IVT Optima 600-1700 User manual

IVT Optima 600-1700
Mixed additional heat
Installation Guide
Art. no: 12343 Version 1.0

Installation Guide IVT Optima 600 – 1700 Mixed additional heat
IVT Industrier AB, 2007/09
Article number: 12343
Version 1.0
Copyright © 2007. IVT Industrier AB. All rights reserved.
This manual contains copyright protected information that is the property of IVT Industrier AB. No part of this document may be copied or forwarded, electronically or mechanically,
without prior, written permission from IVT Industrier AB. This includes photographing and translation to another language.

3
Table of Contents
Innehåll
FOR THE INSTALLER ..................................................................................................... 5
Important information for the installer ............................................................................6
Checklist.......................................................................................................................6
What the shipment includes ...........................................................................................7
General.........................................................................................................................8
Transporting and storage .........................................................................................................................................8
Positioning the heat pump........................................................................................................................................8
Minimum and maximum working temperatures ......................................................................................................9
The heating installation’s different methods of control ..............................................................................................9
Defrosting method ....................................................................................................................................................9
Location of the temperature sensors ........................................................................................................................10
CANbus..................................................................................................................................................................11
Detailed pictures connection area...........................................................................................................................12
Dimensions, clearance and plumbing connections..........................................................14
Optima 600-1100...................................................................................................................................................14
Optima 1400-1700.................................................................................................................................................15
Control cabinet, Accessory unit electric/oil-fired boiler............................................................................................16
Double-shelled hot water heater ..............................................................................................................................16
Fit the particle filter ...............................................................................................................................................16
Connecting to the heating system ..................................................................................17
Flushing the heating system....................................................................................................................................17
Connecting the heat pump to the heating system .....................................................................................................17
Connecting three-way valve ....................................................................................................................................17
Heat carrier pump G2............................................................................................................................................17
Connection principles.............................................................................................................................................18
Filling the heating system .......................................................................................................................................19
Connecting to the power supply ....................................................................................20
Accessories .............................................................................................................................................................20
Safety switch and earth-fault breaker......................................................................................................................21
Emergency operation..............................................................................................................................................21
Wiring diagram Optima 600-1100 .......................................................................................................................22
Wiring diagram Optima 1400-1700 .....................................................................................................................23
Wiring diagram Control cabinet ............................................................................................................................24
Wiring diagram Accessory unit .............................................................................................................................25
External connections diagram ................................................................................................................................26
External connections Heat pump............................................................................................................................27
External connections Control cabinet ....................................................................................................................28
External connections Accessory unit ......................................................................................................................29
Installer and service menu (I/S) ...................................................................................30
Menu over view ............................................................................................................31
Commissioning............................................................................................................34
Start the heat pump ...............................................................................................................................................34
Start up .................................................................................................................................................................34
Other settings .........................................................................................................................................................37
Important points to check after commissioning.......................................................................................................37
Timers ........................................................................................................................ 38
Alarm functions...........................................................................................................39

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Technical information ..................................................................................................40
Factory settings ......................................................................................................................................................40
Technical information............................................................................................................................................43
Sound levels ...........................................................................................................................................................44
Sensor table..................................................................................................................................................... 44
Table of Contents

5
This guide provides the heat pump installer with a description of how the heat
pump and the hot water heater, if used, are installed and commissioned. The
installation section consists of a plumbing part and an electrical part. It also
provides technical data such as measurements, wiring diagrams and installer
menus. We hope that you read through this guide carefully and that you
respect all notes and warning texts.
Note
It is important that as the installer you also read through the User guide for the
heat pump. Here you will find the information necessary to get a comprehensive
understanding of the heating installation.
Contents:
Important information for the installer
Checklist
What the shipment includes
General
Dimensions, clearance and plumbing connections
Connecting the heating installation to the heating system
Connecting the heating installation to the power supply
External connections
Commissioning
Technical information
Important information for the installer
For the Installer

6
This manual gives you all the information necessary to install the heat
pump. The guide is divided into several parts in the order in which installa-
tion and commissioning must be carried out.
Before starting the installation:
The heat pump may be temporarily tilted with the compressor
downwards. It must never be laid down or transported horizontally.
Check that plumbing connections in the heat pump are intact and have
not shaken loose during transport.
If the heat pump is used in a system with fan-assisted radiators, the
water volume in the system is very small. During defrosting, the heat
pump draws some of the energy from the heating system, cooling
it down. It is therefore important that the fans in the fan-assisted
radiators run during defrosting, alternatively are connected to a tank of
approximately 100 litres.
Wiring should be kept as short as possible to protect the system from
downtime, for example during a thunderstorm.
Before the commissioning the heating system must be filled up and
completely vented.
Important information for the installer
Checklist
The following checklist will give you a general description of how the installation
should be carried out.
1. Position the heat pump on a solid base.
2. Install the incoming and outgoing pipes for the heat pump.
3. Install the drainage pipe for the heat pump.
4. Install the new hot water heater, hot water sensor and three-way valve if used.
5. Install G2 heat carrier pump.
6. Install a mixing valve if not already installed.
7. Fit the particle filter.
8. Connect the heat pump to the heating system.
9. Install the control cabinet and the accessory unit for electric/oil-fired boiler.
10. Install the flow sensor, outdoor sensor, and room sensor if used.
11. Connect the CANbus wiring between the heat pump and the control cabinet.
12. Connect the heating installation to the power supply via a safety switch and
any earth fault breaker.
13. Fill and vent the heating system before commissioning.
14. Commission the heating installation by making all the necessary settings on
the control panel.
15. Check the heating installation after commissioning.
Warning
For reasons of safety the main power
supply must be disconnected before
working on the heat pump.
!
Note
Only qualified installers may carry
out the installation. The installer must
follow applicable rules and regula-
tions and recommendations from the
supplier.
Important information to the installer / Checklist

7
What the shipment includes
The following components are included in the delivery of the heat pump:
Circlip pliers
Quantity: 1
Particle filter with screen
Quantity: 1
Rubber feet
Quantity: 4
What the shipment includes
The following components are included in Rego 800 Mixed additional heat:
Control cabinet
Flow/Tank sensor T2 with cable
Quantity: 1
(supplied with control cabinet)
Accessories (not included in delivery):
Room sensor T5
Soft starter
Heating cable: 2m / 30W
3m / 45W
5m / 75W
Three-way valve
Circulation pump G2:
600-1100 Wilo Star RS 25/4
1400-1700 TOP S25/75
Shut off valves for G2 Cu 28 (2 x)
Mixing valve
Accessory unit electric/oil-fired boiler
Includes:
User Guide
Quantity: 1
Installation Guide
Quantity: 1
Hot water heater:
(600-1100) Double shelled: IVT 300/160 (T3 included)
(1400-1700) Coil tank: IVT 320 or IVT 520 (T3 is an accessory)
Tube sensor hot water heater (T3)
Outdoor sensor T2 with cable
Quantity: 1
(supplied with control cabinet)

8
Positioning the heat pump
The heat pump is located outdoors. It contains a number of sensitive
parts. It is important that it stands on a flat and solid base, for example,
concrete slabs on ground insulation.
The installer should take sound propagation into consideration when
positioning the heat pump. See more information under the heading
Technical information/Sound levels.
Pipe routing between the heat pump and the existing heating system
should be as short as possible. The outdoor pipes must be insulated.
The heat pump produces condensation and melted ice during the
defrosting process. It is therefore important to lead off this water from
the heat pump to a floor drain inside the house.
Note that the drainage pipe must slope towards and run out above the
floor drain. This will keep the drainage pipe free of frost as air is drawn
from inside the house. In those cases the drainage pipe is released into
the surface water outdoors, the pipe must be fitted with a heating cable
(accessory) to avoid freezing. A suitable output is 10-20 W/metre. The
cable can be connected to terminals in the heat pump. See External
connections.
The heat pump must be positioned so that air is not prevented from
passing through the evaporator. Minimum distance to a wall is
300 mm. Avoid positions which result in circulation of cold air because
this decreases the heat pump output.
Avoid falling snow and eaves drop. In some cases a protective roof may
be necessary. The roof should then be installed at least 1.5 m above the
heat pump to avoid the recirculation of cold air.
General
Transporting and storage
The heat pump should always be transported and stored in an upright
position. Otherwise the suspension fittings inside the compressor can be
damaged. If the heat pump must be tilted during entry to the installation
site, this should be done for as short a time as possible.
The heat pump must not be stored at temperatures below 0ºC.
Note
The amount of condensation water
can, during days of high humidity,
amount to 30-40 litres.
General

9
Maximum working temperatures
The heat pump can work with a maximum return temperature of approxi-
mately 59ºC. If the temperature rises above this value the heat pump will
stop for reasons of technical safety.
The maximum flow temperature from the heat pump or additional heater is
limited to 65ºC.
Minimum working temperatures
The heat pump stops if the outdoor temperature falls below approx -20ºC.
All heat production then occurs in the existing electric/oil-fired boiler.
The heat pump starts automatically when the outdoor temperature climbs
above approx -20ºC.
The heating installation’s different methods
of control
The control unit uses different methods to control the heating installation.
These are: Control with an outdoor sensor and Control with an outdoor
sensor supplemented with a room sensor.
More information about the control methods can be found in the User
Guide for Optima.
General
Minimum and maximum working temperatures
Defrosting method
The principle of defrosting in the heat pump is known as hot gas defrost-
ing. During defrosting, the flow in the refrigerant circuit is reversed by
means of an electrically-controlled four-way valve. The compressed gas
from the compressor is fed into the top of the evaporator, causing the ice
on the outside to melt. During this process, the heating water is cooled
slightly. Hot gas is sprayed into the evaporator and sensor T11 ensures that
the process functions correctly. The time required for defrosting depends
on the amount of ice and the outdoor temperature.
There is also a fan defrost function, which means that hot air blows
upwards through the fan to prevent it freezing solid.

10
General
T1 Flow sensor
T2 Outdoor sensor
T3 Hot water sensor (if hot water heater is installed)
T5 Room sensor
T6 Sensor compressor temperature
T8 Sensor heat transfer fluid out
T9 Sensor heat transfer fluid in
T10 Sensor condenser temperature
T11 Sensor refrigerant temperature evaporator
T12 Sensor air temperature evaporator
Location of the temperature sensors
Optima Electric/oil-
fired boiler
Hot water
heater

11
General
In Rego 800 the different circuit boards are connected by a communica-
tions cable, CANbus. CAN is an abbreviation of Controller Area Network
and is a two wire system for communication between the microprocessor
based modules/circuit boards. These are connected in series.
The heat pump has one circuit board (IOB circuit board). The accessory
unit electric/oil-fired boiler has one circuit board (IOB circuit board).
Other circuit boards (CPU, PSU and IOB circuit boards) are in the control
cabinet.
Suitable cable for external laying (connection between the circuit
boards) is cable ELAQBY 2x2x0.6. The cable must be twisted pair and
screened. The screen must only be earthed at one end and to the chassis
(not to a circuit board). Maximum cable length is 20 m.
The CANbus cable must not be laid alongside power supply cables. It may
be laid alongside sensor cables.
In the connection area of the heat pump the external CANbus cable must
be laid so that it does not come into contact with high current connections
(230/400V).
The connection between the circuit boards is by four wires since the
12V-supply between the circuit boards must also be connected. The circuit
boards have markings for both the 12V and CANbus connections.
Warning
Do not mix up the 12V and CAN-
bus connections! If 12V (or other
incorrect voltage) is supplied to the
CANbus contacts the processors in the
CANbus are destroyed. Check, there-
fore, that the four cables are connected
to the contacts with the corresponding
marking on the circuit boards in the
accessory unit and the heat pump.
Switch S1
The switch is used to mark the start and end of a CANbus loop. This
means that the IOB circuit board in the heat pump and the accessory unit
circuit board must be terminated using S1, which must be in position Term.
Ensure that this is the case and that all other switches are in the opposite
position.
CANbus
Warning
The CANbus cable must be screened
and laid separately from the power
cable to prevent interference in the
CANbus communication.
Screen
Warning
Handle the circuit boards with great
care. They are sensitive to ESD (Elec-
trostatic discharge), which can cause
faults in electronic components.

12
General
Detailed pictures connection area
Optima 600 - 1100
Optima 1400 - 1700
High pressure
pressostat
Service
connection
Compressor
Expansion valve
Four-way valve
Service
connection
Non-return
valve
Low pressure
pressostat
Drying filter
Sight glass
Condenser
Venting nipple
High pressure switch Drying filter Sight glass Service
connection
Service
connection
Compressor
Condenser
Expansion valve
Four-way valve
Non-return
valve
Low pressure
pressostat
Suction
accumulator

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Accessory unit electric/
oil-fired boiler
General
Control cabinet
IOB board
PSU board
CPU board (mounted on the
inside of the door)
Electrical cabinet Optima
600-1100
(above the compressor)
Electrical cabinet Optima
1400-1700
(left-hand side of heat pump)
Electrical
connections
Soft starter IOB card
Electrical
connections
Soft starter IOB card
Phase sequence relay

14
Dimensions, clearance and plumbing connections
Dimensions, clearance and plumbing connections
Front
Left-hand side
To heating system
(Hose 1 inch internal thread)
Draining, plastic pipe 32 mm
Back
Electric lead-ins
640
1190
60
820
411
220
105
101
165 201
Optima 600-1100
Required installation space for the heat pump.
Minimum distance from the pump to the wall is 300 mm.
Minimum distance in front of the pump 1000 mm, to the sides 500 mm.
If a roof is installed it must be positioned at least 1.5 m above the heat
pump to avoid the recirculation of cold air.
From the heating system
(Hose 1 inch internal thread)

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Optima 1400-1700
Dimensions, clearance and plumbing connections
Required installation space for the heat pump.
Minimum distance from the pump to the wall is 300 mm.
Minimum distance in front of the pump 1000 mm, to the sides 500 mm.
If a roof is installed it must be positioned at least 1.5 m above the heat
pump to avoid the recirculation of cold air.
705
920
1660
From above
Right-hand sideBack
1 Heat transfer fluid out external G25
2 Heat transfer fluid in external G25
3 Drainage external G25
Right
Left
Front
1
2
3

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Dimensions, clearance and plumbing connections
Control cabinet, Accessory unit
electric/oil-Þred boiler
The units must be wall mounted indoors close to the other indoor components.
Control cabinet Accessory unit
Double-shelled hot water heater
See the documentation for the hot water heater. See also Connection
principles.
Fit the particle Þlter
The task of the particle filter is to filter out dirt before it can enter the heat
pump. Consequently, the particle filter supplied with the heat pump should
always be fitted on the incoming hot pipe. It should be fitted as close to the
heat pump as possible and be horizontal.

17
Connecting to the heating system
Connecting to the heating system
Flushing the heating system
It is important that all previously mentioned preparations have been
carried out before the heat pump is connected to the heating system. Also
ensure the pipe system has been well flushed before it is connected to the
heat pump. Flushing protects the heat pump from contamination.
The heat pump is a part in a heating system. Faults in the heat pump can
be caused by poor water quality in the radiators/underfloor coils or that air
is penetrating the system continuously. Oxygen causes corrosion products
in the form of magnetite and sediment. Magnetite has a grinding effect on
the heat pump pumps, valves and components with turbulent flows such
as the condenser. Heating systems which require regular filling or where
the heating water is not clear when drained, requires remedial measures
before the installation of a heat pump, for example the heating system must
be fitted with filters and vents. Do not use any water treatment additives
except agents for raising the pH level.
An intermediate heat exchanger is sometimes necessary to protect the
heat pump.
Connecting the heat pump to the heating
system
Use the information in section Dimensions, clearances and plumbing con-
nections to connect the different parts of the heating unit.
In addition, to avoid vibration transfer between the heat pump and the pipe
system we recommend fitting flexible hoses at the inlet and outlet of the
heat pump.
Between the heat pump and the house we recommend 28 mm copper
pipe for lengths of less than 20 metres. The pipes must be insulated with a
material, such as Armaflex, which cannot absorb moisture. Venting valves
must be provided on the pipes. Short outdoor pipes reduce heat losses.
Connecting three-way valve
Connect a 3-way valve if the hot water heater is to be included. A descrip-
tion how to connect a ESBE type three-way valve is given to the right.
The ESBE 3-way valve must be installed on the return line according to the
system solution. Some 3-way valves are designed to be located on the flow
line. If such a valve is used, install it on the flow line
Heat carrier pump G2
Connect G2 and the shut off valves. The flow across G2 must be set slightly
lower than the flow across G1.
Note
Only qualified installers may carry out
the installation. The installer should
observe applicable rules and regula-
tions and recommendations from the
supplier.
Port A:
From hot water
heater.
Port B:
From heating
system
Port AB: To heat pump

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Q Shut off valve
Q Safety valve outlet
Q Control valve with motor
T Temperature sensor
E Double-shelled water heater with electric element
E Oil-Þred boiler/Electric boiler
E Heat pump
C Expansion tank
W Filter/Screen
G Pump
G Fan
W Filter valve
W Domestic hot water
W Inlet/outlet
Pipe (Arrow denotes direction of ßow)
Crossing pipes
T-piece
Optima with electric/oil-fired boiler and hot water heater
Connection principles
The principle is based on liquid condensation and additional heat from an electric/oil-fired boiler using a mixing valve.
The control unit controls the heat pump using the outdoor sensor T2 and the return sensor T1 according to the set heat
curve. When the heat pump is unable to meet the heating requirements, the electric/oil-fired boiler starts automati-
cally and together with the heat pump provides the required temperature. Hot water is prioritised and controlled by a
sensor, T3 in the heater. While the water is heating in the hot water heater, the heating system from the heat pump is
disconnected temporarily through a three-way valve. If the electric/oil-fired boiler is in operation it provides the required
temperature to the heating system. When the hot water is heated the heat pump continues the heat production.
Hot water mode when the heat pump is not operating:
The heat pump stops automatically at outdoor temperatures below approximately -10ºC and cannot then produce hot
water. The electric element in the hot water heater (IVT 300/160) is then automatically activated by the control unit and
the hot water heater will thus maintain a high temperature. The temperature is adjustable using the thermostat on the
electric element.
Connected sensors:
T1 Flow sensor
T2 Outdoor sensor
T3 Hot water sensor (accessory)
T5 Room sensor (accessory)
T8 Sensor heat transfer fluid out
T9 Sensor heat transfer fluid in
Connecting to the heating system
Mixing valve
Three-way valve
Hot water
Cold water
Particle
filter
Heating
system
Outdoor sensor
Room sensor,
accessory
Note
If a hot water heater is not included,
connect the cold and hot water pipes to
the electric/oil-fired boiler.

19
Connecting to the heating system
Warning
The hot water heater must always be
filled and pressurised before the heat-
ing system is filled.
The installation must not, under any
circumstances, be switched on without
water.
Venting nipple (only Optima 600-1100)
Optima 600-1100
Filling the heating system
After flushing the heating system the hot water heater must be filled with
water. The heating system is then filled.
This is what to do:
1. Open and close the tap between the cold water system and the heating
system in short time intervals.
2. Read the pressure on the expansion tank pressure gauge.
3. Vent the system and refill to the correct pressure.

20
Connecting to the power supply
Check that cables and printed circuit boards are intact. High and low
current cables should be routed separately in order to avoid interference
on the sensors.
The heat pump control unit is mounted in the control cabinet. Connect
additional heat equipment to the accessory unit. The compressor, fan,
sensors, pressure switches, etc. are connected to the heat pump’s junction
box. The cable between the control cabinet, accessory unit and heat
pump’s electrical box is routed according to the diagram External connec-
tions diagram.
The following sensors are to be connected during installation: T1 Flow
sensor, T2 Outdoor sensor, T3 Hot water sensor (accessory), T5 Room sensor
(accessory).
Install the flow sensor T1 in direct contact with the flow pipe.
Accessories
Hot water sensor T3
When IVT 300/160 is used T3 is already installed on the heater. The sensor
is connected according to External connections Control cabinet. Note that
300/160 must be supplemented with a 6 kW electric element, see separate
guide.
Room sensor T5
The room sensor is placed centrally in the house and is connected
according to External connections Control cabinet.
Soft starter
The compressor can be equipped with a soft starter to reduce the inrush
current. The soft starter is fitted on the heat pump and is connected
according to Wiring diagram Optima.
Heating cable
A drainage pipe from the heat pump’s drip collector may need to be fitted
with a heating cable. See Accessories under What the shipment includes?
for information about lengths. The heating cable is according to External
connections Heat pump.
Connecting to the power supply
Warning
Handle the circuit boards with great
care. They are sensitive to ESD (Elec-
trostatic discharge), which can cause
faults in electronic components.