Ochsner AIR HAWK 518 User manual

TRANSLATION OF THE ORIGINAL MANUAL
HIGH EFFICIENCY AIR/WATER HEAT PUMPS
DESIGN AND INSTALLATION
MANUAL
►
AIR HAWK 518

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CONTENTS
PLEASE NOTE
1. Information on documentation 4
1.1 Safety information 4
1.1.1 Arrangement of safety information 4
1.1.2 Symbols and possible dangers 4
1.1.3 Keywords 5
1.2 Other symbols 5
1.3 Units of measurement 5
1.4 Specied performance gures 5
2. Safety 6
2.1 Intended use 6
2.2 General safety information 6
3. How split systems work 8
4. Device description 10
4.1 Scope of delivery 10
4.2 Indoor unit hydraulics 10
4.3 Appliance components 10
4.3 .1 Indoor unit 10
4.3.2 Outdoor unit 11
4.3.3 Heat pump control unit 11
4.4 Name plate 11
ENGINEERING OF A SPLIT SYSTEM
5. Outdoor unit 12
5.1 Installation location 12
5.2 Minimum clearances 12
5.3 Foundations for the outdoor unit 12
5.4 Sound 13
6. Refrigerant lines 14
6.1 Preparing the refrigerant lines 14
6.1.1 Line lengths 14
6.1.2 Refrigerant pipes passing through open air 15
6.1.3 Underground refrigerant pipes 15
6.2 Wall conduit 16
7. Indoor unit 17
7.1 Installation location 17
7. 2 Keep minimum clearances 17
8. Machine-specic engineering and preparation 18
8.1 Outdoor unit 18
8.1.1 Installation location 18
8.1.2 Minimum clearances 18
8.1.3 Installation in coastal areas 19
8.1.4 Foundations for the outdoor unit 19
8.2 Refrigerant lines 21
8. 2.1 Line lengths and height di󰀨erentials 21
8.2.2 Material requirements 22
8.3 Indoor unit 22
8. 3.1 Minimum clearances 23
8.3.2 Minimum area of clear oor space in the installation room
23
8.4 Refrigerant safety pipe 24
8.4.1 Routing the refrigerant safety pipe to the outside 24
8.5 Preparing the electrical connections 24
8. 5.1 Cables from main distributor to indoor unit 26
8.5.2 Cables to sensors and actuators 26
8.5.3 Cables from indoor to outdoor unit 26
8.5.4 Temperature sensor 26
8.5.5 Pumps and servomotors 27
8.5.6 PSU signal contact 27
8.5.7 Smart grid 27
8.5.8 High limit safety cut-out (STB-PUM-EEZ) 27
INSTALLATION
9. Appliance installation 28
9.1 Installation of indoor unit 28
9.1.1 Delivery and transportation 28
9.1. 2 Positioning the appliance 29
9.1. 3 Disassembling the appliance casing 29
9.1.4 Assembling the appliance casing 30
9.2 Installing the outdoor unit 31
9.2.1 Delivery and transportation 31
9.2.2 Positioning the appliance 32
9.2.3 Disassembling the appliance casing 32
9.2.4 Installing the snow cover 32
9.3 Connecting the heat sink system 33
9.3 .1 Connecting the heating water 33
9.3.2 Safety valve drain 34
9.3.3 Filling the heating system 34
9.3.4 Diaphragm expansion vessel (DEV) 34
9.3.5 Cooling version 34
9.3.6 Connecting the DHW 35
9.4 Connection for refrigerant safety pipe 35
10. Electrical connection 35
10.1 General 35
10.2 Electrical connection of the indoor unit 35
10.3 Electrical connection of the outdoor unit 38
10.3.1 Connector assembly cable to outdoor unit 39
10.4 LAN connection 39
11. Initial start-up 40
11.1 Before initial start-up 40
11. 2 Testing the control circuit 40
12. Completion and commissioning 42
12.1 Requirements 42
12.2 System completion 43
12.3 Commissioning the system 43
12.3.1 Activities carried out by OCHSNER 43
SPECIFICATION
13. Data tables 46
13.1 Heat pumps with three-phase compressor 46
13.2 Controller outputs 49
13.3 Flow rate 49
13.4 Temperature sensor pressure drop curve 49
13.5 DHW heat input 49
14. Heat generator pump (HGP) 50
15. Limits of use for heating 50
16. Limits of use for cooling 50
17. Performance diagram for heating 50
18. System principle schematic 51
18 .1 AIR HAWK 518 51
19. Voltage quality in isolated mode 52
20. Dimensions and connections 53
20.1 Indoor unit 53
20.2 Outdoor unit 54
ENVIRONMENT AND RECYCLING

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Information on documentation
PLEASE NOTE
►Connection to the mains electricity supply must be
by means of a xed connection. It must be possible
to isolate the appliance from the mains supply with
a multi pole switch which has a gap of at least 3 mm
across all poles.
►You must not disconnect the power supply even if
heating is not required. If the power supply is discon-
nected, active frost protection of the system cannot
be guaranteed.
►Observe the minimum clearances in order to ensure
fault-free operation of the appliance and to allow for
maintenance work on the appliance.
►Maintenance work such as checking the electrical
safety of the appliance may only be carried out by a
qualied contractor.
►We recommend an annual inspection (to assess the
appliance‘s actual state) and if necessary any main-
tenance (to reinstate it to its expected state) by a
qualied contractor.
►We guarantee trouble-free function and operational
reliability only if the original accessories and spare
parts intended for the appliance are used.
►Observe all applicable national and regional regula-
tions and provisions.
►The appliance is tted with an electric auxiliary heat-
er. The auxiliary heater is not normally switched on
until the bivalent point is undershot. In exceptional
cases the auxiliary heater may also switch on irre-
spective of the bivalent point:
- The auxiliary heater switches on if the heat
pump is not enabled as the heat generator.
This can happen if there is a fault or the limits
of use have been exceeded.
- The auxiliary heater switches on if more output
is required than the heat pump can provide.
This can happen if the heat pump is already
close to reaching the limits of use.
1. Information on documentation
This documentation is aimed at qualied contractors and
specialist design engineers. It is not intended for use by
appliance operators.
Unless otherwise stated, all content of this documentation
applies to the following appliances:
Appliance Article number
AIR HAWK 518 C11A 287310 V
This documentation describes appliances that are not al-
ways in the standard scope of delivery. Therefore there
may be di󰀨erences to your specic appliance.
Note
Read all of this documentation carefully before us-
ing the appliance and keep the documents safe.
Pass this documentation on to any new user.
Note
A separate operating manual is available for op-
erating the system. This also includes the ERP
data. This document is attached to the machine
in printed form or can be found in digital form on
the OCHSNER homepage in the download area.
1.1 Safety information
1.1.1 Arrangement of safety information
KEYWORD: Type of risk
The possible consequences of not observing the
safety information are shown here.
»
Instructions for action to remedy or remove
the source of danger are shown here.
1.1.2 Symbols and possible dangers
Symbol Type of risk
Injury
Electrocution
Burns
(burns, scalding)
Material damage
(appliance, consequential and environmental dam-
age)

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Information on documentation
1.1.3 Keywords
Keyword Meaning
DANGER Failure to observe this information will result in seri-
ous injury or death.
WARNING Failure to observe this information may result in se-
rious injury or death.
CAUTION Failure to observe this information may result in
non-serious or minor injury.
1.2 Other symbols
►This triangular symbol is used as a bullet point.
»
These two arrows represent the symbol for an in-
struction. This shows that there is something you
must do. The actions required are described step by
step.
 These symbols show you the level of a software
menu. In this example, 3 menu levels are
indicated.
Symbol Notes
Must not be disposed of with household waste
Low flammability
Additional documents are available and must be
used
1.3 Units of measurement
Note
In these documents, unless otherwise specied,
all linear measurements (e.g. in tables and illus-
trations) are given in millimetres.
1.4 Specied performance gures
The performance gures of the appliance indicated in
these documents (text, tables and diagrams) have been
calculated according to standardised measurement con-
ditions. However, these measurement conditions often do
not completely correspond to the plant-specic conditions
applicable in the respective user‘s system. System-specic
factors that can a󰀨ect the conditions include, for example,
the specic design of the system, the age of the system
and the actual ow rates. For this reason, the stated perfor-
mance gures can di󰀨er from plant-specic performance
data.
The stated performance gures can be conrmed only
if the measurements taken for the appliance are carried
out according to the relevant standardised measurement
conditions.

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Safety
2. Safety
2.1 Intended use
The appliance is intended for use in a domestic environ-
ment. It can safely be used by persons who have received
no instruction. The appliance can similarly be used in a
non-domestic environment such as commercial premises,
as long as it is used in the same intended manner.
Any use of the appliance that is di󰀨erent from or goes
beyond this is not regarded as intended use. Intended use
also includes observing this documentation and the docu-
mentation for operation and any accessories used.
2.2 General safety information
Observe the following safety information and instructions
for the appliance.
►Only qualied contractors should carry out the elec-
trical work and installation of this appliance. Only
qualied contractors may open the appliance.
►Commissioning of the appliance may be carried out
only by OCHSNER Customer Service or by customer
service partners authorised by OCHSNER.
►The qualied contractor is responsible for compliance
with all relevant regulations during installation and
commissioning.
►Operate the appliance only when fully installed and
with all safety devices tted.
►Protect the appliance from dust and dirt ingress dur-
ing building work.
►Alterations to the appliance may be carried out only
by OCHSNER Customer Service or by customer ser-
vice partners authorised by OCHSNER.
►Functions to protect the heat pump can be enabled
using the controller. However, since the controller
is not certied as a safety device, safety measures
in case of breakdown or damage to the heat pump
(e.g. additional external switching of the safety devic-
es in use) must comply with local regulations.
►The heat pump has no separate ON/OFF switch. In
an emergency, the system must be shut down via the
specied safety devices.
►Before commencing electrical connection and instal-
lation work, the heat pump system must be isolated
from the power supply.
►The appliance must not be used as a step or plat-
form. Do not climb on the appliance or place any
loads on it.
►The appliance may be used by children aged 8 and
up and people with reduced physical, sensory or
mental capabilities or a lack of experience provided
that they are supervised or that they have been in-
structed on how to use the appliance safely and have
understood the possible risks. Children must not be
allowed to play with the appliance. Children must not
be allowed to clean or carry out user maintenance on
the appliance without supervision.
►If the system has obvious damage, makes a noticea-
ble noise or emits smoke, switch o󰀨 the system and
contact OCHSNER Customer Service immediately.
►Contact with refrigerant can cause serious injuries.
- In the event of a leak, avoid contact with the
refrigerant.
- Bear in mind that refrigerant can be odourless.
►Keep potential sources of ignition away from areas
where refrigerant could leak out.
Note
A rising and falling sound from the heat pump does
not indicate a fault. The noise is caused by chang-
es in the compressor speed.
►The refrigerant used is assigned to safety class A2L.
It is not harmful to the environment and is of low
ammability.
WARNING
In the event of a fault, refrigerant could enter the
working area through the heat sink system.
»
Do not use an open ame within 20 cm of the
quick-action air vent valve and the safety valve
outlet.
»
Ventilate the installation room well when en-
tering it.

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8 www.ochsner.com | 00_400_200_202_01_split_Funktionsweise-EN
How split systems work
3. How split systems work
An air/water heat pump extracts thermal energy from the
ambient air (low temperature) and transmits it together with
electrical drive energy in the form of useful heat (higher
temperature) to a heating and/or DHW circuit.
The heat pump consists of separated circuits linked togeth-
er via heat exchangers:
►Heat source circuit (extracting heat)
►Refrigerant circuit
►Heat sink circuit (supply of heat for room heating and/
or DHW)
Outdoor air is a heat source that is available everywhere
in unlimited amounts and can be utilised without approval.
It is especially suitable for retrotting.
A split system consists of an indoor unit and a separately
installed outdoor unit. The outdoor air is routed through the
outdoor unit by means of a fan. The indoor and outdoor
units are connected through refrigerant lines.
Due to the defrosting mode integrated into OCHSNER air/
water heat pumps, the system also operates awlessly at
temperatures below -15°C.
For air/water heat pumps, the most e󰀩cient and therefore
most common operating mode is bivalent parallel opera-
tion.
Due to the integral defrosting mode, the monovalent op-
erating mode is also possible. As the heating output of an
air/water heat pump at an outdoor temperature of +15°C
is approx. triple the heating output at -15°C, such systems
are vastly oversized for operation in spring and autumn
and therefore not recommended.
1 Evaporator (outdoor unit)
2 Compressor
3 Condenser (plate heat exchanger)
4 Expansion valve
5 Heat sink (heating, DHW)

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How split systems work

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Device description
4. Device description
4.1 Scope of delivery
The scope of delivery of your appliance includes the fol-
lowing components.
►1 indoor unit
The following components are installed in the in-
door unit:
- Flow meter (heat sink side)
- Heat generator pump
(circulation pump)
- Internal exible hoses
- Controller
- OTS heat pump controller
- 3-way switching module (DHW)
- Electric auxiliary heater
- Hydraulic bypass
►1x outdoor unit:
The following components are installed in the
outdoor unit:
- Evaporator
- Expansion valve
- Fan
- Snow cover
►4 connection pipes:
For connection to the heating system
►1 outdoor temperature sensor
►1 contact sensor:
For a mixed circuit
►3 cable temperature sensors
►1 foundation xing kit:
For the outdoor unit
►1 pce. 90° high temperature pipe bend
4.2 Indoor unit hydraulics
The system must be engineered using an OCHSNER
standard hydraulic schematic or an OCHSNER special
hydraulic system.
1 Suction gas line
2 Liquid line
3 DHW return
4 Heating water return
5 DHW ow
6 Heating water ow
7 3-way switching module (DHW)
8 Flow meter (heat sink side)
9 Heat generator pump (circulation pump)
10 Electric auxiliary heater
11 Heat exchanger (heat sink side)
12 System pressure sensor
13 Ball valve (hydraulic bypass)
14 Temperature sensor
15 Fill/drain stopcock
4.3 Appliance components
4.3.1 Indoor unit
The indoor unit is intended to be installed inside the build-
ing only. The indoor unit contains the compressor which
is acoustically decoupled from casing at multiple points.
The casing is acoustically optimised and allows particularly
quiet operation.
Compressor:
The fully hermetically sealed compressor is designed for
high e󰀩ciency heat pump applications.
Electric auxiliary heater:
The appliance is tted with an electric auxiliary heater
(immersion heater). At low outdoor temperatures, the ap-