MHG Heating Thermistar L User manual

ThermiStar L .. SP 01/03/10

Index
1Safety............................................................................................................................................................4
1.1 General.......................................................................................................................................................................... 4
1.2 Intended use.................................................................................................................................................................. 4
1.3 Explanation of symbols.................................................................................................................................................. 5
1.4 Personnel requirements................................................................................................................................................. 6
1.5 Special dangers ............................................................................................................................................................. 6
2Standards and Regulations........................................................................................................................9
2.1 Standards and Regulations............................................................................................................................................ 9
3Transport, Packaging, Storage ................................................................................................................12
3.1 Safety notes for transport............................................................................................................................................. 12
3.2 Inspection of the delivery ............................................................................................................................................. 12
3.3 Notes on storage ......................................................................................................................................................... 13
3.4 Handling of packaging material.................................................................................................................................... 13
3.5 Disposal of packaging.................................................................................................................................................. 13
3.6 Disposal of the device.................................................................................................................................................. 13
4General .......................................................................................................................................................14
4.1 Product Description ..................................................................................................................................................... 14
4.2 Scope of delivery ......................................................................................................................................................... 14
4.3 Accessories ................................................................................................................................................................. 14
5Technical Data ...........................................................................................................................................16
5.1 Dimensions and connection ratings ............................................................................................................................. 16
5.2 Type plate.................................................................................................................................................................... 18
5.3 Technical data ............................................................................................................................................................. 20
5.4 Electrical data .............................................................................................................................................................. 22
6Assembly....................................................................................................................................................32
6.1 Safety during assembly................................................................................................................................................ 32
6.2 Requirements on the erection location of the heat pump............................................................................................. 32
6.3 Assembly tools............................................................................................................................................................. 34
6.4 Assembly information .................................................................................................................................................. 34
6.5 Hydraulic connection ................................................................................................................................................... 45
6.6 Electrical connection.................................................................................................................................................... 46

Index
7Operation startup......................................................................................................................................57
7.1 Safety during startup ................................................................................................................................................... 57
7.2 Inspection before startup ............................................................................................................................................. 57
7.3 Startup......................................................................................................................................................................... 58
7.4 Setting the controller.................................................................................................................................................... 60
7.5 Parameterization ......................................................................................................................................................... 61
7.6 Startup protocol ........................................................................................................................................................... 61
8Maintenance...............................................................................................................................................62
8.1 Maintenance................................................................................................................................................................ 62
8.2 Components relevant to safety.................................................................................................................................... 63
8.3 Work activities to be performed ................................................................................................................................... 64
8.4 Spare part drawing and legend.................................................................................................................................... 68
9Troubleshooting........................................................................................................................................69
9.1 Troubleshooting........................................................................................................................................................... 69
10 Warranty.....................................................................................................................................................72
10.1 Warranty...................................................................................................................................................................... 72
10.2 Manufacturer Certificate / EU Design Conformity Declaration..................................................................................... 75
10.3 Proof of Service ........................................................................................................................................................... 77
11 Hydraulic diagrams...................................................................................................................................82
11.1 Hydraulic diagrams...................................................................................................................................................... 82
12 Index...........................................................................................................................................................91

1. Safety ThermiStar L .. SP 01/03/10
4
1 Safety
1.1 General
The assembly, startup and maintenance instructions
- are addressed to technicians of professional heating companies.
- Contains important information for safe handling of the device.
Compliance with all specified safety information and handling
instructions is the prerequisite for safe working.
- Must be following by all persons working on the device.
The information contained in this document is accurate and up to
date to the best of our knowledge at the time of writing. The informa-
tion provided serves as a reference for the safe operation of the
product named in the Assembly, Startup, and Maintenance Instruc-
tions. The information provided is not transferable to any other
products.
1.2 Intended use
The devices are intended as heat sources for closed warm water
central heating systems and for central warm water preparation. Any
other or additional use is considered not in compliance with the
intended use. MHG Heiztechnik does not assume any liability for
consequential damages. The risk will be borne by the owner of the
equipment alone.
MHG devices have been built in accordance with the applicable
standards and guidelines as well as the valid safety rules. However,
personal injuries or property damage may occur if not used properly.
To avoid hazards, the device may only be used:
- For its intended purpose
- In technical flawless condition
- In following the instructions for assembly, startup and
maintenance as well as the operating instructions
- In compliance with the necessary maintenance activities
- Malfunctions that may compromise safety must be remedied
immediately
CAUTION!
Device damages through weather impacts!
Electrical hazard through water and corrosion of the
enclosure and the components.
Therefore:
- The device may not be operated outdoors. It is
suitable only for operation in rooms.

ThermiStar L .. SP 01/03/10 1. Safety
5
1.3 Explanation of symbols
This sections provides an overview of all important safety aspects
for optimal personal protection as well as for safe and troublefree
operation.
The handling instructions and safety notes specified in these
instructions must be followed to prevent accidents, personal injuries
and property damages.
DANGER!
... alerts to life-threatening situations through
electrical current.
WARNING!
… alerts to a possibly dangerous situation which may
cause death or serious injuries if not avoided.
CAUTION!
... alerts to a possibly dangerous situation which may
cause minor or light injuries if not avoided.
CAUTION!
… alerts to a possibly dangerous situation which can
lead to property damage if not avoided.
NOTE!
... highlights useful hints and recommendation as
well as information on efficient and troublefree
operation.

1. Safety ThermiStar L .. SP 01/03/10
6
1.4 Personnel requirements
WARNING!
Danger to life if not sufficiently qualified!
Improper handling leads to considerable personal
injuries and property damages.
Therefore:
- Assembly, startup and maintenance work, repairs
or modifications of the set fuel amounts may only
be done by a heating and/or air conditioning pro-
fessional.
- Consult professionals in case of doubt.
The following qualifications for various task areas are listed in the
instructions:
- Equipment owner
must be informed about the handling of the equipment; in
particular, he must receive the operating instructions for the
device. The necessity of regular service of the devices must be
pointed out.
- Technical personnel
is able because of their technical training, know-how and
experience as well as knowledge of the relevant regulations to
carry out the work activities assigned to him and to detect possible
dangers on his own.
- Cooling systems technician
must provide certification in accordance with Article 5 of the
Commission Regulation (EC) No 303/2008 establishing, pursuant
to Regulation (EC) No 842/2006 of the European Parliament and
of the Council.
1.5 Special dangers
In the following section the remaining risks are specified which result
based on the risk analysis.
The safety information listed here and the warning instructions in the
subsequent chapters of this manual must be followed to reduce
health risks and to avoid dangerous situations.

ThermiStar L .. SP 01/03/10 1. Safety
7
Electrical current DANGER!
Danger of life through electric current!
Touching live parts presents an immediate danger to
life. Damages to the insulation or individual
components can present a danger to life.
Therefore:
- In case of damaged insulation, immediately cut off
the power supply and initiate the repair.
- Work on electrical systems may only be performed
by professional electricians.
- Switch off the device when working on the terminal
strip.
Hot surfaces CAUTION!
Risk of burning through hot surfaces!
Contact with hot components causes burns
Therefore:
- Always wear protective gloves when working near
hot components.
- Make sure that all components have cooled down
to the ambient temperature before commencing any
work.
- Do not touch the compressor and hot gas line
during operation.
Refrigerant The safety datasheet concerning refrigerant R 410A is available for
download at www.mhg.de\Download\Sicherheitsdatenblätter.
NOTE!
In case of emergencies, ring the telephone number
below:
[phone] [CareChem 24] (Europe)
WARNING!
Danger of life through lack of oxygen!
Vapors of the refrigerant R 410A are heavier than air
and may cause suffocation by displacing oxygen.
Therefore:
- Exercise special caution when entering lower lying
closed rooms.
- Work on the refrigerant circulation may only be
performed by persons certified according to
Commission Regulation (EC) No 303/2008.
- Do not smoke when handling refrigerant as its
products of decomposition in the lit cigarette act as
an irritant and a poison!

1. Safety ThermiStar L .. SP 01/03/10
8
CAUTION!
Risk of injury due to refrigerant!
Refrigerant is corrosive and causes cold burns upon
contact with skin.
Therefore:
- Wear chemical-resistant protective gloves when
handling refrigerant at any time.
- Wear protective glasses to avoid contact with eyes.
Modifications on the device WARNING!
Risk of life through electrical shock as well as
destruction of the device from water leakage!
The operating permit becomes void when making
modifications to the device!
Therefore:
Do not make any modifications to the following
items:
- On the heating unit
- On the lines for water and electrical power
- On the safety valve and the drain line for the
heating water
- On structural elements which might impact the
operational safety of the device.
- Opening and/or repairing original parts (e.g. drive,
controller)
Heating water WARNING!
Risk of poisoning through heating water!
The use of heating water leads to poisoning.
Therefore:
- Never use heating water as drinking water because
it is contaminated from dissolved deposits.
Legionella WARNING!
Risk to life through legionella!
Unfavorable conditions may cause the occurrence of
legionella and other germs in the service water
reservoirs and/or pipes in higher concentrations.
Therefore:
- Never use the tapped warm water as drinking water.
- The service water temperature must periodically be
heated over 65°C.

ThermiStar L .. SP 01/03/10 2. Standards and Regulations
9
2 Standards and Regulatio ns
2.1 Standards and Regulations
The following standards and regulations must be observed with the
installation and operation of the heating system.
Standards
Standards Publication
date Title
DIN EN
12828 06.2003
Heating systems in buildings, safety
equipment of warm water heating
systems
DIN EN
60335, Part
1
2004 Safety of electrical appliances for
household and similar purposes
DIN EN
12056 01.2001 Drainage systems
DIN 1986 --- Materials drainage system /
Property drainage
DIN 1988 12.1988 Technical rules for drinking water
installations (TRWI)
DIN 4726 01.2001 Plastic pipes for warm water floor
heating
DIN 4753 03.1988
Water heaters and water heating
systems for drinking and service
water
DIN 18380 10.2006 Heating systems and central water
heating systems (VOB)
DIN EN
12502 01.2001 Corrosion protection of metallic
materials

2. Standards and Regulations ThermiStar L .. SP 01/03/10
10
Stipulations The erection and operation of the heating system requires
compliance with the technical building supervision rules as well as
other legal stipulations of the individual countries.
Stipulations Publication
date Title
EC
Regulation
No 842/2006
07.2006
F-Gas Regulation
Regulation on all chlorine-free
fluorinated refrigerants (CFC and
HFC, i.e. R134A, R404A, R407C,
R410A, R507)
ATV ---
Work sheet ATV-A 115
"Drainage of non-domestic waste
water into a public waste water
systems"
TA Noise 03.2000
Sixth general administrative
stipulation on the federal immisions
protection act (technical
instructions on noise protection)
TRGS 521
Part 4 --- Technical rules for hazardous substances
VDI 2035 12.2006
Guidelines for the prevention of
damages in warm water heating
systems - calcification in drinking
water heating systems and warm
water heating systems
VDE ---
Stipulations and special
requirements of the public utility
companies
Additional Standards / Regulations
for Austria In Austria, the local building regulations as well as the ÖVGW
regulations must be observed with the installation.
Standards Publication
date Title
ÖNORM
EN 14336 2004
Heating systems in buildings -
Planning of warm water planning
systems
ÖNORM
H 5195-1 05.2006
Prevention of damages through
corrosion and calcification in closed
warm water heating systems with
operating temperatures up to 100°C
ÖNORM
M 7550 02.2002
Boilers with operation temperatures
up to 100°C - Terms, requirements,
tests, designations

ThermiStar L .. SP 01/03/10 2. Standards and Regulations
11
Additional Standards / Regulations
for Switzerland Assembly, startup and maintenance may only be performed by
certified installation companies. Work on electrical system
components may only be performed by a licensed
electrician.
The legal standards and stipulations on electrical installations must
be followed, especially:
Directives / Guidelines by
LRV Swiss air purification directive
VKF Association of cantonal fire insurances
SVGW Swiss association of gas and water subjects
SEV Swiss association for electrical, energy and information
technology
PROCAL Supplier association for heating materials
PROCAL Technical Bulletins
Corrosion damages through oxygen in heating water - oxygen
corrosion
Corrosion through halogenated hydrocarbons
BUWAL Technical Bulletins
Approval of systems with refrigerants stable in air

3. Transport, Packaging, Storage ThermiStar L .. SP 01/03/10
12
3 Transport, Packaging, Stor age
3.1 Safety notes for transport
CAUTION!
Damage through improper transport!
Significant property damage may be incurred by
improper transport.
Therefore:
- Be careful when unloading packaging items upon
delivery as well as during in-plant transport and
obey the symbols on the packaging.
- Do not expose the device to hard shocks.
- Use only the intended slinging points.
- Remove the packaging only shortly before
assembly.
CAUTION!
Risk of injury through improper handling!
Improper handling can cause injuries like contusions,
cuts and bruises.
Therefore:
- Personal protective equipment: Wear safety boots
and protective gloves during handling and trans-
port.
NOTE!
The heat pump may only be transported standing and
never horizontally.
CAUTION!
Device damage through improper handling!
The copper pipes can be easily bent!
Therefore:
- Do not hold on to the insulated pipe (hot gas line)!
-Apply force only to the base plate or the frame!
3.2 Inspection of the delivery
Inspect the delivery immediately upon receipt for completeness and
transport damages.
Proceed as follows when noting eternally visible transport damages:
- Do not accept the delivery or only conditionally.
- Note the extent of the damage on the transport documents or the
delivery bill of the freight forwarder.
- Initiate complaint.
NOTE!
Report each defect as soon as it is detected. Damage
compensation claims can only be asserted within the
respective claim periods.

ThermiStar L .. SP 01/03/10 3. Transport, Packaging, Storage
13
3.3 Notes on storage
The shaft of the boiler pump may seize during extended storage.
This is not a defect. Please see the chapter "Pump control" on
page Error! Bookmark not defined..
Moisture condensation, icing and water impact are not permitted.
Temperature range: -10°C … +50°C
Humidity: < 95% r.F.
3.4 Handling of packaging
material WARNING!
Risk of suffocation from plastic foils!
Plastic foils and bags, etc. can become a dangerous
toy for children.
Therefore:
- Do not allow packaging material to lie carelessly
about.
- Packaging material must never get into the hands
of children!
3.5 Disposal of packaging
Recycling: The entire packaging material (carton material, routing
sheets, plastic foils and pouches) are completely recyclable.
3.6 Disposal of the device
NOTES FOR DISPOSAL!
- The device contains electrical and electronic
components.
- Please do not dispose of device or replaced parts in
household waste. Proper disposal of hazardous
waste is required.
- End-of-life devices must be taken to the respective
public collection point for proper disposal.
- Disposal must be in accordance with current local
laws and regulations.
NOTE!
In accordance with EC Regulation No 842/2006, op-
erators of stationary facilities are responsible for put-
ting in place arrangements for the proper recovery of
fluorinated greenhouse gases by certified personnel
to ensure their recycling, reclamation or destruction.

4. General ThermiStar L .. SP 01/03/10
14
4 General
4.1 Product Description
The ThermiStar Air is available in a large variety of designs and
accessories. The standard sizes are available for a capacity range
from 5.2-40.9 kW.
Inner part:
- Air/water heat pump in compact design with integrated
weather/climate-controlled heat pump controller
- Size width x depth x height
•Variant 1: 690x600x900
•Variant 2: 1.030x730x900
- Quiet running through sound-decoupled cooling unit, compressor
and sound-insulated housing
- Outside sensor, and sensors of the flow and return heat pumps,
heat source input, evaporation, refrigerant liquid and warm water
sensor included in scope of delivery
- Refrigerant R 407 C for heating water temperatures up to 55°C -
at outside temperatures up to -7°C
- Min. outside temperature -15°C
Outer part:
- Air evaporator with enlarged lamella spacing and whisper
ventilator with electric motor
- Weather-resistant design with snow protection roof
- Color: Light-grey (RAL 7035)
- Condensate drainage on gravel bed
4.2 Scope of delivery
- Heat pump with inner and outer part incl. heat pump controller
RVS 61.843 and control unit AVS 37.294
- Heating circulation pump (up to L 28)
- Connector for additional electric heater 6.0 kW
- From ThermiStar L 10 SP with soft-start control
- Module for thawing the split evaporator via hot-gas bypass con-
trols
4.3 Accessories
Control unit QAA 75
94.88147-5019 Hard-wired control unit optional use as control unit, service unit or
room unit. Setting of all parameters in the RVS controller, power
reserve for clock times greater than 12 hours

ThermiStar L .. SP 01/03/10 4. General
15
Control unit QAA 78
94.88147-5021 Radio-controlled control unit optional use as control unit, service unit
or room unit. Setting of all parameters in the RVS controller, range
of radio connection approx. 30 m
Radio module AVS 13.399/201
94.88147-5022 Transmitter and receiver for external sensor QAC 34
Repeater AVS 14.390/101
94.88147-5017 Range extension for RVS 61.843 controller
The RF repeater is used for range extension. It is not an amplifier,
but a device for receiving and forwarding signals.
Contact temperature probe
QAD 36.101
94.19314-5015 NTC 10 kOhm
Service water sensor QAZ 36
94.19314-5013 (2 m)
94.19314-5012 (6 m) Service water sensor to record the warm water reservoir
temperature for Boiler Management Unit LMU and RVS with power
cable 2 x 0.5 mm², NTC 10 kOhm, 10000 Ohm at 25°C.
Collector sensor QAZ 36.481/101
94.19314-5018 (1,5 m) For RVS or LMU
Additional heater 6,0 kW
98.38400-6302 Additional electric heater 6.0 kW (3 x 2 kW, 400 V) incl. contactor
and connection cable set for controller RVS 61.843
Reservoir Heat pumps require special reservoirs. MHG carries all required
special high-capacity buffer and zone reservoirs in its program.

5. Technical Data ThermiStar L .. SP 01/03/10
16
Sk09-6200-121
Stand: 06.11.09
5 Technical Data
5.1 Dimensions and connection
ratings
Connections at rear wall of heat pump
Sk09-6200-023_a
Stand: 06.11.09
Fig. 1:Connections at rear wall of heat pump L05 to L15 Fig. 2:Connections at rear wall of heat pump L19 to L41

ThermiStar L .. SP 01/03/10 5. Technical Data
17
Erection measurements and dimensions, split evaporator for ThermiStar L .. SP
Fig. 3: Erection measurements and dimensions, split evaporator for ThermiStar L .. SP
Legend for Fig. 3:
Abbr. Meaning ThermiStar … SP
L 05 L 07
L 10 L 13 L 15 L 19 L 28 L 34 L 41
1Fluid line 10 12 15 18 22
2Suction gas line 15 22 28 35 42
3Hot-gas thawing 10 12 15 18
A Weather guard in mm 1230 2155 3080
B Floor mount in mm 955 1880 2805
C Min. distance to walls and obstacles > 200 mm
D Min. distance to walls and obstacles > 500 mm
EAL Electrical connection of fan (split evaporator) 3x0,75 mm²
supply line for 0-10 V signal 2x0,75 mm²
FA Foundation Take note of the following information!
KB Gravel bed at least 250 mm deep
KRS Refrigerant pipe connection
STR Direction of flow
ZAF Supply line for temperature sensor 2x2x0,75 mm²
(see also page 30 „Electrical data - control“)
NOTE!
Fig. 3 is a basic layout sketch only. It is not to be used instead of a professional layout designed
by professionals.
The foundation and the gravel bed must reach at least across a width of 400 mm.
The gravel bed must reach up to approx. 50 mm to the foundation.

5. Technical Data ThermiStar L .. SP 01/03/10
18
5.2 Type plate
Fig. 4: Sample type plate

ThermiStar L .. SP 01/03/10 5. Technical Data
19
Legend for Fig. 4:
Abbr. Meaning
1Type
2Part number / Item number
3Country of destination
4Serial number
5Refrigerant
6Refrigerant capacity
7Output A2/W35
8Output B0/W35
9Output W10/W35
10 Output W7/W35
11 Rated thermal output
12 max. positive operating pressure
13 max. flow temperature
14 Pressure limiter
15 Electric connection
16 Power consumption
17 Power current
18 Control current
19 Nominal current
20 Operating current
21 Starting current (compressor)
22 Protection class
23 Manufacturer
24 CAUTION HIGH VOLTAGE!

5. Technical Data ThermiStar L .. SP 01/03/10
20
5.3 Technical data
Air/water heat pumps* Thermistar L 05 SP to L 41 SP
ThermiStar L .. 05 SP 07 SP 10 SP 13 SP 15 SP 19 SP 28 SP 34 SP 41 SP
Output A2/W35* Nominal heating
capacity kW 5,2 7,1 10,4 13,0 15,3 19,4 27,4 33,6 40,9
Power consumption condenser kW 1,3 1,7 2,4 3,0 3,5 4,8 6,4 7,9 9,6
Cooling capacity kW 4,0 5,6 8,1 10,0 12,0 14,9 21,3 26,1 31,8
Performance no. COP 3,7 3,9 4,0 3,7 4,0 3,9
Refrigerant R 407 c for hot water temperatures up to 55°C
Refrigerant dosage
for max. 20 m line length** kg 3,5 4,2 5,5 8,5 10,0 12,0 15,5 20,2 20,7
Refrigerant lines Liquid (1) mm 10 12 15 18 22
Suction gas (2) 15 22 28 35 42
Thawing (3) 10 12 15 18
Nominal current consumption A 3,0 4,0 5,4 6,5 7,4 12,6 14,3 16,2 18,6
Operating current, max. A 5,0 5,2 8,2 10,1 11,8 16,0 21,0 25,0 32,0
Starting current with soft-start A 13,0 20,0 25,8 32,0 37,0 49,5 63,5 83,5 99,0
Blocked rotor current A 26,0 40,0 51,5 64,0 74,0 99,0 127,0 167,0 198,0
Power circuit breaker / Automatic
circuit breaker, slow A 3x10 3x16 3x20 3x25 3x32 3x40 3x63
Recommended wire gauge mm² 1,5 2,5 4,0 6,0 10,0
Electrical connection
Compressor
Control current
3NPE, 400 V
1NPE, 230 V
Protection class heat pump IP 40 (according to EN 60529)
Protection class split evaporator IP 54 (according to EN 60529)
Evaporated air flow rate, nominal m³/h 2645 2570 3330 5220 5220 6670 10820 16010 14800
Sound pressure at 5 m dB(A) 32 32 38 35 35 41 43 53 53
Mass flow heating system nomi-
nal kg/h 900 1220 1790 2240 2630 3340 4700 5780 6900
Pressure loss heating water at
nominal flow rate kPa 3,0 3,4 4,7 5,3 5,8 3,2 4,5 4,2 5,2
Heating connection ET“ 1 1½
Outside dimensions WxDxH in-
ner part mm 690x600x900 1030x730x900
Outside dimensions WxDxH
outer part mm 1230x880x1030 2155x880x1030 3080x880x1030
Weight of inner part kg 107 120 140 160 175 200 207 217 225
Weight of outer part kg 66 73 80 138 152 202 223
* Heating capacity and COP at A2/W35 as well as source side 3 K and heating side 10 K spread
** When changes to refrigerant lines lead to lengths exceeding 20 m, refrigerant dosage will change as follows:
Pipe with max. Ø 22 mm +/- 100 g/m, pipe with max. Ø 28 mm +/- 150 g/m, pipe with max. Ø 35 mm +/- 200 g/m
NOTE!
Refrigerant R407C for heating water temperatures up to H55°C.