MASTERTHERM BoxAir User manual

HEAT PUMPS
tiché
HEAT PUMPS
INSTALLATION AND
OPERATING MANUAL
BoxAir
BoxAir Inverter
EasyMaster
EasyMaster IndoorSplit
AirMaster aku
AirMaster mini
AquaMaster
AquaMaster Inverter
AquaMaster Inverter Combi
DirectMaster
Catalog: AM, AQ, EM, BA
Documentation: IOM
Edition: 28/07/2014
Czech
Product

AM, EM, AQ, BA, ASW - IOM
page: 2/64 Ing.Jiří Jiránek
LIST OF CONTENTS:
1Installation and location of the unit....................................................................................................5
1.1 Unit delivery ..............................................................................................................................5
1.2 Handling instructions.................................................................................................................5
1.3 Location of the indoor unit.........................................................................................................5
1.3.1 Working environment and clearances................................................................................5
1.3.2 Mechanical installation ......................................................................................................9
1.3.3 Minimum Inner Volume of the Machinery Room ................................................................9
1.4 Positioning of the Outdoor Unit ...............................................................................................10
1.4.1 Positioning, with Regard to Air Flow and the Condensate Drain ......................................10
1.4.2 Positioning, with regard to noise......................................................................................10
1.4.3 Mechanical installation ....................................................................................................15
1.4.4 Mechanical installation, BoxAir units................................................................................17
2Piping Connection of Indoor and Outdoor Units – AM, EM..............................................................18
2.1 Danger....................................................................................................................................18
2.2 Piping......................................................................................................................................18
2.2.1 Mounting the Piping.........................................................................................................19
2.2.2 Horizontal Parts of the Vapour line ..................................................................................19
2.2.3 Vertical Parts of the Vapour line ......................................................................................19
2.2.4 Liquid line........................................................................................................................20
2.3 Welding...................................................................................................................................20
2.4 Leak Test................................................................................................................................20
2.5 Vacuuming..............................................................................................................................20
2.5.1 Units MINI with In-built Liquid Receiver ...........................................................................21
2.6 Circuit Connection...................................................................................................................21
2.6.1 Opening the ROTALOCK valve .......................................................................................21
2.6.2 Covers and Caps of the Ball Valves and the ROTALOCK Valve .....................................21
2.7 Thermal Insulation ..................................................................................................................21
3Earth Exchanger for Direct Evaporating– AQxxD............................................................................22
3.1 Principle of Operation..............................................................................................................22
3.2 Collector Piping.......................................................................................................................22
3.2.1 Distributor and Collector..................................................................................................22
3.2.2 Distributor and Collector for AQ9Z1D ..............................................................................23
3.2.3 Liquid and Vapor Lines....................................................................................................24
3.2.4 Ground Loop Installation .................................................................................................24
3.2.5 Ground Loop and Heat Pump Interconnection.................................................................25
3.3 Brazing....................................................................................................................................25
3.4 Leak Test................................................................................................................................25
3.5 Vacuuming..............................................................................................................................25
3.6 Circuit Connection...................................................................................................................25
3.7 Thermal Insulation ..................................................................................................................25
4Ground Loop for AQ units ...............................................................................................................26
4.1 System Description .................................................................................................................26
4.2 Horizontal Ground Loop ..........................................................................................................26
4.2.1 Standard Horizontal Loop................................................................................................26
4.2.2 SLINKY H Horizontal Loop ..............................................................................................28
4.2.3 SLINKY V Horizontal Loop ..............................................................................................28
4.2.4 Vertical Ground Loop ......................................................................................................29
4.3 Caution ...................................................................................................................................31
4.4 Piping......................................................................................................................................31
4.5 Manifolds ................................................................................................................................32
4.6 Manifolds Location ..................................................................................................................32
4.6.1 Manifolds in the Collection Shaft .....................................................................................32
4.6.2 Manifolds inside the Building ...........................................................................................32
4.7 Manifolds and Heat Pump Connection ....................................................................................33

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4.8 Hydraulic system schematic....................................................................................................33
4.9 Piping Connection !!! use 2 spanners !!! ..........................................................................34
4.10 Pressure and Leak Test ..........................................................................................................34
4.11 Heat Insulation........................................................................................................................34
4.12 Anti-Freeze Mixture.................................................................................................................35
4.13 Filling and Venting the Ground Loop .......................................................................................35
5Connestion to the Heating System..................................................................................................36
5.1 Heating System – WARNING..................................................................................................36
5.2 Water Quality -Hardness dH and pH value..............................................................................36
5.2.1 Corrosion Inhibitors .........................................................................................................36
5.2.2 Bacterial and mould protection ........................................................................................36
5.3 Connection of Heat Pumps “AKU” – AM..................................................................................37
5.4 Connection of AQ Heat Pumps ...............................................................................................38
5.4.1 AQ Single-circuit Heating System....................................................................................38
5.4.2 AQ Multi-circuit Heating System – Switchable Heating of DHW.......................................39
5.4.3 AQ Multi-circuit Heating System – DHW Heating Using Charge Pump............................40
5.4.4 AQxxIC (combi) units recommended connection.............................................................41
5.5 Connection of AM MINI, EM Heat Pumps ...............................................................................42
5.5.1 Heating System with Pump Circuits and Through-flow Pre-heating of DHW....................42
5.5.2 AM MINI, EM Single-circuit Heating System....................................................................43
5.5.3 AM MINI, EM Multi-circuit Heating System - Switchable Heating of DHW........................44
5.5.4 AM MINI / EM Multi-circuit Heating System - DHW Heating Using Charge Pump............45
5.6 BoxAir and BoxAir Inverter system connection........................................................................46
5.6.1 Single loop heating system..............................................................................................46
5.6.2 BoxAir and BoxAir Inverter multi-circuit system with DHW...............................................47
5.6.3 BoxAir / BoxAir Inverter multi-circuits, charging pump DHW............................................48
5.6.4 Heating system charge for BoxAir and BoxAir Inverter ....................................................48
5.6.5 Venting the system for BoxAir a BoxAir Inverter ..............................................................48
5.7 ASW units connection .............................................................................................................49
5.8 Heating Circuits.......................................................................................................................50
5.8.1 Manifolds.........................................................................................................................50
5.8.2 Pump heating circuits ......................................................................................................51
5.8.3 Mixing heating circuits .....................................................................................................51
5.9 Preparation of Domestic Hot Water (DHW) .............................................................................52
5.9.1 3 way valve tank in tank ..................................................................................................52
5.9.2 3 way valve with tank with heat exchanger (indirect, non-direct)......................................52
5.9.3 Charging pump for tank with heat exchanger ..................................................................53
5.9.4 Preheating in Accumulation Vessel of the Heating System and Electric Afterheating ......54
5.9.5 Safety / PT relief valve outlet...........................................................................................54
5.10 Piping Connection !!! use 2 spanners !!! ..........................................................................55
5.11 Pressure and Leak Test ..........................................................................................................55
5.12 Heat insulation ........................................................................................................................55
5.13 General Instructions................................................................................................................55
6Electric Power Connection..............................................................................................................56
6.1 Hlavní napájení.......................................................................................................................56
6.2 Tariff signal, remote on/off signal ............................................................................................57
6.3 AM/EM indoor and outdoor unit electrical interconnection.......................................................57
6.3.1 EM60Z/EM75Z , 1OEM26-45VK, 1OEM60-75VK additional connection..........................57
6.4 External components (pumps, valves) ....................................................................................58
7Control and measurement ..............................................................................................................58
7.1 Standard unit...........................................................................................................................58
7.2 Optional „Expansion Card“......................................................................................................58
7.3 Probes connection ..................................................................................................................58
7.4 Mixing valves servo.................................................................................................................59
7.5 Circulating pumps ...................................................................................................................59
7.6 pAD room terminals ................................................................................................................59

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8Commissioning ...............................................................................................................................60
8.1 Mechanical Installation Inspection...........................................................................................60
8.2 Piping Network Inspection.......................................................................................................60
8.3 Electrical wiring check.............................................................................................................60
8.4 Start-up and Filling of Start-up Protocol...................................................................................60
9Maintenance ...................................................................................................................................61
9.1 Introduction .............................................................................................................................61
9.2 Personnel Qualification ...........................................................................................................61
9.3 Quarterly Maintenance............................................................................................................61
9.4 Annual Maintenance ...............................................................................................................61
9.5 Warranty .................................................................................................................................62
10 Legislation ..................................................................................................................................62
11 Revision history ..........................................................................................................................62

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1 Installation and location of the unit
The equipment must be installed and commissioned by an authorized, specialized installation
company. The installation must comply with this installation manual and national regulations.
1.1 Unit delivery
Check the unit for possible damage or missing parts. Should you find any damage, or should
the delivery not be complete, immediately contact the supplier’s forwarder or the manufacturer
directly.
1.2 Handling instructions
Handle the unit in accordance with the presented drawings. Using other handling methods may
damage the unit.
1.3 Location of the indoor unit
1.3.1 Working environment and clearances
Indoor units are dedicated for indoor installation in dry, non explosive and non corrosive
environment at temperatures +5÷+30˚C without free public access. There must be a sufficient
clearance around the unit for the antifreeze, heating water, refrigerant and electric connections.
Minimal clearance for different unit please see on pictures below.
* Obligatory for units with passive cooling.
400mm recommended for standard units.
It is possible to fully integrate standard
units. Service is possible from the front
and top sides for the standard units.
Clearances: AirMaster AKU, AQxxIC

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Clearances: AquaMaster, EasyMaster, AirMaster MINI AquaMaster x.2, AirMaster x.2

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Spiro tube 400mm
+25mm PUR
inlet grille
PMR-400W
SONOFLEX 406mm
pipe
draining 40mm flexi outlet grille/ gravity valve
PMR-400W (PER-400W)
fan motor
access
panel
access panel
- electric
- fan propeller
Clearances and installation: 1OEM26-45VK (evaporator - indoor split)

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Spiro tube 400mm
+25mm PUR
inlet grille
PMR-400W
SONOFLEX 406mm
tube
fan
access
panel
electric
access panel
XPS 40mm
outlet grille / gravity valve
PMR-400W (PER-400W)
compressor access panel
Clearances and installation: ASW

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1.3.2 Mechanical installation
The inner unit of the Heat Pump should be located in a detached room – a machinery room.
In the case the room is next to protected areas (bedroom, children rooms etc.), the wall
between must be made as sound-proof, minimum sound reduction of 30dBA. It is also not
recommended to install fixtures of piping system or circulating pumps etc. on the dividing wall.
Make sure to always check the noise values of heat pumps in the catalogue sheets and verify
the installation area for acoustically protected areas.
Always check the load capacity compared with the unit weight. If necessary, build a concrete
base. Do not position the units on light structures as floor heating etc.
Do not position the Heat Pumps in higher floors of the building, we recommend installation in
the lowest floor – on solid ground. Installation in higher floors can cause transfer of vibrations to
the heated building.
The units have adjustable legs which allow for balancing of minor uneveness and inclination (up
to 20 mm) of the floor.
1.3.3 Minimum Inner Volume of the Machinery Room
Each area for installation has to be inspected with regard to the refrigerent charge of the Heat
Pump. Permitted limit is 0,3kg refrigerant/m3 of the room volume. This is important due to safety
in the case of refrigerant leakage. For approximate minimum room volumes for MasterTherm
heat pumps see table below:
Heat Pump - AQ17-30
AQ37-45
AQ60-90
AM, EM LM AQxxD
Refrigerant Charge kg 1.8 2.2 3.0 5.7 4.5 12
Min. Room Volume m3 6.0 7.3 10.0 19.0 15.0 40.0
In the case the room volume does not reach the values from the table, please see EN378. In
most cases the room must be ventilated and a special equipment operating guideline
established. Problems usually occur with DirectMaster units which have big volume of
refrigerant.

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Warning:
Please keep in mind that not respecting the minimum room volume can in the case of coolant
leakage result in injury or even death. Always respect actual national directives regarding
installation of cooling equipment (for EU EN378).
Underground unventilated rooms are extra hazardous because the coolant always stays near
the ground. Try to avoid such applications and use only as the last solution, which requires
special operating mode and forced ventilation of the space. In such cases we recommend
installing a remote terminal (PGD display) in a safe place.
1.4 Positioning of the Outdoor Unit
The air/water heat pumps are equipped also with an outer unit. These are the AirMaster and
EasyMaster types.The units are designed for outside installation. They must be equipped with
additional electric protection, more info in the “Electric installation” chapter.
1.4.1 Positioning, with Regard to Air Flow and the Condensate Drain
The units must be installed in an environment with free air flow, with the suctioning parts at least
300 mm from a building wall. Do not install the outer unit underground or in partly or completely
enclosed spaces, except in the case of the targeted use of waste heat. Under the unit must be
installed a condensate and melted water drain, with a sufficient height reserve for frosty periods,
when percolation is problematic.
1.4.2 Positioning, with regard to noise
When selecting the place of installation, you must observe the applicable limits for protected
rooms inside buildings and with regard to the environment. The usual acoustic pressure level
limit at the boundary of the property (land, building) is 50 dBA during the day (6:00 a.m. to 10:00
p.m.) and 40 dBA at night (10:00 p.m. to 6:00 a.m.). The noise levels of outdoor units are
specified in the catalogue sheets as the levels of Sound Power in dBA. There are various
methods of estimating the acoustic pressure level in a particular position, with regard to the
source of noise. In practice, the use of the ARI275-97 standard has proven to be suitable. It is a
practical evaluation that allows you to estimate the resulting noise level quite quickly. In making
the estimate, it is advisable to draw the situation on a plan. You can estimate the noise level as
follows:
Noise source position factor:
Free space without reflecting walls U=0
One reflecting wall:
d<3m, FU = +3dBA

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Two reflecting walls:
d<3m, FU=+6dBA
Between reflecting walls:
FU=+6dBA

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Barrier attenuation factor:
INSTALLATION ON A FLAT ROOF WITH DAMPENING WALL
EVALUATION POINT
EVALUATION POINT
BUILDING CORNER AS A NOISE BARRIER
EVALUATION POINT
EVALUATION POINT
BARRIER
NOISE SOURCE
L=L1+L2-D
L1+L2– Distance between the noise source and evaluation point around a barrier
D – Direct distance between the noise source and evaluation point
FB – Attenuation factor
L m 0.15 0.3 0.6 0.9 1.8 3.7
FB dBA -4 -7 -10 -12 -15 -17

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Evaluation point factor:
OPEN WINDOW/DOOR
OUTSIDE
NOISE SOURCE
CLOSED WINDOW/DOOR
Outside, FB = 0dBA
Open window/door, FB = -10dBA
Closed single window/door, FB = -17dBA
Closed double window/door, wall, FB = -23dBA
Distance factor:
Distance m 1.2
1.5
1.8
2.1
2.4
2.7
3
4.6
6.1
7.6
9.1
FL dBA -9.5
-11.5
-13
-14.5
-15.5
-16.5
-17.5
-21
-23.5
-25.5
-27
Distance m 12.2
15.2
18.3
21.3
24.4
27.4
30.5
38.1
45.7
53.3
61
FL dBA -29.5
-31
-33
-34.5
-35.5
-36.5
-37.5
-39.5
-41
-42.5
-43.5
Determining the acoustic noise level at the evaluation point:
The resulting noise level represents the plain sum of the acoustic output level and all the
factors.
Sound Power Level dBA
Noise source position factor dBA dBA
Barrier attenuation factor dBA dBA
Evaluation point factor dBA dBA
Distance factor dBA dBA
Sound Pressure Level at evaluation point dBA
This approach leads to an “ESTIMATE” of the resulting noise level. This estimate assumes the
usual installation conditions. The actual noise level can only be established with a measurement
after the installation, in every particular case. If this estimate approximates the noise level limit,
you should consider the necessity of additional measures.
MASTER THERM CZ IS NOT LIABLE FOR ANY DIFFERENCES BETWEEN THE RESULTS
OBTAINED WITH THE USE OF THIS METHOD AND THE INSTALLED REALITY

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Layout drawing for the noise evaluation:

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1.4.3 Mechanical installation
There are 3 different variants of the outer units. A vertical one with a bracket on the wall, a
vertical one on legs, and a horizontal one on legs. For types with legs a special base must be
built.
Vertical with a bracket:
This variant is supplied directly with the bracket. The
bracket is placed on the wall. For attaching use chemical
anchors and stainless screw rod only, or use stainless
screw rod and screw it through the wall. The bracket has 4
holes of 10mm DIA for attachment to the wall. The chemical
anchors and stainless screw rods are not a part of the
supply.
Vertical and horizontal on legs:
The outer unit is supplied with 4 pcs of stands for
positioning on a suitable base. Recommended base is on the
following drawing.
SERVICE PANEL
PLASTIC PÍPE 150mm
HEIGHT DEPENDS ON SNOW
CONCRETE
GROUND
DRAIN(GRAVEL)
SERVICE PANEL

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EM60Z / EM75Z outdoor unit:
4 legs are delivered with the outdoor unit for location on a suitable basement. Recommended
basement is on picture below.
wall
plastic tube
concrete 100-150mm
like casing
terrain draining
acc. snow
base

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1.4.4 Mechanical installation, BoxAir units
BoxAir packaged air source heat pumps are dedicated for outdoor installation. Operating range
is -20÷+30˚C. Because of outdoor installation, power supply requires additional protection, like
RCD circuit breaker or additional earth wiring. Minimum free area around unit is neccessary for
sufficient air flow, heating water piping and electrical connection. Minimum clearances are
shown on the picture below.
Clearances: BoxAir
We recommend preparing of following basement, before unit installation. Height of the
basement should be corresponding to the ussual snow height during winter.
PLASTIC PIPE
150mm
LIKE
BOARDING
ZTRACENÉ BEDNĚNÍ
SNOW HEIGHT
TERRAIN
CONCRETE
DRAINING

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2 Piping Connection of Indoor and Outdoor Units – AM, EM
After mechanical installation of split heat pumps AM and EM, installation of piping connection
between the indoor and outdoor unit must be performed..
2.1 Danger
The inner units of heat pumps are filled with coolant r407c or r410a by the manufacturer. The
outer units are pressured by nitrogen to 1,0MPa. Please follow the following safety guidelines:
•Always use safety googles and protection gloves during manipulation
•In the case of servicing and repairs make sure the equipment has been disconnected
from the power source
•Pay attention to the working areas of fans when the equipment is connected to the power
source
•Refrigerant causes frostbites
•The coolant becomes toxic after burning, be careful during manipulation with the flame of
the welding unit
2.2 Piping
For installation deoxidized, plugged Cu piping with certification for cooling equipment must be
used. The piping must be certified in accordance with EN12735-1. We recommend using pre-
insulated piping. The connection comprises always of the steam piping and liquid piping.
Never use piping dedicated for water.
Piping dimensions of different types of heat pumps see table below:
typ TČD vapour line
[mm] d liquid line [mm] max. length [m] max. height [m]
AM3015 18x1 (3/4“) 12x1 (1/2“) 15 10
AM3021 18x1 (3/4“) 12x1 (1/2“) 15 10
AM3030 22x1(7/8“) 12x1 (1/2“) 15 10
AM3038 22x1(7/8“) 12x1 (1/2“) 15 10
AM3045 22x1(7/8“) 12x1 (1/2“) 15 10
AM3060.2 2x 22x1(7/8“) 2x 12x1 (1/2“) 15 10
AM3076.2 2x 22x1(7/8“) 2x 12x1 (1/2“) 15 10
AM3090.2 2x 22x1(7/8“) 2x 12x1 (1/2“) 15 10
EM26Z 22x1(7/8“) 12x1 (1/2“) 15 10
EM30Z 22x1(7/8“) 12x1 (1/2“) 15 10
EM37Z 22x1(7/8“) 12x1 (1/2“) 15 10
EM45Z 22x1(7/8“) 12x1 (1/2“) 15 10
EM60Z 28x1 15x1 (16x1) 20 10
EM75Z 28x1 15x1(16x1) 15 15
Also follow the following instructions:
•Always use only the Cu roller-type pipe cutter for cutting the piping, never use a saw
•Cut the piping immediately prior to connecting operation
•Remove the plugs no sooner than immediately prior to connecting operation
•Never leave the piping and components open to the atmosphere, not even for a short
time
•During bending pay attention that the piping is not deformed (narrowed), always use
special equipment and tools
•Never bend the piping by hand, over the knee etc.

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2.2.1 Mounting the Piping
The piping must be mounted to a firm base (wall etc.) using special brackets. Recommended
pitch between brackets is 1 to 2m to prevent vibrations of the piping during operation. The
piping must not be in contact with the base. The holes through walls and bases must be
insulated and filled with PU foam so that the piping is not in contact with the wall, concrete etc.
Holes under the ground must be waterproofed to prevent the humidity and water from
penetrating the building.
2.2.2 Horizontal Parts of the Vapour line
The horizontal parts of the vapour piping must be descended by 1:100 toward the coolant flow
in the heating mode (always in direction from the outer toward the inner unit).
2.2.3 Vertical Parts of the Vapour line
In the case the piping is vertical and the coolant ascends (typical for cases where the outer unit
is lower than the inner one), the piping must be equipped with oil traps. For typical installation
see picture below.
max. 250mm
min. 80mm
max. 10m
max. 3m
< 1:100

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2.2.4 Liquid line
There are no special requirements for liquid piping.
2.3 Welding
Only hard oxygen-propane or oxygen-acetylene flame welding can be employed. Welding
material to be used is solder with minimum content of silver 5% (L-Ag5P). The welding is
performed with inner protection atmosphere of nitrogen (N2). No chemicals are allowed to be
used for welding. After connecting the piping and prior to the welding, the piping is filled with
nitrogen using pressureless method. The service valve of the outer unit must remain open to the
atmosphere during welding to prevent pressurization due to its warming. Sensitive elements of
the cooling circuit, especially the ball valves of the inner unit, must be cooled during welding
using a wet cloth covering the body of the valve. Proceed with care, no moisture must get into
the cooling circuit under any circumstances.
Instructions for ball valve welding Removing the core of the
service valve of the outer unit
Inspect visually after welding and cooling of joints.
2.4 Leak Test
After welding put the core back to the service valve of the outer unit and pressurize it using
nitrogen to 10 bars (1,0MPa). Inspect tightness of joints using detection liquid. We recommend
attaching the air-pressure gauge to the service valve and after 24 hours check the pressure
which must be the same as after the pressurizing. In the case there is a pressure loss the
tightness of joints must be rechecked.
2.5 Vacuuming
After successful leak test the nitrogen must be emptied from the circuit and the system must be
vacuumed. We recommend using the 2-level vacuum pump. After the pressure is stabilized,
close the service valves. After 15 minutes check if the pressure did not increase again and
vacuum again for 30 minutes.