Dimplex WI 90CG User manual

INSTALLATION and
OPERATING INSTRUCTIONS
Water-Water Heat Pump
for indoor installation
CE
Order No.: 452225.66.94 FD 8209
WI 40CG WI 90CG

2
CONTENTS
1 PLEASE READ IMMEDIATELY 3
1.1 Important notes
1.2 Legal requirements and guidelines
1.3 Energy-saving heat pump operation
2 APPLICABILITY OF THE
HEAT PUMP 4
2.1 Field of application
2.2 Mode of operation
3 BASIC UNIT 4
4 ACCESSORIES 5
.1 Control cable
.2 Heat pump control
5 TRANSPORT 5
6 INSTALLATION SITE 6
6.1 General notes
6.2 Sound emission
7 INSTALLATION 6
7.1 Connection of the heating system
7.2 Connection of the heat source
7.3 Connection to power supply
8 STARTUP 8
8.1 General notes
8.2 Preparation
9 MAINTENANCE/CLEANING 9
9.1 Maintenance
9.2 Cleaning the heating side
9.3 Cleaning the heat source side
10 MALFUNCTIONS/
TROUBLE SHOOTING 10
10.1 Eliminating minor faults
11 SHUTDO N 10
11.1 Shutdown during summer
11.2 Final discommissioning/disposal
12 ANNEX 11

3
PLEASE READ IMMEDI-
ATELY
1.1 Important notes
During transport the heat pump must
not be inclined to any side by more than 45°.
The heat pump is not attached to the
wooden grating.
Disconnect all voltage supplies prior
to opening the unit.
Service of the heat pump must be
performed by authorized and experienced
service personnel only.
The wor ing fluid R407C is free of CFC,
does not disturb ozone and is non-combustible.
Ensure the cloc wise rotating field
when connecting the supply cable.
The covering hood can not be painted.
The well water must be of the water
quality specified.
The startup procedure must follow the
Installation and Operanting Instructions for the
heat pump control.
PLEASE READ IMMEDIATELY
CAUTION !
CAUTION !
CAUTION !
CAUTION !
CAUTION !
CAUTION !
After cleaning it is essential to neu-
tralize the system by suitable means in order to
prevent secondary damages to the heating
system.
The heat pump is not intended to meet
the increased heat requirements of de-humidi-
fying a building. Therefore it is necessary to use
dedicated equipment provided by the client to
generate the extra amount of heat needed for that
purpose.
1.2 Legal requirements and guide-
lines
The heat pump complies with all relevant DIN/
VDE regulations and EEC directives. These are
listed in the attached CE conformity statement.
Electric wiring of the heat pump must comply with
the applicable VDE EN and IEC standards.
Furthermore the electrical supply conditions
stipulated by the power provider must be
observed.
The heat pump must be interconnected with the
heat source and the heating system in compli-
ance with the relevant regulations.
Service of the heat pump must be
performed by authorized and experienced
service personnel only.
1.3 Energy-saving heat pump opera-
tion
By operating this heat pump you contribute to the
protection of our environment. Proper dimen-
sioning of the heating system and the heat source
are of prime importance for the efficiency of heat
pump operation. Low water inlet temperatures
are of particular importance. Therefore all con-
nected heat consumers must be suitable for low
water inlet temperatures. An increase in the
heating water temperature by 1 K causes an
increase in the electrical power consumption by
approx. 2.5%. An underfloor heating system with
forward temperatures between 30 and 40 °C is
particularly well suited for energy-saving oper-
ation.
1
CAUTION !
CAUTION !
CAUTION !
CAUTION !
CAUTION !
CAUTION !

4
BASIC UNIT
The basic unit consists of the heat pump for
indoor installation covering hood and basic
control and is delivered ready for installation. The
refrigerating circuit is filled with the refrigerant
R407C. The covering hood is lined with sound
insulating material.
The basic control contains all components that
are required for heat pump operation. The power
cable and the load cable (accessories) between
heat pump and basic control have to be installed
by the client.
The well pump that is also provided by the client
has to be interfaced with the basic control. Make
sure that the rating of the motor protector istalled
by the client is sufficient for the pump in use.
1 2 3 4 5
67
1) Condensor 5) Flow switch
2) Liquefier 6) Terminalbox
3) Evaporator 7) Filter dryer
4) Dirt trap
The wor ing fluid R407C is free of CFC,
does not disturb ozone and is non-combustible.
The covering hood can not be painted.
3
APPLICABILITY OF THE HEAT PUMP
BASIC UNIT
APPLICABILITY OF THE
HEAT PUMP
2.1 Field of application
The water-water heat pump can be used in
existing or new heating plant installations. Water
is used as the heat transfer medium. The water
may be supplied from a well or similar sources.
The well water must be of the water
quality specified.
Under normal conditions an intermediate circuit
has to be provided. If the system is to operated
without an intermediate circuit it is independent
of the leagl requirements necessary to perform
a water analysis in order to be able to detzermine
the compatability of the ground water with the
evaporator of the heat pump (refer to the project
designing and installation manual for heating
heat pumps).
2.2 Mode of operation
A well pump feeds the water to the evaporator of
the heat pump. There its thermal content is
transferred to the working fluid (refrigerant) in the
refrigeration circuit.
Then the working fluid is sucked into the elec-
trically powered condensor where it is
condensed i.e. "pumped" to a higher tempera-
ture level. How-ever the electric energy used to
drive this process is not lost but is also transferred
to the working fluid.
Finally the working fluid reaches the liquefier unit
where its thermal energy is transferred to the
water circulating through the heating water
system. Depending on the operating point the
temperature in the heating water system may rise
up to 55 °C.
2
CAUTION !
CAUTION !
CAUTION !

5
TRANSPORT
A lift truck can be used for transporting the heat
pump over smooth surfaces. Carrier belts should
be used where it must be transported across
uneven surfaces or through staircases. The belts
can be inserted directly through the wooden grate.
As an alternative the unit may be lifted by means
of eyebolts that can be screwed into the corners
of the base frame.
The heat pump is not attached to the
wooden grate.
The heat pump must not be inclined
by more than 45° (to any side).
5
ACCESSORIES
TRANSPORT
CAUTION !
CAUTION !
ACCESSORIES
.1 Control cable
Two control cables serve to interconnect the heat
pump control and the basic control unit as well
as the basic control unit and the terminal box of
the heat pump. These cables are available in
several lengths.
.2 Heat pump control
The use of a heat pump control from our product
line is mandatory for the operation of your water-
water heat pump. The heat pump control is a
comfortable electronic control device. It is avail-
able as an accessory. The heat pump control
regulates and monitors the entire heating system
in regard to outdoor temperatures hot water
heating process and safety-relevant equipment.
The functional method and the operation of the
heat pump control is described in detail in the
accompanying Installation and Operating Instruc-
tions.
4
45°
45°
Eye bolt

6
INSTALLATION SITE
6.1 General notes
The heat pump is intended for indoor installation.
The mounting surface must be smooth solid and
load-bearing. If necessary the heat pump must
be levelled by shimming.
The installation site of the heat pump must be
chosen so that service work can be performed
easily. This is ensured by a free space of about 1
m at the front and both sides of the heat pump.
6.2 Sound emission
Owing to the sound insulation the heat pump
emits very little noise. But placing a suitable
decoupled rubber mat underneath the heat
pump base frame is recommended in order to
prevent any sound conductance to the foundation
especially in case of uneven foundations.
67
INSTALLATION SITE
INSTALLATION
INSTALLATION
7.1 Connection of the heating system
Before connecting the heat pump to the heating
system the heating plant should be flushed
thoroughly to prevent any particles to flow through
the heating circuit which could impair smooth
heatpump operation.
Flexible pressure hoses should be used for
connections in order to prevent noise from being
conducted to the heating circuit.
The completed heating circuit must be filled
ventilated and checked for leakage. Where the
risk of frost exists the filled system must remain
in operation continuously so that frost damage is
precluded.
7.2 Connection of the heat source
Connect the water lines from the well to the flow
and return lines of the heat source.
For this observe the refrigeration and hydraulic
plans.
The well water must be of the water
quality specified.
CAUTION !
Wärmepumpe
1 m
0,2 m
1 m 1 m
Heat pump

7
INSTALLATION
It must be ensured that the the power supply to
the terminals of the well pump will not be turned
off by the tariff contactor to make sure that the
cutoff delay of the well pump remains effe-
ctive.The motor protector installed by the client
must be adjusted according to the data
specified by the pump manufacturer. The
terminals for the power supply to the well pump
are X1-L11/L21/L31.
Control voltage
The basic control unit is powered by the heat
pump control via the control cable. A separate
cable to the basic control unit is not required.
Connection between the basic control unit and
the terminal box of the heat pump
The connection between the terminal box of the
heat pump and the basic control unit as well as
between the brine pump and the basic control
unit must be provided by the client.
Select the cable cross section according to the
power consumption of the heat pump (see
technical specifications) and the power con-
sumption of the used brine circulating pump.
Run the power cables in the existing plastic
tubing.
Terminals of the condenser:
X1-1/2/3/PE
X1-4/5/6/PE
Terminals of the well pump:
X1-7/8/9/PE
7.3 Connection to power supply
All components needed for connecting the
electric supply to the heat pump are located in
the basic control unit. Mount this unit to a
smooth wall surface of the building. A heat
pump control is necessary for controlling these
components. The wiring of the descrete compo-
nents contained in the basic control unit and in
the heat pump control must be provided by the
client (plug connectors).
Power supply for the basic control unit
A breaker controlling all poles with at least 3
mm contact gap (e.g. EVU blocking contactor
power contactor) and a three pole automatic
circuit breaker separating simultaneously all
external leads must be provided in the power
feed to the basic control unit. Select the wiring
cross section according to the power consump-
tion of the heat pump the technical power
connecting requirements stipulated by the
respective power provider and the require-
ments of VDE 0100. The power consumption of
the heat pump is specified in the technical
documentation. The terminals (X1-L1/L2/L3 at
the circuit breaker) are rated for a maximum wire
gauge of 16 mm².
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8
INSTALLATION
STARTUP
STARTUP
8.1 General notes
For reasons of warranty comissioning of the heat
pump should be performed by authorized service
personnel.
8.2 Preparation
Confirm the following prior to startup:
- The heat source system and the heating water
circuit must have been filled and tested.
- The shut-off valves in the well and heating
circuits must be in the correct position.
- The power supply field must rotate in the cw
direction.
- The heat pump control must have been
prepared according to the relevant installation
and operating instructions.
The startup procedure must follow the
installation and operating instructions for the heat
pump control.
8
CAUTION !
Control cable between the basic control unit
and the terminal box of the heat pump
The control cable between the terminal box of
the heat pump and the basic control unit is
available as a custom-made cable (see price
list). Connect the round 16-pole connector of the
control cable to the basic control unit. Slightly
rotate the connector ccw and cw to feel for the
anti-rotation lock. Then insert the connector until
the ring nut of the contactor catches. Turn the
ring nut clockwise to secure the connector in its
position. Feed both the rectangular connec-tors
through the opening in the bottom right corner of
the basic control unit and plug them into the
matching connectors (non-interchange-able).
Use the strain relief to secure the control cable
in the basic control unit . Any excessive cable
length should be kept in the cable duct or as a
loop on the wall.
Connection between the heat pump control and
the basic control unit (using the 1.5 m control
cable, see price list)
The power for the heat pump control can be
provided from the basic control unit. Plug the
round connector of the cable into the basic control
unit and connect the two rectangular connectors
to the heat pump control. A more detailed
description is contained in the instal-lation and
operating instructions for the heat pump control.
Ensure the cloc wise rotating field
when connecting the supply cable. (If the field
rotates ccw the heat pump generates no power
and is very loud.)
CAUTION !

9
MAINTENANCE/CLEANING
After cleaning it is essential to neu-
tralize the system by suitable means in order to
prevent secondary damages to the heating
system.
Attention - heating plant installers -
Depending on the fill water quality and volume
occasional dirt collection (rust sludge, calcerous
deposits) may occur especially in case of mixed
installations and plastic piping so that the
performance of the heating system may be
compromized. This is due to the water hardness
and the oxygen solved in the fill water and the
oxygen in the air that may enter the system at
valves, fittings and plastic pipes (oxygen diffu-
sion). To prevent this from happening we
recommend the use of a physical water treatment
device li e e.g. ELYSATOR .
CAUTION !
9.3 Cleaning the heat source side
Install the enclosed dirt trap in the heat source
inlet of the heat pump in order to protect the
evaporator from impurities. After the initial startup
the filter screen of the dirt trap should be cleaned
regularly in relatively short intervalst. As soon as
detectable impurities become less the intervalls
can be extended accordingly.
9
MAINTENANCE/
CLEANING
9.1 Maintenance
The heat pump operates maintenance-free.
Make sure that the heat source and heating
circuits are kept free from impurities to prevent
malfunction of the heat pump due to dirt
collections in the heat exchangers. Should a
malfunction of that type occur clean the unit as
described below.
Disconnect all voltage supplies prior
to opening the unit.
9.2 Cleaning the heating side
Oxygen may cause the formation of oxydation
products (rust) in the hot water circuit. Pipe
connections must not allow oxygen diffusion
which applies particularly to pipes used in
underfloor heating. Remnants of lubricants and
sealants may also contaminate the heating
water.
If contamination is so bad that the performance
of the liquefier in the heat pump is degraded
the installation must be cleaned by a specialist.
Based on today's experience we suggest to use
5% phosphorous acid for general cleaning or if
cleaning is required in shorter intervals 5%
formic acid .
In both cases the cleaning liquid should be used
at room temperature. Scavenging the heat ex-
changer in the direction opposite to the normal
flow is recommendable.
In order to prevent acid-containing cleaning li-
quid from entering the heating water circuit we
suggest to connect the scavenging unit directly
to the forward and return lines of the liquefier in
the heat pump.
Following that it is essential to thoroughly rinse
the system with a suitable neutralizing agent
so that all remnants of the cleaning agent are
removed from the system.
Handle acids with care. Always follow the
instructions of the occupational associations.
In case of doubt consult with the manufacturer
of the cleaning agent!
CAUTION !
CAUTION !

10
11
SHUTDOWN
11.1 Shutdown during summer
Heat pumps used exclusively for heating pur-
poses can be shut down for the summer time
(no hot water service). This is done by means of
the operating mode selector of the heat pump
control. Please observe the Installation and
Operating Instructions.
Due to the risk of frost damages shutdown
without draining the heating circuit is permissible
only in regions where outdoor temperatures do
not drop below 0 °C .
11.2 Final decommissioning/disposal
Before removing the heat pump it is necessary to
disconnect all cables as well as the connections
to the heat source and the heating system.
Furthermore all electrical supplies must be
switched off and all valves must be closed.
Please observe the applicable environmental
regulations in regard to recycling reuse and
disposal of working materials and fluids accord-
ing to DIN EN 378 when taking the heat pump
out of operation. Especially the disposal of
refrigerants and refrigeration machine oil must
comply with the relevant regulations.
MALFUNCTIONS/
TROUBLE SHOOTING
10
10.1 Eliminating minor faults
This heat pump is a maintenance-free high-
quality product and should run without any
problems. Most faults that may occur can be
remedied by the user. Please refer to chapter
'Malfunctions and Troubleshooting' in the
installation and operating instructions for the heat
pump control.
If you are not successful in eliminating a fault
please contact your customer service.
Service of the heat pump must be
performed by authorized and experienced
service personnel only.
CAUTION !
MALFUNCTIONS/TROUBLE SHOOTING
SHUTDOWN

11
ANNEXE
12
ANNEX
12.1 Dimensional drawings
12.1.1 Heat pump .. 0C 12
12.1.2 Heat pump ..90C 13
12.2 Equipment data 14
12.3 Performance characteristics/
pressure losses
12.3.1 Characteristics .. 0C / 2 cond. 15
12.3.2 Characteristics .. 0C / 1 cond. 16
12.3.3 Pressure losses .. 0C 17
12.3. Characteristics ..90C / 2 cond. 18
12.3.5 Characteristics ..90C / 1 cond. 19
12.3.6 Pressure losses ..90C 20
12.4 Circuit diagrams
12. .1 External basic control unit .. 0C 21
12. .2 Load .. 0C 22
12. .3 Internal terminal box .. 0C 23
12. . Terminal assignment incl.
heat pump control .. 0C 2
12. .5 Legend .. 0C 25
12. .6 External basic control unit ..90C 26
12. .7 Load ..90C 27
12. .8 Internal terminal box ..90C 28
12. .9 Terminal assignment incl.
heat pump control ..90C 29
12. .10 Legend ..90C 30
12.5 ydraulic schematic diagram 31
12.6 CE conformity statement 32
12.7 Warranty certificate 33

12
ANNEX: 12.1 DIMENSIONAL DRAWINGS
12.1.1 eat pump ..40C
Connections on heating side: Connections on heat source side:
External thread External thread
Turning lock
Heating water outlet Heat source inlet Heat source outlet
Inlet of control cable/load cable Heating water inlet

13
12.1.2 eat pump ..90C
ANNEX: 12.1 DIMENSIONAL DRAWINGS
Connections on heat source side 2" External thread
Turning lock
Heating water inlet
Heating water outlet
Heat source inlet
Inlet of control cable/load cable
Heat source outlet

14
ANNEX: 12.2 EQUIPMENT DATA
Equipment data
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15
12.3.1 Characteristics ..40C / 2 condensers
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
0
10
20
30
40
50
60
70
Heizleistung in [kW] Wasseraustrittstemperatur in [°C]
0
1
2
3
4
5
6
7
8
Leistun
g
szahl im Heizbetrieb
(
incl. der anteili
g
en Pum
p
enleistun
g
en
)
35
5
0
2
4
6
8
10
12
-10-8-6-4-202468101214161820222426
Soleeintrittstemperatur in [°C]
35
5
Leistungsaufnahme in [kW] (incl. der anteiligen Pumpenleistungen)
Bedingungen:
Heizwasserdurchsatz 2,9 m³/h
Soledurchsatz 8,4 m³/h
35
50
Heating capacity [kW] Water outlet temperature [°C]
Performance figure in heating operation (incl. pump power consumptions)
Power consumption [kW] (incl. pump power consumptions)
Cold water inlet temperature [°C]
Conditions:
Heating water flow 3500 l/h
Cold water flow 9500 l/h

16
12.3.2 Characteristics ..40C / 1 condenser
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
0
5
10
15
20
25
30
35
40
Heizleistung in [kW] Wasseraustrittstemperatur in [°C]
0
1
2
3
4
5
6
7
8
9
10
35
50
Leistungszahl im Heizbetrieb (incl. der anteiligen Pumpenleistungen)
Bedingungen:
Heizwasserdurchsatz 2,9 m³/h
Soledurchsatz 8,4 m³/h
35
50
0
2
4
6
8
-10-8 -6 -4 -2 0 2 4 6 8 101214161820222426
Kaltwassereintrittstemperatur in [°C]
35
50
Leistungsaufnahme in [kW] (incl. der anteiligen Pumpenleistungen)
Heating capacity [kW] Water outlet temperature [°C]
Performance figure in heating operation (incl. pump power consumptions)
Cold water inlet temperature [°C]
Conditions:
Heating water flow 3500 l/h
Cold water flow 9500 l/h
Power consumption [kW] (incl. pump power consumptions)

17
12.3.3 Pressure losses ..40C
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
0
5000
10000
15000
20000
25000
30000
35000
0123456789101112
Kaltwasserdurchflußin [m³/h]
Druckverluste Verdampfer
Sole/Wasser 30C bei 10°C
Druckverlust 15 kPa bei
Sole-Nenndurchfluß8,4 m³/h
Druckverlust in [Pa]
0
5000
10000
15000
20000
25000
30000
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
Heizwasserdurchflußin [m³/h]
Druckverlust in [Pa]
Druckverluste Verflüssiger
Sole/Wasser 30C bei 10°C
Druckverlust 9 kPa bei
Heizwasser-Nenndurchfluß2,9 m³/h
Pressure loss [Pa]
Pressure loss [Pa]
Cold water flow 1000l/h
Heating water flow [l/h]
Pressure losses in the liquefier
Water/water 40C at 35°C
Pressure loss ,14 bar at nominal
heating water flow 35 l/h
Pressure losses in the evaporator
Water/water 40C at 10°C
Pressure loss ,175 bar at
nominal cold water flow 95 l/h

18
12.3.4 Characteristics ..90C / 2 condensers
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
0
10
20
30
40
50
60
70
80
90
100
110
120
130
Heizleistung in [kW] Wasseraustrittstemperatur in [°C]
0
1
2
3
4
5
6
7
8Leistun
g
szahl im Heizbetrieb
(
incl. der anteili
g
en Pum
p
enleistun
g
en
)
35
5
0
5
10
15
20
25
-10-8-6-4-202468101214161820222426
Soleeintrittstemperatur in [°C]
35
5
Leistungsaufnahme in [kW] (incl. der anteiligen Pumpenleistungen)
Bedingungen:
Heizwasserdurchsatz 6,0 m³/h
Soledurchsatz 16,0 m³/h
35
50
Heating capacity [kW] Water outlet temperature [°C]
Performance figure in heating operation (incl. pump power consumptions)
Cold water inlet temperature [°C]
Conditions:
Heating water flow 8000 l/h
Cold water flow 20000 l/h

19
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
12.3.5 Characteristics ..90C / 1 condenser
0
10
20
30
40
50
60
70
80
90
100
Heizleistung in [kW] Wasseraustrittstemperatur in [°C]
0
1
2
3
4
5
6
7
8
35
50
Leistungszahl im Heizbetrieb (incl. der anteiligen Pumpenleistungen)
Bedingungen:
Heizwasserdurchsatz 6,0 m³/h
Soledurchsatz 16,0 m³/h
35
50
0
2
4
6
8
10
12
-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26
Kaltwassereintrittstemperatur in [°C]
35
5
Leistungsaufnahme in [kW] (incl. der anteiligen Pumpenleistungen)
Heating capacity [kW] Water outlet temperature [°C]
Performance figure in heating operation (incl. pump power consumptions)
Power consumption [kW] (incl. pump power consumptions)
Cold water inlet temperature [°C]
Conditions:
Heating water flow 8000 l/h
Cold water flow 20000 l/h

20
12.3.6 Pressure losses ..90C
ANNEX: 12.3 PERFORMANCE CHARACTERISTICS/PRESSURE LOSSES
0
5000
10000
15000
20000
25000
30000
35000
0 2 4 6 8 101214161820222426
Kaltwasserdurchflußin [m³/h]
Druckverluste Verdampfer
Sole/Wasser 70C bei 10°C
Druckverlust 12,5 kPa bei
Sole-Nenndurchfluß16,0 m³/h
Druckverlust in [Pa]
0
5000
10000
15000
20000
012345678910
Heizwasserdurchflußin [m³/h]
Druckverlust in [Pa]
Druckverluste Verflüssiger
Sole/Wasser 70C bei 10°C
Druckverlust 6 kPa bei
Heizwasser-Nenndurchfluß6,0 m³/h
Pressure loss [Pa]
Pressure loss [Pa]
Cold water flow 1000l/h
Heating water flow [l/h]
Pressure losses in the evaporator
Water/water 90C at 10°C
Pressure loss ,19 bar at
nominal cold water flow 2 l/h
Pressure losses in the liquefier
Water/water 90C at 35°C
Pressure loss ,13 bar at nominal
heating water flow 8 l/h