alphainnoTec WWC100HX User manual

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

2Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
1 
This operating manual provides important informa-
tion on handling the unit. It is an integral part of the
product and must be stored so that it is accessible in
the immediate vicinity of the unit. It must remain avail-
able throughout 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
󰀨        
parameters for the respective model.
This operating manual is intended only for persons
assigned to work on or with the unit. Treat all con-
      
copyright. 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.
2 Symbols
The following symbols are used in the operating man-
ual. They have the following meaning:
Information for uers.
     
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 inju‑
ries.
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

3
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Table of contents
  ..................................................2
2 Symbols ..................................................................2
3 Intended use .........................................................4
4 Disclaimer ..............................................................4
5 EC conformity.......................................................4
6 Safety.......................................................................4
7 Customer service ...............................................5
8 Warranty / Guarantee ........................................5
9 Disposal ..................................................................5
10 Operating principle of heat pumps .............5
11 Area of use and
heat source requirements...............................6
12 Heat metering.......................................................7
13 Operation................................................................7
14 Care of the unit....................................................7
15 Maintenance of the unit ...................................7
  .....7
16 Malfunctions..........................................................8
17 Scope of delivery................................................8
17.1 Functionally necessary accessories ..........9
17.2 Main components...........................................9
18 Installation..............................................................9
18.1 Installation room.............................................9
18.2 Transport to installation location................10
18.3 Installation .....................................................10
19 Installing the hydraulic connections.........12
19.1 Safety assembly...........................................13
19.2 Expansion vessel .........................................13
20 Domestic water heating.................................13
21 Domestic hot water tank................................13
22 Electrical connection work ...........................14
  ...................16
23.1 Water quality .................................................16
 
the domestic hot water tank .......................17
24 Bleeding................................................................17
25 Insulating the
hydraulic connections.....................................18
26 Installing the control panel ...........................18
27 Installation and removal of the screen....19
  ....................................20
29 Commissioning..................................................21
29.1 Pump settings for WWC 220 H/X..............21
29.3 Safety temperature limiter ..........................22
30 Dismantling..........................................................22
Technical data /Scope of delivery............24
Performance curves........................................26
WWC 100H/X .........................................................26
WWC 130H/X .........................................................27
WWC 160H/X .........................................................28
WWC 190H/X .........................................................29
WWC 220H/X .........................................................30
Dimensional drawings and
installation plans................................................31
Dimensional drawings ...........................................31
Installation plans.....................................................32
Hydraulic integration........................................33
Default......................................................................33
󰀨 ..............................................34
Legend Hydraulic integration................................35
Terminal diagram..............................................36
Circuit diagrams ................................................37
WWC 100H/X .........................................................37
WWC 130H/X – 220H/X .......................................40
EC declaration of conformity.......................43

4Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
3 Intended use
The unit is only to be used for its intended purpose.
This means:
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 sys-
tem.
4 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 de-
scribed 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
      
written consent of the manufacturer
5 EC conformity
The unit bears the CE marking.
EC Declaration of Conformity
6 Safety
The unit is safe to operate for its intended use. The
construction and design of the unit conform to current
state of the art standards, all relevant DIN/VDE regu-
lations 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 per-
son concerned 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 wear-
ing of personal protective clothing.
DANGER!
Risk of fatal electric shock!
All electrical connection work must be car‑
ried out by qualied electricians only.
Before opening the unit, safely disconnect
the system from the power supply and pre‑
vent it from being switched back on!
WARNING!
Only qualied personnel (trained heating,
refrigerating system and refrigerant engi‑
neers 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:
 󰀨
– Thoroughly ventilate installation room.
– Notify the manufacturer’s authorised ser-
vice centre.
IMPORTANT
For safety reasons:
Never disconnect the unit from the power
supply, unless the unit is being opened.

5
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
IMPORTANT
Only install the heat pump indoors.
Dimensioned drawing and installation plan for
the respective unit model
7 Customer service

technician or the manufacturer’s local service partner.
For a current list and additional partners of the manu-
facturer, please visit
DE: www.alpha-innotec.de
EU: www.alpha-innotec.com
8 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.
9 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 compo-
nents of refrigerating units.
“Dismantling”
10 Operating principle of
heat pumps
Heat pumps operate on the same principle as a refrig-
   
The refrigerator extracts heat from foods, which is

The heat pump extracts heat from our environment:
air, earth or ground water. The extracted heat is con-
ditioned 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

44= usable energy
approx. 34= environmental energy
approx. 14= external electrical
energy

6Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
11 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 sys-
tem 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
      
water table (persistence) in order to provide informa-
󰀩
operation of the well, during the initial start-up the

side. Any appropriate components, which enable bal-
ancing are to be installed in the pipe network here.
The material of the components used must be chosen

(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

the suction and return pipe always extends below the
󰀩  
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
        
-
duction well. The following table helps to assess the
water quality.
IMPORTANT
A water analysis and pump test must be car-
ried out before installing the water/water heat
pump.
NOTE
Water analyses are prepared by water test
laboratories. Initial information about possi-
ble use of groundwater is available from your
local water management authority. A pump
test provides information as to whether a suf-
        
cover the requirements for the heating output
  
rate must at least be available as a continu-
ous output.
“Technical data/scope of supply” overview,

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 tak-
ing water samples is the DVGW Standard, Technical

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
Turbidity keine
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
    
industrial wastewater or mixtures of water
and alkali solutions, acids or chlorine is also
not allowed.

7
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
12 Heat metering
       󰀩 
EEWaermeG (German law on renewable energy heat)
also requires heat metering (referred to in the following
as WME). The WME is mandatory for air/water heat
pumps. For brine/ water and water/water heat pumps,

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.
13 Operation
Energy saving use of the heat pump heating
By deciding to purchase a heat pump or a heat pump
system you are making a long-term contribution to
protecting 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
controller.
NOTE
Make sure that the control settings are cor-
rect.
Operating manual of the heating and heat
pump controller
To ensure that your heat pump or heat pump system
󰀩
way in heating mode, please pay particular attention to
the following:
€ENERGY SAVING TIP

  -
󰀩
€ENERGY SAVING TIP
Preferably use purge ventilation. Compared
to continuously open windows, this form of
ventilation (fully opening windows for a short
period, two to three times a day) reduces
energy consumption and your heating bill.
14 Care of the unit
You can clean the outer surfaces of the unit with a
damp cloth and proprietary household cleaning prod-
ucts.
Do not use cleaning or care products that contain
abrasives, acids and/or chlorine. Such products would
irreparably damage the surfaces and could also cause
technical damage to the unit.
15 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,
        
       -

It is best to arrange a maintenance agreement with
a heating installation company. The company will
arrange the necessary regular maintenance work.
15.1 
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 technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
16 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
17 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

sensors for monitoring the heat source


2 Screen
3 Safety assembly for the heating circuit
4 Separate package with control panel,
external temperature sensor, dirt trap,
Sylomer strips, seals
5 Vibration isolators for the heating circuit
and for the heat source
6 Expansion vessel for the heating circuit
with cap valve
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 technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
17.1 Functionally necessary
accessories
IMPORTANT
Only use the manufacturer's original acces-
sories.
If the unit is to be used for heating water, a 3-way
switching valve must be installed. This is not included
with the unit and must be ordered separately.
17.2 Main components
1 evaporator
2 compressor
3 condenser
18 Installation
The following applies to all work to be done:
NOTE
Always comply with the relevant local acci-
dent prevention regulations, statutory regula-
tions, guidelines and directives.
NOTE
Note the sound information for the respective
model.
“Technical data / Scope of delivery” overview,
“Sound” section
18.1 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 room volume = Refrigerant capacity [kg]
Limit [kg/m³]
NOTE
If several heat pumps of the same type are
installed, only one heat pump must be con-
sidered.
     󰀨  
installed, the heat pump with the largest re-
frigerant capacity must be considered.

10 Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
18.2 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 con-
nections 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
    -
dition (on the wooden pallet with packaging) using a
pallet truck.
           
installation 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 packag-
ing material properly and in an ecologically com-
patible 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
connections 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).
18.3 Installation
CAUTION!
Several people are required to install the
unit.
NOTE
Always refer to and follow the installation plan
for the respective model. Note the minimum
clearances.
Installation plan for the respective model
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 packag-
ing material properly and in an ecologically com-
patible way.

11
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Set unit on a stable, solid and level, preferably
      
designed for the weight of the heat pump.
Set up the unit so that the switchbox side (= oper-
ator 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 trans-

Place the Sylomer strips under the heat pump as
follows:
•
Tilt the unit to one side, slowly and carefully.
Secure unit in raised tilted position so that it can-
not 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 dur‑
ing the following work!
•
 
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 technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
19 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
groundwater 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
      -
ning 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 com-
pression of the circulation pumps must be
able to deliver at least the minimum through-
put 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 ade-
quately dimensioned.
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 char-
acteristic 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
 󰀨

pump side.
  󰀨      
and heat source outlet on the heat pump side.
NOTE
󰀨-
rator and condenser of the heat pump can be

       
source circuit before connecting to the unit.
NOTE
Dirt and deposits in the heating circuit and
heat source can cause malfunctions.
 
the corresponding connections at the rear of the
unit. Use vibration isolators.
Vibration isolators must be installed to prevent
structurally borne sound transfer -
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 technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
         
the relevant connections at the rear of the unit.
Use vibration isolators.
Vibration isolators must be installed to prevent
structurally borne sound transfer -
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.
19.1 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 regulations. Discharging the safety valve dis-
charge 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
19.2 Expansion vessel
The expansion vessel for the heating circuit and the
corresponding cap valve are included in the scope of
delivery. They must both be integrated in the heating
circuit on site in compliance with the relevant stand-
ards, guidelines and directives.
IMPORTANT
     
 󰀨      
install an additional, adequately-dimensioned
expansion vessel.
20 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 acces-
sories.
Domestic water heating with the heat pump requires
an additional heating water circuit (parallel) to the
heating circuit. When connecting, make sure that the
󰀨
tank in the heating circuit.
“Hydraulic connection” documents
21 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 available 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 trans-
ferred with minimum spread.
You can choose a domestic hot water tank from our
product range. They are optimally matched to your
heat pump.

14 Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
NOTE
Integrate the domestic hot water tank in the
heat pump system as shown in the hydraulic
diagram for your system.
“Hydraulic connection” documents
22 Electrical connection work
The following applies to all work to be done:
DANGER!
Risk of fatal electric shock!
All electrical connection work must be car‑
ried out by qualied electricians only.
Before opening the unit, safely disconnect
the system from the power supply and pre‑
vent 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

15
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Opened switch box:
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
      
power supply (compressor).
Operation with the incorrect rotary direction
of the compressor can cause serious, irrepa-
rable 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
E
D
C
B
www.alpha-innotec.de
D - 95359 Kasendorf
Industriestraße 3
Alpha-InnoTec GmbH
1
1
Ers. d.
Ers. f.
Benennung
Durchusssensor VFS5-100
603772
-
Zust. Änderungstext Datum
9.2.2009 HS
Von
Blatt
von
Werksto Gewicht
-
Maßstab 1:2
Det. Maßstab
Datum Name
Erstellt
Gepr.
Norm.
9.2.2009 Stenglein
toleranz
Allgemein-
DIN ISO 2768 -c
Oberächen
ArtikelNr.
---
1 2 3 4
Schutzvermerk nach DIN 34 beachten
Blattformat: A4 hoch
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 com-
puter or network using a suitable network
cable, enabling the heating and heat pump
controller to be controlled remotely from
there.
If this is required, install a shielded network
cable (category 6, with RJ-45 connector)
through the unit when installing the connec-
tions 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.

16 Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
23 
IMPORTANT
The system must be absolutely free from air
before commissioning.
23.1 Water quality

heating systems according to VDI 2035 Part
I and II
   󰀩   
is becoming increasingly widespread. Their ingenious
technology enables these systems to achieve very
󰀩
heat generators has led to the development of compact
units with increasingly smaller cross-sections and high
capacities. This means the complexity of the systems
and the material diversity are also increasing, which
plays an important role especially in their corrosion
      󰀨 
󰀩          
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
experience has shown that the safest and most
trouble-free running of the systems is achieved with
so-called low-salt operation.
VDI 2035 Part I gives 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
heating 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 and commissioning is carried out
the system is closed in corrosion terms
adequately dimensioned pressurising is inte-
grated
the guide values for the heating water are com-
plied with
and regular servicing and maintenance are car-
ried out.
A system log should be kept, in which the relevant
planning data is entered (VDI 2035).
Damage that can occur in case of non-
compliance
malfunctions and the failure of components (e.g.
pumps, valves)
internal and external leaks (e.g. from heat ex-
changers)
cross-section reduction and blockaging of compo-
nents (e.g. heat exchanger, pipes, pumps)
Material fatigue
gas bubbles and gas cushion formation (cavita-
tion)
󰀨-
ings, deposits) and associated noises (e.g. boiling

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
      󰀩 
and the energy costs rise. A rule of thumb is that 1
millimetre of limescale deposit causes an energy loss
of 10%. In extreme cases it can even cause damage
to the heat exchangers.
Water softening to VDI 2035 – Part I
 
accordance with the VDI 2035 guidelines, no scale
   󰀨   
      󰀨
on the entire heating system.
Corrosion – an underestimated problem
VDI 2035, Part II, deals with the problem of corrosion.
Softening the heating water can prove to be
󰀩      
the limit of 10. pH values higher than 11 can set in,
which even damage rubber seals. The VDI 2035, Part
        
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 – and aluminium is attacked without the
presence of oxygen. Therefore, apart from softening

should also be appropriately conditioned. This is the
only way to comply with the VDI 2035 requirements
and the recommendations and installation instructions
of the heat pump manufacturer.

17
Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Part 2 of VDI 2035 also points out 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
contains dissolved, corrosion-promoting salts, which
󰀨
in the heating system 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 neither corrosive salts such as
sulphates, chlorides and nitrates nor alkalising sodium
hydrogen carbonate are in the heating water. The
corrosive properties of deionised water are very low
and in addition, fur 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.
        
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
substances is of decisive importance. Therefore, they
should be monitored regularly using appropriate water
test equipment.
23.2 
and
the domestic hot water tank
Place a bleeder (vent) at the highest point of the

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
 
IMPORTANT
Do not exceed a pressure of 2.5 bar when
        -
ing circuit safety valve must be closed before

24 Bleeding
View of inside of unit
1 Electrical switchbox
 
3 Electric heating element
4 Circulation pump, heating circuit
5 Fill and drain tap, heating circuit

18 Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Bleeding the unit
The unit is bled automatically if the bleeder (vent valve)
of the safety assembly is open. If the heating circuit is
-
bly opens.
Bleeding the circulation pump of the heating
circuit
Unscrew the screw cover in the middle of the circula-
tion pump until loose and close again after venting.
Bleeding the domestic hot water tank
To bleed the domestic hot water tank, the domestic hot

To do this, manually switch the domestic hot water
changeover valve to domestic hot water charging.
After bleeding, return it to the initial position.
NOTE
Once the heat pump, heating circuit and
domestic hot water charging circuit have been

and heat pump controller must be started,
after the control panel has been installed.
If no further steps follow, install the front panel.
25 Insulating the
hydraulic connections
NOTE
Insulate the heating circuit and the heat
source according to relevant local standards
and guidelines.
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-di󰀨usion tight.
26 Installing the control panel
󰀨
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

19
Subject to technical amendments without notice | 83050700gUK – Translation of the original 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 heat-
ing 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

“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

27 Installation and removal
of the screen
27.1 Installing the screen
NOTE
The masking plate is provided in the as deliv-
ered 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

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.
Then, beginning on one side, latch the lugs on the
masking plate from the bottom up into the slots
provided in the front panel.

20 Subject to technical amendments without notice | 83050700gUK – Translation of the original operating manual | ait-deutschland GmbH
Then, on the opposite side, latch the lugs on
the masking plate from the bottom up into the
slots provided in the front panel.
Finally, press the upper latching lugs of the mask-
ing plate into the slots provided in the front panel.
27. 2 Dismantling the masking plate
In order to dismantle the masking plate, the latching
lugs must be completely released on one side rst by
pushing towards the middle of the masking plate.
Then release the lugs on the opposite side.
28 
REMARQUE
The activities in this section are only neces-
sary for in-line tank integration.
Complete the worksteps quickly, otherwise
the maximum return temperature can be ex-
ceeded and the heat pump switches to high-
pressure fault.

󰀨-
rence (the temperature drop), turn it to the left
to reduce it.
System is running in heating mode (ideally in cold
condition).
In case of low heating curve: Set the system to
“Forced heating”.
Operating manual of the heating and heat
pump controller.
 󰀨
          -

         
heating and heat pump controller.
Operating manual of the heating and heat
pump controller.
     
       
and return temperature is set as follows:
Heat source
temperature
Recommended
settings
10 °C 9 K
 
 
Open valves to heating circuit.
Reset the heating and heat pump controller.