WARNING!
During installation and when carrying out
electrical work, comply with the relevant
EN-, VDE and/or local safety regulations.
Comply with technical connection require-
ments of the responsible power supply
company (if required by the latter)!
NOTE.
All live cables must be stripped before they are
laid in the cable duct of the switchbox!
Open unit, if closed…
“Transport to the installation location”, and
.
Open electrical switchbox inside the unit…
1 Cover plate of the switchbox
2 Screw plugs

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Opened switch box size 1:
1 Controller board connections
2 Power and control
cable connections
Opened switch box size 2:
1 Controller board connections
2 Power and control
cable connections
Feed the load and control cables as well as the
cables for sensors into the inside of the unit through
the openings provided at the rear of the unit…
For positioning of the rubber grommets for
feeding through the cables, see “dimensioned
drawing” for the respective model.
Lay load and control leads in the cable duct inside
the unit all the way to the switchbox.
Install electrical connections according to the ter-
minal diagram and the circuit diagrams.
“Terminal diagrams” and “Circuit diagrams” for
the respective model.
IMPORTANT
Install electric connections only according to the
terminal diagram and the circuit diagrams that
apply to your model.
IMPORTANT
Ensure clockwise rotary eld of the load power
supply (compressor).
Operation with the incorrect rotary direction of
the compressor can cause serious, irreparable
damage to the compressor.
IMPORTANT
The power supply for the heat pump must be
equipped with a three-phase automatic circuit-
breaker with at least 3mm contact spacing to
IEC 60947-2.
Note the level of the tripping current.
“Technical data / Scope of delivery” overview,
“Electrics” section.
IMPORTANT
The sensor cable for heat quantity recording
may not be shortened!
NOTE.
The control panel of the heating and heat pump
controller can be connected to a computer or
network using a suitable network cable, enabling
the heating and heat pump controller to be con-
trolled remotely from there.

16 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
If this is required, install a shielded network cable
(category 6, with RJ-45 connector) through the
unit when installing the connections and run it
through the front panel of the unit, parallel to
the existing control cable of the heating and heat
pump controller.
After completing all electrical installation work,
close the switchbox inside the unit…
Screw on the front panel of the unit, if no further
installation work inside the unit is to be carried out
immediately.
Flushing and lling the system
IMPORTANT
The system must be absolutely free from air
before commissioning.
WATER QUALITY OF THE FILL AND MAKE-UP WATER IN
WATER HEATING SYSTEMS ACCORDING TO VDI 2035
PART I AND II
Use of modern, energy-efcient heat pump systems
is becoming increasingly widespread. Their ingenious
technology enables these systems to achieve very good
efciencies. The decreasing space available for heat gen-
erators has led to the development of compact units
with increasingly smaller cross-sections and high capaci-
ties. This means the complexity of the systems and the
material diversity are also increasing, which plays an
important role especially in their corrosion behaviour.
The heating water not only affects the efciency of the
system, but also the life of the heat generator and the
heating components of a system.
The guide values of VDI 2035 Part I and Part II must
therefore be complied with as minimum requirements
for proper operation of the systems. Our practical expe-
rience has shown that the safest, most reliable and fault-
free running is achieved with so-called low-salt operation.
VDI 2035 Part I provides important information and
recommendations regarding scaling and its prevention in
heating and domestic hot water heating systems.
VDI 2035 Part II primarily deals with the requirements
for reducing heating water corrosion in hot water heat-
ing systems.
PRINCIPLES OF PART I AND PART II
The occurrence of scaling and corrosion damage in hot
water heating systems is low, if
- proper planning, design and commissioning is carried
out
- the system is closed in corrosion terms
- adequately dimensioned pressurising is integrated
- the guide values for the heating water are complied
with
- and regular servicing and maintenance are carried out.
A system log should be kept, in which the relevant plan-
ning & design data is entered (VDI 2035).
DAMAGE THAT CAN OCCUR IN CASE OF FAILURE TO
COMPLY WITH THE ABOVE
- Malfunctions and the failure of components (e.g.
pumps, valves)
- Internal and external leaks (e.g. from heat exchangers)
- Cross-section reduction and blockaging of compo-
nents (e.g. heat exchanger, pipes, pumps)
- Material fatigue
- Gas bubbles and gas cushion formation (cavitation)
- Negative effect on heat transfer (formation of coat-
ings, deposits) and associated noises (e.g. boiling
noises, ow noises)
LIMESCALE – THE ENERGY KILLER
Filling with untreated drinking water inevitably leads to
the precipitation of all calcium as scale. The consequence:
limescale deposits form on the heat transfer surfaces of
the heating. The efciency falls and the energy costs rise.
A rule of thumb is that 1 millimetre of limescale deposit
causes an efciency loss of 10%. In extreme cases it can
even cause damage to the heat exchangers.
WATER SOFTENING TO VDI 2035 – PART I
If the water is softened in accordance with the VDI 2035
guidelines before it is used to ll the heating system, no
scale can form. This effectively and permanently prevents
limescale deposits and the resulting negative effects on
the entire heating system.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
CORROSION – AN UNDERESTIMATED PROBLEM
VDI 2035, Part II, deals with the problem of corrosion.
Softening the heating water can prove to be insufcient.
The pH value can signicantly exceed the limit of 10. pH
values higher than 11 can set in, which even damage rub-
ber seals. The VDI 2035, Part 1 guidelines are fullled;
however, VDI 2035, Part 2 suggests a pH value between
8.2 and maximum 10.
If aluminium materials are used, which is the case in
many modern heating systems, a pH value of 8.5 must
not be exceeded! Because otherwise there is a threat of
corrosion – aluminium is attacked without the presence
of oxygen. Therefore, apart from softening the heating
ll and make-up water, the heating water should also be
appropriately conditioned. This is the only way to com-
ply with the VDI 2035 requirements and the recommen-
dations and installation instructions of the heat pump
manufacturer.
Part 2 of VDI 2035 also refers to the reduction in total
salt content (conductivity). The risk of corrosion is far
lower if deionised water is used than is the case if the
system is operated with salty, i.e. softened water.
Even if the water has been softened beforehand, it con-
tains dissolved, corrosive salts, which act as electrolytes
due to the use of different materials in the heating sys-
tem and therefore accelerate corrosion processes. This
can ultimately result in pitting.
ON THE SAFE SIDE WITH LOW-SALT OPERATION
The problems listed above do not occur at all with low-
salt operation, as the heating water contains neither
corrosive
salts such as sulphates, chlorides and nitrates nor alkalis-
ing sodium hydrogen carbonate. The corrosive proper-
ties of deionised water are very low and in addition, scale
cannot form in the boiler. This is the ideal approach for
closed heating circuits, in particular, because low oxygen
input into the heating circuit can also be tolerated.
In general, when the system is lled with deionised
water, the pH value sets itself within the ideal range due
to “self-alkalinisation”. If necessary, a pH value of 8.2
can be very easily alkalised by adding chemicals. In this
way, optimum protection of the entire heating system is
achieved.
MONITORING
Analytical recording and monitoring of the relevant
water values and the added active conditioning sub-
stances is of decisive importance. Therefore, they
should be monitored regularly using appropriate water
test equipment.
FLUSH AND FILL THE HEATING CIRCUIT AND
THE DOMESTIC HOT WATER TANK
Place a bleeder (vent) at the highest point of the
heating circuit in the heating water outlet (ow)…
If necessary, place a bleeder at the highest point
of the heating circuit in the heating water inlet
(return)…
Open unit, if closed…
“Transport to the installation location”, and
.
Flush and ll the unit via the lling and draining tap...
IMPORTANT
Do not exceed a pressure of 2.5 bar when ush-
ing the unit. The drain line of the heating circuit
safety valve must be closed before ushing and
lling.

18 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Bleeding
VIEW OF INSIDE OF UNIT, SIZE 1
1 Electrical switchbox
2 Overow valve
3 Electric heating element
4 Circulation pump, heating circuit
5 Fill and drain tap, heating circuit
VIEW OF INSIDE OF UNIT, SIZE 2
AB
A 28kW unit
B 44kW unit
1 Electrical switchbox
2 Overow valve
3 Circulation pump, heating circuit
4 Fill and drain tap, heating circuit
BLEEDING THE UNIT
The unit is bled automatically if the bleeder (vent valve)
of the safety assembly is open. If the heating circuit is
lled or drained, the venting valve of the safety assembly
opens.
BLEEDING THE CIRCULATION PUMP OF THE HEATING
CIRCUIT
Unscrew the screw cover in the middle of the circulation
pump until loose and close again after venting.
BLEEDING THE DOMESTIC HOT WATER TANK
To bleed the domestic hot water tank, the domestic hot
water charge circuit must be ushed separately.
To do this, manually switch the domestic hot water
changeover valve to domestic hot water charging. After
bleeding, return it to the initial position.

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Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
NOTE:
Once the heat pump, heating circuit and domes-
tic hot water charging circuit have been ushed,
the bleeding program of the heating and heat
pump controller must be started, after the con-
trol panel has been installed.
If no further steps follow, install the front panel.
Insulating the
hydraulic connections
NOTE.
Insulate the heating circuit and the heat source
according to relevant local standards and guide-
lines.
Check all hydraulic connections for leaks. Perform
leak test…
Insulate all connections, vibration isolators, con-
nections and pipes of the heating circuit and the
heat source. Insulate the heat source so that it is
vapour-diffusion tight.
Installing the control panel
There are 4 each recesses at different heights in the
front panel of the unit for fastening the control panel:
1 four upper recesses
2 four lower recesses
There are 4 hooks at the rear of the control panel,
which are used to hook the control panel on the front
panel of the unit:
Hook the control panel's hooks into the recesses
of the front panel (either in the upper or lower
recesses)...
Example:
Control panel in upper recesses

20 Subject to change without notice | 83050700fUK – Translation into English of the original German operating manual | ait-deutschland GmbH
Push down the hooked in control panel, until it
latches into place…
Push the control cable of the heating and heat
pump controller into the right-hand socket on the
underside of the control panel…
NOTE.
A connection to a computer or a network can
be made via the left socket at the bottom of the
control panel, thereby allowing the heating and
heat pump controller to be controlled remotely
from there. This requires a shielded network
cable (category 6) to be laid through the unit
during the electrical connection work.
Operating manual for the heating and heat pump
controller, “Qualied technician” version, “Web
server” section.
If this network cable is available, insert the
network cable's RJ-45 connector into the left
socket of the control panel.
NOTE.
The network cable can be exchanged at any
time. In order to be able to connect it, the
screen must rst be removed.
Installation and removal
ofthescreen
INSTALLING THE SCREEN
NOTE.
The masking plate is provided in the as delivered
unit so that the control panel is inserted in the
upper recesses of the front panel.
If the control panel has been inserted in the
lower recesses of the front panel, you must rst
remove the masking plate's dummy cover and
then reinsert it above the logo.
Screen at time of delivery:
1 Recess for control panel
2 Logo
3 Dummy cover
First, insert the masking plate below in the slots
provided in the front panel…