nilan CTS 700 Instruction Manual

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Compact P GEO 3
Compact Polar GEO 6
Version: 1.02, 01-06-2016
Installation and maintenance
CTS 700 by Nilan

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Table of contents
Table of contents ............................................................................................................................2
General information before starting installation............................................................................... 3
Safety.............................................................................................................................................4
Compact P......................................................................................................................................5
The function....................................................................................................................................5
Installing Compact P.......................................................................................................................6
Condensation drain/water trap........................................................................................................9
Water connection.......................................................................................................................... 10
Power supply................................................................................................................................ 12
Duct connection............................................................................................................................ 13
Supplementary heating element DHW.......................................................................................... 14
Fault finding.................................................................................................................................. 15
Operation and maintenance ......................................................................................................... 16
Energy-saving tips for the optimal operation................................................................................. 18
GEO 3 + GEO 6 ........................................................................................................................... 19
System construction..................................................................................................................... 19
Connection the heat pump............................................................................................................ 20
Operation and maintenance ......................................................................................................... 21
Starting the heat pump.............................................................................................................. 21
Pressure in ground source loop (ground pipe)........................................................................... 22
Filling the ground source loop with brine................................................................................... 22
Water pressure in the central heating loop................................................................................ 22
Filling water in the central heating loop..................................................................................... 23
Dirt filters in central heating and ground source loops............................................................... 23
Maintenance and Warranty....................................................................................................... 23
Function Description..................................................................................................................... 24
Heat pump compressor............................................................................................................. 24
Frequency-controlled compressor (variable capacity) ............................................................... 24
Ground pipe and brine .............................................................................................................. 24
Condenser and heating circulation pump.................................................................................. 24
Permitted area of action for the heat pump ............................................................................... 25
Auxiliary heating........................................................................................................................ 25
Central heating.......................................................................................................................... 25
Frost protection......................................................................................................................... 27
Event log Menu ............................................................................................................................ 28
High pressure alarm.................................................................................................................. 28
Low pressure malfunction ......................................................................................................... 28
Leakage.................................................................................................................................... 29
Installation....................................................................................................................................30
Electrical connection GEO 3 ..................................................................................................... 33
The heat pump must be connected to electrical installation by an authorised electrician........... 33
Electrical connection GEO 6 ..................................................................................................... 33
The heat pump must be connected to electrical installation by an authorised electrician........... 33
Floor heating loop..................................................................................................................... 33
Ground source loop .................................................................................................................. 34
Testing for leaks:....................................................................................................................... 36
Brine filling................................................................................................................................ 36
Safety ground coil system......................................................................................................... 36
Isolation of the tubes................................................................................................................. 36
Drainage and collection tray...................................................................................................... 36
Disposal of the heat pump ........................................................................................................ 36
Check list for brine/water pump system at start-up and commissioning........................................ 37
Accessories / spare parts ............................................................................................................. 40

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General information before starting installation

Check that the following papers have been supplied with the product:
- Installation and maintenance (this document)
- User manual
- Wiring diagram
Should you have any further questions concerning installation of the product after reading the
guide, please contact your nearest Nilan dealer, by visiting www.nilan.dk/dealers
The product is controlled by an CTS 700 control system, which provides a wide range of functions.
Compact P is a heat recovery ventilation system with a capacity of up to 330m3/h at 100Pa exter-
nal counter pressure. The system prioritises first the heat pump, second a 180-litre hot water tank
and then intake air.
The geothermal heat pump GEO is intended for heating homes with low-temperature heating sys-
tems with flow temperatures up to 45 ° C.
Before the establishment of a geothermal system, it is important to obtain any potential permis-
sions and approvals from the relevant authorities.
The unit is supplied with integral G4 panel filter and humidity sensor. The unit can also be fitted
with a pollen filter (accessory).
This manual might describe functions and facilities that are not present in your system.
IMPORTANT: If the plant is damaged in any way it must be inspected and repaired by an author-
ized person.

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Safety
Always disconnect the electrical supply to the heat pump if any malfunction occurs
that cannot be remedied via the control unit.
If any malfunction arises on the electrical part of the heat pump, always contact a
licensed electrician to repair the fault.
Avoid direct contact with the heating system pipes in the heat pump, as they can
be very hot.
Many types of antifreeze are hazardous to health, dangerous when ingested, and
must be kept out of the reach of children.
To protect the heat pump from damage, it is supplied with the following safety
equipment:
•Expansion systems for central heating and brine/ground source loop
•Safety valves for central heating and brine/ground source loop
•Low and high-pressure cut-off switches for compressor
•Pressure guard brine loop/ground pipe (mandatory environmental
pressure switch)
•Minimum/frost thermostat (cuts off the heat pump if the temperature
becomes too low in the brine loop)
The heat pump must be subjected to appropriate servicing in accordance with appli-
cable laws and regulations so that the plant is maintained in a good condition and
follow the requirements for safety and the environment.
The responsibility for maintenance of the heat pump lies with the owner / user. The
geothermal circuit contains antifreeze, which can damage groundwater if released. If
you have any suspicions about leaks in your geothermal system, please contact an
authorized service technician.

Compact P
The function

The installation of the plant must be performed by an authorized service technician or a
field engineer who knows about heat pumps.
Electrical installation/power supply (incl. Safety switch) must be installed by a certified
electrician.
The plant is connected according to the circuit diagram.
The Compact P plant is a complete solution that ventilates the property and ensures a good indoor
climate. Furthermore, the Compact P produces hot water.
Unit components (function)
The Compact P consists of a counter flow exchanger followed by a heat pump with a reversible
cooling circuit.
The unit draws the warm and humid air from moisture strained spaces, such as bathrooms, kitch-
ens and utility rooms. The heat in the exhaust air flows through the counter flow exchanger, where
it heats the fresh air and blows it into the rooms of the property, after. The energy that has not
been utilized in the counter flow exchanger is recovered in the heat pump in order to produce hot
water. When there is no need for the production of hot water, the heat pump can be used to heat
the supply air as needed. During summertime, the heat pump can cool and dehumidify the warm
air from outside in order to obtain a comfortable indoor climate.
Figure 1: System build-up

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Installing Compact P

When installing the unit, it is important to take future service and maintenance into ac-
count. There should be a minimum clearance of 60 cm in front of the unit, measured from
the Compact P front panel.

When lifting the unit with straps it is important that the straps have
an angle of maximum
45°C off perpendicular.
Individual connectors have been marked out at the factory to facilitate installation. Please note the
attached labels. The connectors should be connected to the duct system using flexible adapters
(flex tube, soundproofed flex tube or similar).
Figur 2: Duct Connections
1. Ø160
Udeluft
Aussenluft
Fresh air
Air frais
2. Ø160
Tilluft
Zuluft
Inlet air
Air pulsè
3. Ø160
Fraluft
Abluft
Exhaust air
Air repris
4. Ø160
Afkastluft
Fortluft
Discharge air
Air extrait

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Figur 3: Sketch of Compact P
The unit must be installed and leveled on a firm, vibration-free surface. There should be at least
10mm clearance to walls or other permanent installations. Although the unit itself is practically
noise and vibration free, care must be taken to prevent any vibration from being propagated to ad-
joining parts of the building.
The rear angular slide bar of the base frame of the Compact P can be removed in order to make it
possible to push the unit towards the wall to hide water connections etc.
It is important that the condensation outlet of the Compact P be connected to a drain. The unit is
supplied complete with water trap. The outlet should be led frost-free with steady decline to the
nearest drain. The safety valve overflow must also be led to a drain.
If Compact P is enclosed by any covering, it must be possible to remove the covering easily.

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TPanel
T1:
Outdoor air
T2:
Inlet air
T3:
Extract
T4:
Yield
T5:
Condenser
T6:
Evaporator
T7:
Supply air (after residual heat-
ing surface)
T8:
Supply air (before preheating
surface)
T9:
On residual heat surface
T11:
Top of container
T12:
Bottom of container
TPanel:
CTS700 control panel
T13:
Brine, flow
T14:
Brine, return
T16:
Central heat, before condenser
T17:
Central heat, forward motion
T18:
Buffer tank, forward motion
T20:
Outside temperature
T21:
Hot-water tank, top
T22:
Hot-water tank, bottom
T23:
Evaporation temperature
TPanel:
CTS700 control panel
Figur 4: Location of temperature sensors

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Condensation drain/water trap
Compact P is supplied with 20mm condensation outlet (PVC, GF fittings). The unit is also equipped
with built-in water trap.

The condensation outlet must be led frost-free with a steady decline of at least 1 cm/m to
the nearest drain. The safety valve overflow must also be led to a drain.

In order to prevent ice formation, it may be necessary to equip the condensation outlet
with a heating cable where frost is possible Protecting the condensation outlet from frost
is the responsibility of the fitter.

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Water connection
The inner tank surface is enamelled and the tank is equipped with a sacrificial anode.
All connectors have 3/4” threads, with the exception of the anode access which is a 5/4” sleeve.
All water pipes are connected to the bottom of the unit.
If you wish, you can establish a hot water circulation system. Simply fit a return valve to the tank's
circulation connector.
If hot water circulation is not required, the connector and fitted blanking plug should be left un-
touched.
Hot water circulation may result in considerable heat loss within the piping system. A large propor-
tion of heat pump output may therefore be lost. To prevent heat loss, circulation and hot water
pipes must be insulated with at least 30mm of mineral wool or other type of pipe insulating materi-
al.
Figur 5: Location of sacrificial anode

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Figur 6: Water connections
Supplementary coil is standard only in the Compact P Sun and Compact P Cool Sun unit type.
1. Tilslutning for cirkulationsrør ¾”
Anschluss für zirkulationrohr ¾”
Circulation pipe connection ¾”
Branchement à tuyeau de circulation ¾”
2. Varmtvandsudtag ¾”
Warm Wasser ¾”
Hot water connection ¾”
Sortie eau chaude ¾”
3. Koldt vandsindtag ¾”
Kalt wasser ¾”
Cold water connection ¾”
Alimentation eau froide ¾”
4. Retur suppleringsspiral ¾”
Rücklauf Sol ¾”
Return supplementary coil ¾”
Retour échangeur supplémentaire¾”
5. Fremløb suppleringsspiral ¾”
Vorlauf Sol ¾”
Inlet supplementary coil ¾”
Alimenration échangeur supplémentaire ¾”

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Power supply

Power supply including safety switch must be installed by an authorized electrician.
The Comfort-unit must be connected according to the attached electrical chart.
The unit is delivered with 3 m test cable for the CTS 700 panel. The panel should be connected to
the CTS 700 control in the unit with cable type cat 5e twisted in pairs. (Maximum length 20m).
The CTS 700 panel must be placed dry and frost-proof. The panels’ integrated feeler prevents fur-
ther cooling of the building if the primary heat-supply stops by stopping the ventilation if the panel
feeler gets below a specific value. (Factory setting is 10°C; the value can be set from 1-20°C.)
Figure 7: CTS 700 control
If a water heating element is installed in the system, the regulation vent must be connected electri-
cally as described in the enclosed wiring diagrams.

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Duct connection
Ducting and fittings with rubber seals of tightness class B are recommended. It is also advisable
that all duct connections to Compact P be made with approx. 1m of soundproofed flex tube in order
to dampen sound emission.
Ducting should be cut to length using a hacksaw or angle grinder and laid in accordance with the
design drawing. Ducting is usually either attached to rafter feet using perforated strip or suspended
in fitting strip. Avoid pinching the ducting in any way and any unnecessary bends.
The ducting must be insulated. Sometimes, standard loft insulation can be used for the purpose.
All ducting should be insulated with mineral wool to prevent heat loss and condensation. Such in-
sulation requirements also apply to soundproofed flex tubing. It is recommended that two layers of
50mm insulating material be used. If ducting is installed in an unheated room, it is inadvisable to
switch the system off for prolonged periods as air from heated rooms will rise into the ducting and
condensate, thus possibly causing moisture problems.
Figur 8: Insulation of ducting
The discharge duct leads the exhaust air (from which the system has recovered the energy it con-
tained) to the outside through the roof or outer wall. It is important that the roof stack or wall grille
has at least the same area as the duct immediately ahead of the stack or grille. Any contraction will
cause unnecessary pressure drop, which may reduce ventilation capacity.
Holes for inlet and exhaust valves should be cut to fit the frame of the valve concerned. Secure the
valve frame in position using screws and then attach the valve. Where the valves should be posi-
tioned depends on room design and use. It is, for example, inadvisable to install inlet valves
immediately above where people usually sit as inlet air may sometimes be perceived as a draught.
Loft insulation mate-
rial
Duct
Granulate

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Supplementary heating element DHW
The hot water tank has a supplementary heating element of 1,5kW. The heating element can be
activated and de-activated via the CTS 700 control, see the “Settings → Compac → DHW settings”
menu.
The temperature, at which the heating element should be active (T11), can be set in the “Settings
→ Compac → DHW settings” menu, see “Directions for use of the CTS 700 control

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Fault finding
If problems arise during operation, please check the following before calling the service centre.
Check that the alarm mark on the CTS 700 panel is displayed. If so, investigate the cause of the
alarm and remedy the fault. If necessary, contact your local service centre. For details of alarms
and how to reset them, please refer to the operating instructions for the CTS 700 controls.
- Compact P is operating but with reduced output.
Check that sufficient air is being supplied to Compact P. Check filters for excessive dirt ac-
cumulation. Check that valves are sufficiently open. In 98% of cases, the fault is caused by
clogged filters. If necessary, increase the ventilation step. Any dampers to the open air
should be shut at outdoor temperatures lower than 6°C.
- Compact P is operating but there is no hot water.
Check whether the tank has been emptied of hot water. If the system is equipped with a
circulation pump but the circulation circuit has not been insulated, considerable heat loss
may result, significantly reducing Compact P capacity.
- Has the required water temperature (T12) (Not directly T12) been set correctly in the CTS
controls? Usually, water temperature should be set to between 40–50°C. Please refer to
the CTS 700 operating instructions for details on checking and setting water temperature.
Is the air supplied too cold or the quantity supplied too low? Check filters and valves. Check
whether duct insulation is sufficient and complete.
- Compact P is not operating.
Check whether a fuse has blown. Check whether the hot water safety thermostat has cut
out. If it has, press the button and the thermostat will cut in again once the water tempera-
ture has dropped 10-15°C. If the thermostat continues to cut out, contact your local service
centre.

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Operation and maintenance
At least every 3 months:
The filters should be cleaned and renewed when needed. Usually the filters need to be renewed
once every 3 month. The filter guard in the CTS 700 control can be used in order to make sure that
the filters are checked. The filters can be cleaned by vacuuming or shaking them.
Changing filters:
1. Loosen screws
2. Remove the filter hatch
3. Pull out the two filter frames for change/vacuuming
Once a year:
-The sacrificial anode must be checked to ensure that monitoring of the anode is intact.
oThe wire “yellow/green” is dismantled at the anode.
This produces the “Anode fail”
oThe wire “yellow/green” is reassembled at the anode.
Delete the alarm in the event log (reset). Delete is only for installation contractors.
The hot-water tank can corrode if the anode is left unchanged.
- The intake should be inspected and any uncleanness should be removed.
- The evaporator should be inspected and cleaned.
- It should be checked that the condensate has free passage through the water seal and the
condensation drain.
- The safety switch for the hot water tank should be controlled.
- It is recommended to take out a subscription for service.
Figur 9: Air Filter change

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Figur 10: Safety Switch
Tilbehør
Zubehör
Accessories
Accessoires

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Energy-saving tips for the optimal operation
- Maintain a low temperature of the hot water. Try for example. at 45 ° C.
- The auxiliary heating element should be cut off and only be used at very large hot-water
demands. Please see CTS 700 directions
- The ventilation speed should not be set higher than necessary.
- Avoid hot-water circulation.
- Spread out the bathing times as the Compact P needs 6-7 hours to heat the 180L water.
- Insulate the ducting as prescribed.
- Do not cool during winter time.

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GEO 3 + GEO 6
System construction

Electrical installation/power supply (including safety switch) should be installed by an
authorised electrician.
Connect the unit according to the wiring diagram supplied.
Figure 71: Example of system design
Function of ground source heat system
The Geothermal heat pump GEO is designed for heating homes with low temperature heating sys-
tems with forward-flow temperatures of up to 45 °C, for example floor heating systems.
System components (function)
The ground source heat system obtains heat from the ground through the ground pipe loop (3).
The ground stores heat, which it accumulates from the sun in the summer and releases the heat to
the ground pipe loop (3) in the winter. The temperature in the water/antifreeze mixture (= brine);
from the ground pipes (1). Brine to be protected against freezing form a freezing point of -20 °C to
-18 °C. To exploit the heat energy in the brine, the system uses a heat pump to transfer energy
from a low temperature in the brine to a higher temperature in the central heating system. Circula-
tion pumps (8) maintain flow in both the ground pipe loop (3) and the central heating/floor heating
loop (10).
The heat pump consists of an evaporator (4), compressor (5), condenser (6) and an expansion
valve (7). These elements are connected and filled with a refrigerant in a closed cycle in a closed
system. The antifreeze in the ground source loop is heated by the ground and cooled in the evapo-
rator. After the evaporator the refrigerant is compressed in the compressor and the temperature
and pressure of the refrigerant are increased. In the heat exchange process in the condenser, the
refrigerant then releases heat energy to the central heating water, and the temperature of the cen-
tral heating water rises. After the condenser the refrigerant pressure is reduced in the expansion
valve, and the refrigerant continues into the evaporator where it cools the brine before flowing re-
turn into the ground pipe loop (2).
An auxiliary heating element (9) is installed in the central heating loop, which can supplement the
ground source loop in the event of particularly high heating demand.

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Connection the heat pump
Lable attached at the heat pump