Heiko Thermal 6 User manual

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INSTALLATION MANUAL
HEAT PUMP HEIKO THERMAL
• The device is granted a 5-year warranty only if commissioned by an Authorised Service
Centre and registered in the guarantor’s system. The cost of service commissioning
according to the current APS rates xed by the general distributor of Refsystem
devices.
• Please read this manual carefully before commencing installation.
• This device is lled with R32 refrigerant.
• The device contains uorinated greenhouse gases.
• Keep this manual for future reference.
THERMAL 6
THERMAL 9
THERMAL 12
THERMAL 15
THERMAL 19

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1. Before use ........................................................................................................................3
2. Warranty terms .........................................................................................................12
3. Main Components...................................................................................................16
4. Data sheet ....................................................................................................................18
5. Capacity tables .........................................................................................................20
6. Unit dimensions ......................................................................................................32
7. Power supply..............................................................................................................35
8. Power distribution room ...................................................................................36
9. Terminal blocks for indoor units...................................................................37
10. Terminal blocks for outdoor units ............................................................ 40
11. Installation elements required by the warranty ...............................42
12. Installation requirements................................................................................45
13. Installation diagrams..........................................................................................45
13.1. Heiko THERMAL heat pump with CH system only .................... 46
13.2. Heiko THERMAL heat pump with CH and WH systems ........55
13.3. Heiko THERMAL heat pump with HUW system and floor
heating without control............................................................................... 65
13.4. Heiko THERMAL heat pump with heating and HUW
system.......................................................................................................................75
13.5. Heiko THERMAL heat pump with CH system and auxiliary
heat source ............................................................................................................86
13.6. Heiko THERMAL heat pump with CH + HUW systems and
auxiliary heat source .......................................................................................97
14. Emergency activation of electric heater ............................................108
15. Failure codes...........................................................................................................109
16. Circuit diagrams .................................................................................................... 111
Table of Contents

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Safety Precautions
Cautions:
Do not accelerate the defrosting process or clean the device in a manner other than
recommended by the manufacturer. The device shall be stored in a room without
continuously operating ignition sources (for example: open ames, an operating gas
appliance or an operating electric heater.).
Do not pierce or burn.
Note:the refrigerant contained in the device may be odourless.
Servicing shall be performed only as recommended by the manufacturer.
The appliance shall be stored in a well-ventilated area where the room size corresponds
to the room area as specied for operation. All procedures that affect the safety of the
installation shall only be carried out by competent persons.
The device contains uorinated greenhouse gases.
It is forbidden to release the refrigerant into the atmosphere! All the products are
in conformity with the following European regulations: Low Voltage Directive,
Electromagnetic Compatibility Directive
General information:
1. Transport of equipment containing ammable refrigerants
In compliance with the transport regulations
2. Marking of equipment using signs
In compliance with local regulations
3. Disposal of equipment using ammable refrigerants
In compliance with national regulations
4. Storage of equipment/devices
The equipment shall be stored in accordance with the manufacturer’s instructions.
5. Storage of packed (unsold and brand new) equipment
Storage packaging design shall ensure protection against refrigerant leakage in the case
of mechanical damage of the device inside the packaging. The maximum number of
pieces of equipment permitted to be stacked shall be determined by local regulations.
6. Information on servicing
1) Work area inspection
Prior to beginning work with systems containing flammable refrigerants, safety checks
are necessary to ensure that the risk of ignition is minimised. For maintenance or repair
of the refrigerant installation, the following precautions shall be complied with prior to
conducting such works.
Before Use
Air-to-water heat pump
DC inverter

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Before Use
2) Work procedure
Work shall be undertaken under a controlled procedure so as to minimise the risk of a
flammable gas or vapour being present while the work is being performed.
3) General work area
All maintenance and other personnel working in the device vicinity shall be instructed
on the nature of work being carried out. Work in confined spaces shall be avoided. The
work area around shall be sectioned off. Ensure that the conditions within the work
area have been made safe by control of flammable material.
4) Checking for presence of the refrigerant
The area shall be inspected with an appropriate refrigerant detector prior to and during
work. This lets the technical personnel know whether the atmosphere in their work
place is not toxic or flammable. Tightness detectors should enable the detection of the
type of refrigerant present in the installation. They must be intrinsically safe providing
the appropriate level of protection, and non-sparking.
5) Presence of re extinguisher
If hot work is to be performed, appropriate fire extinguishing equipment must be
available. Have a dry powder or CO2 fire extinguisher adjacent to the charging area.
6) No ignition sources
No person carrying out work in relation to a refrigeration system which involves
exposing any pipe work that contains or has contained flammable refrigerant shall use
any sources of ignition in such a manner that it may lead to the risk of fire or explosion.
All possible ignition sources, including cigarette smoking, should be kept sufficiently
far away from the site of installation, repairing, removing and disposal, during which
flammable refrigerant can possibly be released to the surrounding space. Prior to work
taking place, the area around the equipment is to be surveyed to make sure that there
are no flammable hazards or ignition risks.“No Smoking” signs shall be displayed.
7) Ventilated area
Ensure that the area is in the open or that it is adequately ventilated before opening
the refrigerant circuit or conducting any hot work. Ventilation shall continue until the
completion of work. The ventilation should safely disperse any released refrigerant and
preferably expel it externally into the atmosphere.
8) Checks to the refrigeration equipment
Where electrical components are being changed, they shall be fit for the purpose
and to the correct specification. At all times the manufacturer's maintenance and
service guidelines shall be followed. If in doubt consult the manufacturer’s technical
department for assistance. The following controls should be applied to installations
containing flammable refrigerants:

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The charge size is in accordance with the room size within which the refrigerant
containing parts are installed; The ventilation machinery and outlets are operating
adequately and are not obstructed; If an indirect refrigerating circuit is being used,
the secondary circuit shall be checked for the presence of refrigerant; Marking to the
equipment continues to be visible and legible. Markings and signs that are damaged
or illegible shall be replaced with new ones; Refrigeration pipe or components shall be
installed in a places where they are unlikely to be exposed to any substance which may
corrode refrigerant containing components, unless the components are constructed
of materials which are inherently resistant to being corroded or are suitably protected
against being corroded in this manner.
9) Checks to electrical devices
Repair and maintenance to electrical components shall include initial safety checks and
component inspection procedures. If a fault exists that could compromise safety, then
no electrical supply shall be connected to the circuit until it is satisfactorily dealt with.
If the fault cannot be corrected immediately but it is necessary to continue operation,
an adequate temporary solution shall be used. This fact shall be reported to the owner
of the equipment. Initial safety checks shall determine that: Capacitors are discharged:
this shall be done in a safe manner to avoid the possibility of sparking; There are no live
electrical components and wiring exposed while charging, recovering or purging the
system; .That there is continuity of earth bonding.
7. Repairs to sealed components
1) During repairs of sealed components, all electrical supplies shall be disconnected
from the equipment being worked upon prior to any removal of sealed covers, etc. If it is
absolutely necessary to have an electrical supply to equipment during servicing, then a
permanently operating form of leak detection shall be located at the most critical point
to warn of a potentially hazardous situation.
2) Particular attention shall be paid to the following to ensure that by working on electrical
components, the casing is not altered in such a way that the level of protection is affected.
This shall include damage to cables, excessive number of connections, terminals not
made to original specification, damage to seals, incorrect fitting of cable glands, etc.
Ensure that all electrical devices are connected and mounted securely.
Ensure that seals or sealing materials have not degraded to such an extent that they
no longer serve the purpose of preventing the ingress of flammable atmosphere.
Replacement parts shall be in accordance with the manufacturer's specifications.
Before Use

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CAUTION:
The use of silicon sealant may inhibit the effectiveness of some types of leak detection
equipment. Intrinsically safe components do not have to be isolated prior to working on
them.
8. Repair to intrinsically safe components
Do not apply any permanent inductive or capacitance loads to the circuit without
ensuring that this will not exceed the permissible voltage and current permitted for the
equipment in use. Intrinsically safe components are the only types that can be worked
on while live in the presence of a flammable atmosphere. The test apparatus shall be at
the correct rating.
Replace components only with parts specified by the manufacturer. Other parts may
result in the ignition of refrigerant in the atmosphere from a leak.
9. Wiring
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration,
sharp edges or any other adverse environmental effects. The check shall also take into
account the effects of ageing or continual vibration from sources such as compressors
or fans.
10. Detection of ammable refrigerants
Under no circumstances shall potential sources of ignition be used in the searching for
or detection of refrigerant leaks. A halide torch (or any other detector using a naked
flame) shall not be used.
11. Leak detection methods
The following leak detection methods are deemed acceptable for systems containing
flammable refrigerants:
Electronic leak detectors shall be used to detect flammable refrigerants, but the
sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall
be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source
of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set
at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant
employed and the appropriate percentage of gas is confirmed (max. 25%).
Leak detection fluids are suitable for use with most refrigerants but the use of detergents
containing chlorine shall be avoided as the chlorine may react with the refrigerant and
corrode the copper pipe-work.
Before Use

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If a leak is suspected, all naked flames shall be removed/ extinguished.
If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall
be recovered from the system, or isolated (by means of shut off valves) in a part of the
system remote from the leak. Oxygen free nitrogen (OFN) shall then be purged through
the system both before and during the brazing process.
12. Removal and evacuation
When breaking into the refrigerant circuit to make repairs - or for any other purpose
-conventional procedures shall be used. However, it is important that best practice is
followed since flammability is a consideration. The following procedure shall be adhered
to:
- remove refrigerant from the circuit;
- purge the circuit with inert gas;
- evacuate the circuit;
- purge again with inert gas;
- open the circuit by cutting or brazing.
The refrigerant charge shall be recovered into the correct recovery cylinders. The system
shall be “flushed” with OFN to render the unit safe. This process may need to be repeated
for several times. Compressed air or oxygen shall not be used for this task.
Flushingshall beachievedbybreakingthe vacuuminthesystemwith OFNandcontinuing
to fill until the working pressure is achieved, then venting to atmosphere. Finally, the
system shall be vacuumised. This process shall be repeated until no refrigerant is within
the system. When the final OFN charge is used, the system shall be vented down to
atmospheric pressure to enable work to take place. This operation is absolutely vital if
brazing operations on the pipe-work are to take place. Ensure that the outlet for the
vacuum pump is not close to any ignition sources and there is ventilation available.
13. The procedure of refrigerant charging
In addition to conventional charging procedures, the following requirements shall be
followed.
Ensure that contamination of different refrigerants does not occur when using charging
equipment. Hoses or lines shall be as short as possible to minimise the amount of
refrigerant contained in them.
Cylinders shall be kept upright.
Ensure that the refrigeration system is earthed completely before commencing the
refrigerant charge. Label the system with the appropriate F-gas label upon completion.
Before Use

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Extreme care shall be taken not to overfill the refrigeration system. Prior to recharging
the system it shall be pressure tested with OFN. The system shall be leak tested on
completion of charging but prior to commissioning. A follow up leak test shall be carried
out prior to leaving the site.
14. Decommissioning
Before carrying out this procedure, it is essential that the technician is completely
familiar with the equipment and all its detail. It is recommended good practice that all
refrigerants are recovered safely.
Prior to the task being carried out, oil and refrigerant samples shall be taken in case
analysis is required prior to re-use of reclaimed refrigerant. It is essential that electrical
power is available before the task is commenced.
a) Become familiar with the equipment and its operation..
b) Isolate the system from the electrical supply.
c) Before attempting the procedure, ensure that::
• Mechanical handling equipment is available, if required, for handling refrigerant
cylinders;
• All personal protective equipment is available and being used correctly;
• The installation emptying process is supervised at all times by a competent person;
• Recovery equipment and cylinders conform to the appropriate standards.
d) Pump down the refrigerant system, if possible.
e) If vacuum is not possible, make a manifold so that refrigerant can be removed from
various parts of the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine / system and operate it in accordance with the
manufacturer’s instructions.
h) The cylinder must not be filled with excessive amount of refrigerant (maximum 80%
of liquefied refrigerant volume).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure
that the cylinders and the equipment are removed from site promptly and all isolation
valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigeration system unless it
has been cleaned and checked.
Before Use

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15. Labelling
Equipment shall be labelled stating that it has been de-commissioned and emptied
of refrigerant. The label shall be dated and signed. Ensure that there are labels on the
equipment stating the equipment contains flammable refrigerant.
16. Refrigerant recovery
When removing refrigerant from a system, either for servicing or decommissioning, it is
recommended good practice that all refrigerants are removed safely.
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant
recovery cylinders are employed. Ensure that enough cylinders for holding the total
system refrigerant are available. All cylinders to be used shall be attested for the recovered
refrigerant and labelled for the refrigerant
used in the installation stating its type.
The cylinders shall be equipped with safety and cut-off valves. Check that the valves are
fully functional. Empty recovery cylinders are evacuated and, if possible, cooled before
recovery occurs.
The recovery equipment shall be in good working order and include the instructions
for use. The equipment shall be suitable for the recovery of flammable refrigerants.
In addition, a set of calibrated weighing scales shall be available and in good working
order. Hoses shall be complete with leak-free disconnect couplings. Check that they
are in good technical condition. Before using the recovery machine, check that it is
in satisfactory working order, has been properly maintained and that any associated
electrical components are sealed to prevent ignition in the event of a refrigerant release.
Consult manufacturer if in doubt.
The recovered refrigerant shall be returned to the refrigerant supplier in the correct
recovery cylinder, and the relevant Waste Transfer Note attached. Do not mix refrigerants
in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been
evacuated to an acceptable level to make certain that flammable refrigerant does not
remain within the lubricant. The evacuation process shall be carried out prior to returning
the compressor to the suppliers. Only electric heating to the compressor body shall be
employed to accelerate this process. Oil drainage from the system shall be carried out
safely.
Before Use

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1.1 Safety Cautions
The following symbols are very important. Please be sure to understand their meaning,
which concerns the product and your personal safety.
Before Use
Warning Caution Prohibition
Fuse
Steel Copper
The installation, dismantlement and
maintenance of the unit must be
performed by qualified personnel. It is
forbidden to make any changes to the
product design, otherwise there is a
risk of injury or product damage.
Make sure the power supply to the
heat pump unit is off before any
operations are done on the unit.
When the power cord gets loose or
is damaged, always get a qualified
person to fix it.
Be sure to read this manual before use
Ground wire
Before taking shower, please always
add a mixture valve before water tap
and set it to proper temperature.
A properly adapted socket must
be used, otherwise it may not work
properly.
The power supply to the unit must be
grounded.
This appliance can be used by children aged from 8 years and above and
persons with reduced physical, sensory or mental capabilities or lack of
experience and knowledge under the supervision of adult guardians trained in
safe operation of the device and understanding the hazards involved. Children
shall not play with the appliance. Cleaning and user maintenance shall not be
made by children without supervision.
Do not touch the ventilation grille
when the
ventilator's engine is on.
Do not touch the power plug with
wet hands. Never pull out the plug by
pulling the power cable.
Water or any kind of liquid must not
be poured onto the product, or it may
cause product malfunction.
When the power cord gets loose or
is damaged, always get a qualified
person to fix it.
Please select the correct fuse or
breaker as per recommended. Steel
wire or copper wire cannot be used
as substitutes for fuse or breaker, or it
may cause product damage.
Please note that there is a risk of finger
injury by the heat exchanger ribs.