kensol HYDROBOX KTH1 User manual

Installation and operating instructions for HYDROBOX KENSOL KTH1
INSTALLATION AND OPERATING
INSTRUCTIONS
HYDROBOX KENSOL KTH1

Installation and operating instructions for HYDROBOX KENSOL KTH1 2/11
Table of contents
1. INTRODUCTION.......................................................................................................................................................3
2. ILLUSTRATIVE INSTALLATION DIAGRAM.......................................................................................................3
3. PRECAUTIONS AND RECOMMENDATIONS......................................................................................................3
4. TECHNICAL DATA AND COMPONENTS.............................................................................................................4
5. TRANSPORTATION AND STORAGE...................................................................................................................5
6. WALL INSTALLATION AND SERVICE DISTANCES ........................................................................................5
7. HYDRAULIC CONNECTIONS................................................................................................................................6
8. ELECTRICAL CONNECTIONS ..............................................................................................................................7
9. MAGNETIC FILTER OPERATION .........................................................................................................................8
10. CIRCULATION PUMP OPERATION .....................................................................................................................9
11. LAUNCHING AND OPERATING THE SARG1 SYSTEM ................................................................................... 10
12. CLEANING AND MAINTENANCE........................................................................................................................11
13. DISPOSAL................................................................................................................................................................11

Installation and operating instructions for HYDROBOX KENSOL KTH1 3/11
1. Introduction
Hydrobox is a module designed for indoor installation, speeding up the installation of a system with a
monobloc air-to-water heat pump, a buffer tank and a hot water storage tank. The compact form and
thoughtful design makes the entire installation take up less space, while providing easy access for
maintenance activities.
Due to the company’s philosophy of continuous product improvement, we reserve the right to change
the manual and any specifications in this document without notice.
2. Installationsschema
FIG. 1. EXAMPLE INSTALLATION DIAGRAM USING HYDROBOX MODULE KTH1
Heating circuit Heat pump
DHW tankCH buffer
HYDROBOX
3. Precautions and recommendations
PRECAUTIONS:
• All installation work must be performed only by a qualified and trained installer. Improper in-
stallation carries the risk of fire, flooding, electrical shock or damage to the unit and heat pump.
• Please refer to the instructions of the individual main components, in particular the magnetic
filter, the anti-freeze system and the controller.
• The device is not intended to be operated by children.
• For the sake of safety of use, it is necessary to regularly check the technical condition of the
device.
• Lightning can damage the device, so it should be unplugged during a storm.
• The device must not be misused.
• Do not touch the device with wet hands - risk of shock!

Installation and operating instructions for HYDROBOX KENSOL KTH1 4/11
ELECTRICAL:
• Live electrical device. Before doing anything with the power supply (connecting cables, instal-
ling the device, etc.), make sure that the device is not connected to the grid.
• Connection of heating elements must be carried out taking into account the electrical para-
meters of the device and in accordance with applicable regulations. The electrical installation
components used such as electrical wiring and apparatus must be selected properly.
HYDRAULIC:
• The device can be filled with low-oxygen water, preferably using dedicated corrosion inhibitors
for heating systems.
• The device should be installed with a view to applying the necessary pressure and thermal pro-
tection in accordance with PN-EN 12828+A1:2014-05.
• Dry operation of the heater and circulation pump is not allowed.
• Do not block the trigger of the safety valve. ON THE SECTION FROM THE SAFETY VALVE TO THE
HEAT PUMP, DO NOT INSTALL BALL VALVES, CHECK VALVES, FILTERS OR OTHER SHUT-OFF
DEVICES!
• When using the device for installations operating in cooling mode, vapor-proof hydraulic compo-
nents should be additionally insulated to reduce the effect of condensation.
4. Technical data and components
Diverter valve DN25
Electric heater 3 x 2 kW (level adjustable)
Circulation pump IBO AMG 25-60
Anti-freeze kit SARG1
Magnetic filter 11000G magnet, 500μm mesh
Safety valve 3 bar
Size of hydraulic connections GW 1”
Dimensions H x W x D. 530 mm x 650 mm x 295 mm
Mass 35 kg
Noise < 35 dB
Recommended electrical supply min. 3 x 10A, 230V AC, 50Hz
Recommended power cord 5 x 2,5 mm²
Recommended cable for sensor with SARG1 2 x 1 mm² shielded

Installation and operating instructions for HYDROBOX KENSOL KTH1 5/11
FIG. 2. COMPONENTS AND DESCRIPTION OF HYDRAULIC CONNECTIONS
ELECTRIC SOCKETS SAFETY VALVE CH/DHW VALVE FLOW THROUGH HEATER
PC CONTROLLER
JUNCTION BOX ELECTRICAL MODULE
DHW TANK
CH BUFFER
HEAT PUMP INLET
HEAT PUMP OUTLET
DHW/CH RETURN
PRESSURE GAUGE
AIR VENT
CIRCULATION PUMP
HYDRO MODULE SARG1
MAGNETIC FILTER
5. Transportation and storage
• Store the device in a dry and dust-free place.
• Do not store the device below 0°C and above 40°C.
• It is not recommended to transport the device unpacked from the supplied packaging. Moving the
device requires at least two people or the use of a transport cart.
• When lifting the device, be careful against accidentally opening the door. Do not lift by grasping
the connector pipes.
6. Wall installation and service distances
Installation of the device should be carried out on the wall or a structure that allows vertical hanging.
Observe the minimum distances from obstacles according to Figure 3. Suspend the device by first
fastening the two top M8 screws according to Figure 4. For installation, you can use the supplied set
of screws and screw anchors or use others adapted to the condition of the wall/ or structure. The
installer selects the appropriate anchoring elements. Then further fix the device using the lower
installation holes.

Installation and operating instructions for HYDROBOX KENSOL KTH1 6/11
FIG. 3. MINIMUM DISTANCES FROM OBSTACLES
FIG. 4. INSTALLATION HOLES
7. Hydraulic connections
All hydraulic connections should be made using piping and fittings of the correct diameters. Examples
of recommended diameters for the most popular systems are shown in Table 2.

Installation and operating instructions for HYDROBOX KENSOL KTH1 7/11
Pump model Required flow
[M3/H] Pp-R-Gf Press Steel Copper Multilayer Pipe
KTM 6 1,4 Ø40x6,4 Ø 28x1,5 Ø 28x1 Ø32x3
KTM 10 2,2 Ø50x8,3 Ø 35x1,5 Ø 35x1 Ø40x3,5
KTM 14 3,1 Ø50x8,3 Ø 35x1,5 Ø 35x1 Ø40x3,5
The device should be connected to the installation according to the purpose of the connector pipes as
described in Figure 5.
FIG. 5. HYDRAULIC CONNECTIONS
DHW TANK
CH BUFFER
DHW/CH RETURN
HEAT PUMP INLET
HEAT PUMP OUTLET
REMEMBER TO INSTALL A SAFETY VALVE, AN EXPANSION VESSEL AND A PROPER SELECTION IN
ACCORDANCE WITH PN-EN 12828:2014 OR LATER.
8. Electrical connections
The basic electrical connections for the HYDROBOX installation include:
• Power supply to the heater (Figure 6) - plug the power wires into the ZUG rail bonds and into the
• N and PE rails.
• Installation of temperature sensors of the SARG1 system (Figure 7) - extend the wires of sensors
T1 (outdoor temperature IN1) and T2 (water circulation temperature IN2),
• THE POWER SUPPLY OF THE OUTDOOR UNIT MUST BE DONE SEPARATELY ACCORDING TO THE
INSTALLATION INSTRUCTIONS OF THE HEAT PUMP!
• REFER TO THE CONTROLLER/HEAT PUMP MANUAL FOR HOW TO CONNECT THE OTHER SENSORS
AND OTHER DEVICES!
Cable list:
Recommended power cord 5 x 2,5 mm²
Recommended cable for sensor with SARG1 2 x 1 mm² vvvv

Installation and operating instructions for HYDROBOX KENSOL KTH1 8/11
FIG. 6. CONNECTIONS IN THE ELECTRICAL BOX
NPE
POWER L1
POWER L2 POWER L3
FIG. 7. SARG1 SYSTEM SENSOR SOCKET LOCATION
9. Magnetic filter operation
The circulation is protected by a magnetic filter. It is recommended to clean it for the first time after
about a month of operation of the installation, and then a minimum of once a year.
STEP-BY-STEP ACTIVITIES:
1. Close the shut-off valve (1),
2. Empty the filter chamber with the drain valve (4),
3. Unscrew the filter chamber (3),
4. Remove and clean cartridge and magnetic element under running water the mesh (2),
5. Remove and clean cartridge and magnetic element under running water the mesh (2),
6. Carefully screw the filter chamber, paying attention to the correct position of the gasket,
7. Unscrew the ball valve (1).

Installation and operating instructions for HYDROBOX KENSOL KTH1 9/11
FIG. 8. MAGNETIC FILTER
10. Operation of the circulating pump
If a pump malfunction occurs, verify the malfunction and remove the cause according to Figure 9.
FIG. 9. CIRCULATION PUMP ERROR CODES
ERROR CODE
Shaft blockage
Voltage too high or too low
No phase
Engine overload
The pump shaft is blocked
Mains voltage is too low
or too high
No phase
Engine overload
DISPLAY CAUSE LÖSUNG
Dismantle the motor ho-
using and then check
whether the pump impeller
rotates without resistance,
if there is resistance, the
pump shaft should be di-
smantled and then cleaned
from the accumulated de-
posits.
Check the line voltage, if
there are deviations, con-
tact an electrician.
Check the electrical
network
Replace the pump
11. Launching and operating of the SARG1
Place the probe of the outdoor temperature sensor T1 outside, away from heat sources and in the
shade. Place the probe of the heating water temperature sensor T2 as close as possible to the heat
pump on the outlet pipeline, directly on the pipe, under the insulation layer or in a suitable capillary.
In the case of pipes made of poorly conductive material, such as PP-R, it is advisable to find another
location for the sensor, such as on a metal made fitting, and insulate effectively. If necessary, the
probe cable can be extended.

Installation and operating instructions for HYDROBOX KENSOL KTH1 10/11
FIG. 10. INSTALLATION OF CIRCULATION SENSOR
Installation of a circulating water temperature sensor:
1 - pipe, 2 - clamp, 3 - thermal insulation (insulation
lagging), 4 - temperature sensor
It is imperative to make sure that the T1 and T2 sensors are correctly identified. Incorrect connection
of sensors may result in malfunction of the system and lack of antifreeze protection of the heat pump!
If there are cyclic beeps, first verify the correct plugging in of the sensor wires and the circulating
pump, as well as the connections when extending the wires if necessary. After repair, the error si-
gnaling subsides with a time delay (except for an error related to battery damage - in which case the
error must be reset).
If you need to mute the acoustic signal (e.g., until the arrival of a technician), it is possible to disable
the buzzer by removing jumper #3 on connector SW1.
Error reset is possible by removing jumper #2 on SW1 connector for 30 seconds.
FIG. 11. INTERIOR OF SARG1 MODULE
12. Cleaning and maintenance
Basic maintenance activities include:
• Washing the housing with a damp cloth with a possible mild detergent,
• Vacuuming the inside of the case,
• Cleaning the magnetic filter (see „Magnetic filter operation”), Checking the condition of the
electrical cables,

Installation and operating instructions for HYDROBOX KENSOL KTH1 11/11
• Checking the condition of hydraulic connections,
• Checking the operation of the anti-freeze system.
13. Disposal
Caring for the environment is of paramount importance to us. Awareness that we manufacture de-
vices that contain electronics, batteries and many other complex components, obliges us to dispose
of used components and devices in a nature-safe manner. The crossed-out garbage symbol on the
product indicates that the product must not be disposed of in regular waste containers. By segre-
gating waste for recycling, we help protect the environment. It is the user’s responsibility to take
used equipment to a designated collection point for recycling of waste generated from electrical and
electronic equipment.

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