elco Aquatop TC Series User manual

Operating Instructions
Only for Authorized Service Technicians
Brine-Water and Water-Water
Heat Pumps
AQUATOP TC
02/2008 Art. No. 11 051 525

2
Table of Contents
Table of Contents …………………………………………………....... 2
Basic Information Safety Information…………………….................. 3
General Info....................................................... 4
Legal Guidelines, Rules...................................... 5
Warranty Terms.................................................. 5
Receiving Inspection............................................ 5
Installation and
Connection Instructions Delivery Scope..................................................... 6
Transport and Setup........................................... 7
Hydraulic Connections........................................ 8
Heat Reclamation Connection............................ 9
Heater-Side Connection...................................... 11
Condensate and Safety Line.............................. 13
Electrical Connection General.............................................................. 14
Wiring Diagram and Terminal Assignment......... 15
Assembly Control Panel....................................................... 16
Charging
Geothermal Heating Systems Problems and Issues........................................... 18
Incorrect Brine Concentration............................. 18
Flushing.............................................................. 18
Charging with Antifreeze..................................... 19
Correctly Charging a Geothermal Heating System 19
Initial Startup Heat Pump Controller LOGON B RVS51........... 21
Quickstart........................................................... 22
LOGON B RVS51.843, Control Elements.......... 22
Basic Display...................................................... 24
Parameterization.................................................. 27
Troubleshooting Troubleshooting AQUATOP LOGON WP........... 35
System Characteristic Curve of Sensor NTC 1 k............ 38
Characteristic Curve of Sensor NTC 10 k.......... 38
Equipment Dimensions AQUATOP T05C+T06C, T08C-T14C,
T07C-HT, T11C-HT, T19C................................. 39
Technical Data AQUATOP T05C-T10C...................................... 40
AQUATOP T12C-T19C...................................... 42
AQUATOP T07C-HT, T11C-HT......................... 44
Initial Startup Log ........................................................................... 46
Notes ........................................................................... 47

3
Basic Information
Safety Notes
E
Components and piping of the cooling
circuit may never be used for transport.
E
The heat pump is fastened to the
transport pallet.
E
All electric circuits must be de-energized
before opening the unit.
E
All work on the cooling circuit must be
carried out by trained technicians who
must be familiar with and trained in the
use and handling of the coolant.
L
Never us harsh, abrasive, acidic or
chlorine-containing cleansers on the
surface of the equipment.
Safety Notes
The following notes and information are
generally used in the operating
instructions:
LComply with information about
function and operation.
EAlways comply with and
observe all safety notes and
safety information.
Information about the operating
instructions of the controller
LOGON B WP
E
Setup, installation, configuration, and
initial startup of the heat pump system
must be carried out by a qualified
technician applying the relevant
statutory rules, regulations, and guide-
lines, as well as the operating
instructions.
E
The use of the heat pump must be
reported to the local utility or electric
company.
E
Do not exceed a tilt of 30° when tran-
sporting the heat pump. Avoid exposing
the heat pump to any type of moisture
or humidity.
Protect the heat pump from damage
and dirt during all construction phases.

Basic Information
General
4
General
Usage Range
The heat pump is designed only for
heating as well as generating service
water.
The heat pump can be utilized in newly
installed or existing heating systems
by complying with the usage limits as
defined by the AQUATOP planning
document.
E
Setup
The heat pumps can be set up on a
smooth, level, and plane surface
without the need of a base or pedestal.
The installation room must be dry and
frost-free. Rooms with much humidity
such as laundry rooms, etc. are not
very suitable for installing the heat
pump. The min. clearances must be
adhered with for all equipment to
ensure access in case of maintenance
and control tasks.
Function Principle of the
Brine-Water/Water-Water Heat Pump
The heat pump converts the heat
contained in the soil or rock
(groundwater) with a low temperature
into heat with a higher temperature.
This is achieved by routing the brine
liquid through a heat exchanger in the
soil (groundwater) and a pump to the
evaporator. The liquid working medium
in the evaporator boils and evaporates
at a low temperature and low pressure.
The evaporation heat required is drawn
from the brine liquid and returned to
the heat exchanger.
The evaporated working medium is
suctioned by the compressor and
compressed to a higher pressure.
The compressed, gaseous working
medium is fed to the condenser where
it is condensed at a high pressure and
high temperature.
The condensation heat is transferred
to the heating water and the tempera-
ture of that water increases.
The energy transferred to the heating
water corresponds with the energy
previously extracted from the soil
(groundwater) plus the small amount
of electrical energy required for
compressing the working medium.
Energy-Saving Use of the Heat
Pump System
Your decision to obtain a heat pump
heating system is an important contri-
bution to saving the environment by
having lower emissions and reduce
your primary energy use.
Please observe the following points to
ensure your new heating system
functions efficiently:
L
The heat pump heating system must
be carefully dimensioned and installed.
L
Avoid unnecessarily high flow tempera-
tures. The lower the flow temperature
on the heating side the more efficient
the heat pump is working. Make sure
the controller is set correctly and
properly.
L
Rush airing (several windows open at
once for short period) is to be preferred
over continuously leaving a small gap
open. Rush airing reduces the energy
consumption.

5
Basic Information
Legal Guidelines, Rules,
Warranty Terms,
Receiving Inspection
General Information
These operating instructions serve the
correct installation, adjustment, and
maintenance of the equipment.
The following information must there-
fore be read carefully and the heat
pump must be installed, inspected, and
maintained by correspondingly trained
technicians.
The manufacturer is not liable for
mechanical, hydraulic, or electrical
modifications after the warranty
expires. The warranty becomes null
and void in case of not explicitly
authorized actions carried out contrary
to or in violation of these operating
instructions.
All applicable safety standards must
be observed during installation. Check
whether the properties of the power
supply system match those of the heat
pump (type plate).
These operating instructions and the
electrical scheme (diagram) of the heat
pump must be stored carefully and
made available to the operating per-
sonnel if needed.
E
The manufacturer is not liable for per-
sonal injury or property damage, direct
or indirect, caused by noncompliance
with these instructions.
The equipment may be opened only
by qualified personnel.
Legal Guidelines and Rules
All guidelines based on CE standards
were observed during design and
manufacture of the heat pump.
(See CE Conformity Declaration.)
Compliance with the corresponding
SEV, EN, and IEC standards is
required for the electrical connection
of the heat pump. The connection
specifications of the local utility or
electric company must be complied
with as well.
E
Explanations Concerning Our
Warranty Terms
Our warranty does not cover damages
caused by or due to the following
reasons:
- Unsuitable or improper use or
operation,
- Incorrect setup, adjustment, or
incorrect initial startup by buyer
or third parties
- Installation of third party parts
- Operating the equipment under
overpressure or in excess of the
specifications indicated by the
factory
- Noncompliance with the notes
and information of the operating
instructions
The heat pumps have a warranty
period of 24 months after the day of
delivery. The sales, delivery, and
warranty terms and conditions ac-
cording to the order confirmation apply
in all other instances.
Receiving Inspection
The equipment is shipped on a
wooden pallet and a corresponding
protective cover.
The equipment must be checked for
completeness and transport damage
upon receipt.
E
If damages are detected, the corre-
sponding damage must be noted
immediately on the shipping document
and identified with the following
phrase: "Conditional acceptance due
to obvious damage."

Installation and Connection Instructions
Delivery Scope
6
1
23
4
5
6
7
8
Preattached tubes in rear of unit
Additional items enclosed in accessory bag
The following components are included
with the heat pump:
1 1 Plexiglas cover
2 1 controller receptacle
3 1 front panel
4 1 LOGON B WP controller
5 1 exterior sensor
6 4 vibration dampening rubber
pads
7 4 tube seals
8 1 set of documentation
9 4 vibration-dampening tubes

7
Installation and Connection Instructions
Transport and Setup
Transport
Before every transport, make sure the
lifting or transport equipment has the
lifting power needed to transport the
respective equipment weight. All of the
tasks described here must be carried
out based on the relevant safety
standards. This applies to tasks as-
sociated with the equipment as well as
the process or procedure of each task
itself.
Transport with Forklifts, Lifting
Platform or Similar Equipment
Insert forks lengthwise under the
wooden pallet.
When lifting, make sure the weight is
equally distributed. Never tilt the heat
pump beyond max. 30º (in any direction)
when transporting it. Avoid exposing
the heat pump to any type of moisture
or humidity.
(Also applies to setup and installation!)
Never stack objects on the heat pump or
hang up wet clothes over it.
Setup
The heat pump is designed to be set
up in an interior location (IPXO, i.e.
only dry rooms). The base frame must
be set up on a smooth, level, and plane
surface.
The heat pump must be setup in a way
that allows servicing the pump without
access problems. This is ensured
when complying with the wall
clearances depicted below.
Control station
Plan view with min. clearances
After moving the unit to the installation
location, remove the transport
protection and safety elements and
attach the vibration dampening rubber
pads included with the equipment into
the now exposed threaded openings
at the bottom of the unit.
These pads are also adjustable to
ensure the heat pump is level.

8
Installation and Connection Instructions
Transport and Setup
Hydraulic Connections
After the unit is placed into position,
make sure to check for visible damage.
Properly dispose off the packaging
material.
Transport safety device
The flexible connection tubes and
hoses included in the delivery scope
are attached to the rear of the
AQUATOP TC.
The heating and the heat reclamation
sides are connected to the rear as
well (hold on to nut when tightening
cap nut to prevent twisting the flexible
connection lines).

9
Connections
Connection pipes and distributor
Delivery/installation by
ELCO/ installation company
On-site
Trenches and openings
Geothermal Heating System
Boreholes for geothermal heating
systems/installation and backfill
Delivery/installation by
ELCO/ drilling company
On-site
sludge trough
Recommended: 8 m
Heat Pump Connection
Heat source booster pump and
safety devces, connection lines,
insulation, heat carrier fill
Delivery/installation by
ELCO/ installation company
Probe depth
Installed in compact
heat pumps
Installation and Connection Instructions
Heat Reclamation Connection
The general schematic also applies to
geothermal tube collectors.
L
Brine-side circulating pump, expansion
vessel, manometer, charging element,
and safety valve are already installed
into the AQUATOP TC unit.
L
Lead safety line at an incline into
suitable collection container.
Geothermal Heating System / Geothermal Tube Collector

10
Installation and Connection Instructions
Heat Reclamation Connection
Connections
• Tapping and return lines
• Trenches and opening
Delivery/installation by installation
company or builder
Intermediate Circuit
• Poss. groundwater pump
• Establishing intermediate
circuit incl. heat carrier fill
Delivery/installation by installation company Heat Pump
Bank
Terrain
Brine concrete
Sealing
borehole
Heat Source Systems
• Establishing tapping
and return wells
• Poss. groundwater
pump
• Delivery/installation by
installation company
or drilling company
Key
1 Poss. filter
2 Slide valve
3 Intermediate exchanger
4 Manual air exhauster
5 Filling and draining valve
6 Safety valve
7 Thermometer
8 Expansion vessel
9 Manometer
11 Flow monitor
12 Circulating pump
13 Return valve
14 Poss. flow rate meter
15 Flow control valve
16 Antifrost thermostat
17 Submerged pump
18 Fine filter, mesh size
= 280 – 350 my
Installed in compact
heat pumps
L
When using groundwater or well water
as heat source, the following must be
observed:
- Min. temperature > = 7°C
- Filtered, clean water; provide water
filter in pressure line
L
Brine-side circulating pump, expansion
vessel, manometer, charging element,
and safety valve are already integrated
into the AQUATOP TC.
L
Lead safety line at an incline into
suitable collection container.
Water (with intermediate circuit)

11
Installation and Connection Instructions
Heater-Side Connection
Key
1 Heating water outlet, inside thread
2 Heating water inlet, inside thread
3 Heat source outlet, inside thread
4 Heat source inlet, inside thread
5 Electrical feed
6 Sensor cable
7 Safety valve outlet

12
Installation and Connection Instructions
Heater-Side Connection
Two different basic concepts exist:
a) Direct connection, without buffer storage, comply with min. circulating water volume requirement
The coil area of the service water storage
must be adjusted to the heat pump capacity.
b) Indirect connection, with buffer for hydraulic decoupling
The coil area of the service
water storage must be
adjusted to the heat pump
capacity.

13
Installation and Connection Instructions
Condensate and Safety Line
The condensate line and the safety
line of the heating side must be installed
freely visible and at an incline towards
the building drainage system.
L
The safety line of the heat reclamation
side (heat gain with brine) must be
installed freely visible and at an incline,
leading into a suitable collection
container.

14
Electrical Connection
General
E
Compliance with the corresponding SEV,
EN, IEC, as well as the corresponding
VDE standards is required for the
electrical connection of the heat pump.
The connection specifications of the
local utility or electric company must be
complied with as well.
E
The power supply to the equipment must
be interrupted before each electrical
connection or service or maintenance
work. The upper cover on the equipment
must be removed for the electrical
connection. This requires unscrewing
four hexagonal screws on the rear
upper cover plate of the unit and re-
moving the cover by pulling towards
the top.
The power supply is carried out via the
inlet of the cable connection at the rear
side of the heat pump. All other neces-
sary control connections such as flow
monitor, frost protection, thermostat,
and temperature sensor are also at the
rear of the heat pump.
E
Power Supply to the Switchbox
The power supply for the heat pump
must feature
a main switch or all-pole
cut-off switch with a contact distance
of at least 3 mm, as well as a 3-pole
circuit breaker with shared trigger for all
outer conductors. See technical data or
type plate on rear of heat pump for the
tripping current! The power cables must
have a cross-section that meets the
equipment output as well as locally
applicable rules and standards.

15
Electrical Connection
Wiring Diagram and Terminal Assignment
L
The sensors, pumps, mixing valves, etc.
to be connected may vary depending
on the system configuration and are
listed in the corresponding standard
documentation.
L
Depending on the technical connection
requirements (TCR) of the electric
company, a separate input of power
element (compressor) and control
element (control, pumps) may be
needed. Comply with the corresponding
connection scheme (diagram)!
L
Hot cables and sensor cables must be
installed separately!
Electric
company
block
On-site setup
Contact closed – HP released
Flow monitor
HP supply
Terminals in HP
Heat pump
Heat pump
Power consumption
Ext. fuse
Load
(optional)
Malfunction
Switching valve
Heizungsregler
Heat pump
Exterior - Service- Service
sensor water - water
sensor sensor
Remote
control
Control unit
(optional)

16
Assembly
Control Panel
The front cover, the controller case, and
the control panel are to be assembled
in the following order:
Connection Plug to Control Panel 1
Insert the connection plug to the control
panel through the opening in the front
upper cover plate.
Connection Plug to Control Panel 2
Insert Controller Receptacle into
Upper Front Cover Plate
The controller receptacle is inserted
into the 4 lengthwise grooves of the
upper front cover panel.
Make sure the connection plug is
threaded through the opening for the
control panel.
Insert Connection Plug into
Control Panel

17
Assembly
Control Panel
Insert Control Panel into
Controller Case
Attach Front Cover
Insert the front cover panel into the
controller case from bottom to top
while holding at a slant.
Snap Front Cover into Place
Snap front cover into the provided
lengthwise grooves.

18
Charging Geothermal Heating Systems
Problems and Issues
Incorrect Brine Concentration
Flushing
Problems
Problems with charging a geothermal
heating system (GHS) with antifreeze
may occur occasionally and result in a
reduced capacity of the system or even
total system failure. Most problems are
as follows:
Dirt in the Circuit
Drilling companies generally strive to
fill only clean water into geothermal
heating systems. However, dirt may
reach the probe due to inattention.
This dirt can damage the circulating
pump or the evaporator of the heat
exchanger.
Insufficiently Mixed Brine Solution
If the correctly calculated antifreeze
volume is charged directly as a concen-
trate without corresponding mixing
device, individual probes may jam or
become completely disconnected due
to the viscosity of the concentrate.
Water without the required glycol
content circulates in the remaining
probes. Without the required glycol
content, the heat pump may freeze
already upon initial startup, which may
destroy the associated evaporator.
Incorrect Brine Concentration
In some cases, the detected glycol
concentration differed greatly from the
calculation.
This was mostly due to a lack of the
proper equipment to prepare the
mixture correctly. If the concentration
is too high, the heat pump's capacity is
reduced and works less efficiently.
The heat pump may also overheat.
An insufficient concentration (<20%)
may cause corrosion and frost damage.
Correctly Charging the GHS with the
Help of a Mixing Tank, Mixing
Equipment with Filter
All of the problems listed previously
can be avoided by properly charging the
GHS circuit. The right equipment can
make all the difference as well.
Use a mixing and charging tank to
charge the GHS circuit according to
the following requirements:
- Clean mixture
- Correct concentration:
- Homogeneous mixing
Flushing
Use filtered potable water and pres-
sure to flush first the circulating pump
of the GHS circuit and the evaporator
and remove pollutants such as welding
beads, little stones, and dirt.
After closing a slider in the heat pump
circuit, each circuit of the GHS is
flushed one after the other.
A pressure of 2 bar is used to flush
a 140-m long ø 32 mm probe for
6 minutes as depicted below.
Min. Flushing
Time for 32-mm Probe
10
9
8
7
6
5
4
3
2
1
0
0 50 100 150 200
Probe length
Duration in minutes
2 bar pressure
3 bar pressure
Charging hose
Excess pressure
valve 2.5 bar
Mixing
tank
120 l
Jet pump.
e.g. Grundfos
max. 5 m3/h
max. 5 bar
GHSs
Brine circulating pump
Heat pump
Expansion vessel
GHS circuit
Drain hose
Filter

19
Charging Geothermal Heating Systems
Charging with Antifreeze
Correctly Charging a Geothermal Heating System Circuit
Charging with Antifreeze
After flushing, the entire geothermal
heating system circuit is to be filled
with clean tap water. Follow the steps
below to prepare the required con-
centration of antifreeze with a 100%
concentrate. For example:
The required antifreeze concentration
is 25% (ideal range is 25-30%) with a
140-m Duplex® ø 32 mm BHE.
(Content per meter = 4 pipes x 10 dm,
length x 0.13 dm,
inner radius2x rr = 2.12 l/m.)
Correctly Charging a Geothermal
Heating System in 14 Steps
1. Flush the GHS circuit as described
on page 18.
2. Calculate the probe volume acc. to
table above. One GHS (GHS
ø 32 mm) has 2.12 l/m content per
meter. This yields the following
GHS content for our example:
140 m x 2.12 l/m = 296.8 liters
(297 l). Do not forget the content of
the connection lines up to the heat
pump, 30 liters in our example.
This results in a total system content
of 297 liters + 30 liters = 327 liters.
3. Required volume of 100% anti-
freeze concentrate:
25% of 327 liters = 82 liters.
4. Close the sliders to the heat pump.
Remove the drain hose from the
tank and place in drain.
5. Open the sliders of the GHS – if
several probes have been
installed, one slider after the other
is opened during charging.
6. Fill the mixing tank with an approx.
mixture of 1:1 of antifreeze
concentrate and fresh water.
Depending on tank size, not all of
the 82 liters of concentrate fit into
the tank (see calculation, item 3).
7. Switch the feed pump on.
As soon as the tank begins to
empty, continuously fill in the
remaining antifreeze concentrate
and additional fresh water into the
mixing tank at a ratio of approx.
1:1. Make sure that always at least
40 liters of mixed reserve remains
in the tank. Volume markers can
be attached to the edge of the
tank to help you determine its
volume.
8. The feed pump is allowed to run
until the entire antifreeze
mixture – except for the 40 liters
reserve – are filled in and then is
switched off at once. Excess tap
water drains from the drain hose
into the drain.
9. Now insert the drain hose into the
tank, turn the feed pump back on,
and allow it to run until glycol and
water are thoroughly mixed. This
takes about 6-times to 8-times as
long as it takes for flushing (see
diagram, item flushing).
10. Close charging valves at drain
hose and then those at the
geothermal heating system
distributor. The excess pressure
valve (2.5 bar) routes the excess
mixture back into the tank. Shut off
feed pump. About 40 liters remain
in the tank. Some of the mixture
was absorbed by the expansion
of the geothermal heating system.
11. In case of relatively long geo-
thermal heating systems and
insufficiently mixed mixture, the
excess pressure valve at the tank
is triggered and thereby intensifies
mixing.
12. If several GHSs are combined into
one system, the second, third, etc.
GHS is first flushed and then
charged individually until all have
been processed.
13. Once all geothermal heating
systems are charged, the eva-
porator and the brine circulating
pump must be charged next.
All sliders to the geothermal
heating systems are closed for
this purpose and the sliders to the
evaporator are opened.
The remaining mixture is now
carefully pumped via the slider at
the filling hose. Allow water in the
circuit to escape via the drain
hose. As soon as the glycol
mixture emerges as the drain hose
(color change), close the corre-
sponding valve and allow the
pump pressure to charge the
expansion vessel (2.5 bar). Then
close the valve at the filling hose.
The system is now charged with
the correct concentration and
correct operating pressure without
introducing pollutants to the
system.
14. Now carry out a pressure test.
This test should be performed
over an extended period to avoid
the hassle of finding leaks later on.
Note: Antifreeze mixtures are
more likely to result in leaks earlier
than water alone!
Geothermal heating
system (probe)
diameter
Content per
meter
25 mm 1,31 l/m
32 mm 2,12 l/m
40 mm 3,34 l/m

20
Charging Geothermal Heating Systems
Charging with Antifreeze
Correctly Charging a Geothermal Heating System Circuit
Heating and Brine Charging Valves
L
The brine circuit is to be charged with
a charging pressure of 1 bar
(diaphragm-type expansion vessel
initial pressure) + 0.3 bar as brine
header = total of
1.3 bar .
L
The temperature difference during
this operation should not exceed 4 K
between sole inlet and outlet.
Flushing and charging (heating side).
The heating side must be flushed and
charged as well.
The initial pressure in the diaphragm-
type expansion vessel (heater, factory-
set at 1 bar) must be adjusted to meet
local requirements. (Static height in
m 0.1 bar.).
The charging pressure should be as
follows while cold: initial pressure
diaphragm-type expansion vessel
+ 0.2 bar (water header).
L
The Aquatop TC 19 and the
AQUATOP TC 11 HT are equipped
with 2 heater-side expansion vessels.
L
Important: Comply with water quality,
VDI 2035
L
Charging must be carried out in
accordance with DIN EN 1717.