Sunerg Solar Energy Calor Top 200D Operating instructions

Calor Top 200D
Air-source Heat Pump Water Heater
INSTALLATION & OWNER’S MANUAL
v. 13.04

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Content
1. GENERAL INFORMATION........................................................................................................4
1.1M EASUREMENTS.......................................................................................................................................................... 4
1.2 E XTERNALAPPEARANCE................................................................................................................................... 4
1.3 N OMENCLATURE........................................................................................................................................... 4
2. COMBO TYPE HEAT PUMP WATER HEATER.....................................................................................5
2.1F EATURES............................................................................................................................... 5
2.2 R EFRIGERANT CIRCUIT........................................................................................................................ 6
2.3U NIT STRUCTURE................................................................................................................................... 7
2.4S PECIFICATIONS.................................................................................................................................... 8
2.5D IMENSION ..............................................................................................................................................9
2.6 P ERFORMANCE DIAGRAM........................................................................................................... 10
2.7 W IRING DIAGRAM............................................................................................................... 11
2.8 I NSTALLATION ..................................................................................................................................... 12
2.9 W ATER AFFUSION AND EFFUSION.................................................................................................. 18
2.10T RIALRUN................................................................................................................................................... 19
2.11M AINTENANCE........................................................................................................................................... 19
2.12T ROUBLE SHOOTING......................................................................................................................... 20
2.13 F UNCTION................................................................................................................................ 24
2.14 FREQUENTLY ASKED QUESTION...........................................................................................25
2.15 O PERATION.................................................................................................................................. 27
2.16A CCESSORIES........................................................................................................................................... 33
2.17 EXPLODED VIEW........................................................................................................................34
2.18 TYPICAL APPLICATIONS IN COOLING AND PURIFICATION OF AIR.................................36
2.19 RUNNING LOCIC.........................................................................................................................39

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1. General information
1.1 Measurements
Model Label Dimension (mm, D×H) Power Supply
Calor Top 200D
RSJ-15/190RDN3-D
Ф560×1680 220-240V~, 50Hz, 1Ph
1.2 External appearance
1.3 Nomenclature
Design Code
Refrigerant Type
N3: R134a
Function
D: E-Heater
Refrigerant Cycle-heating Type
Water Storage (Unit: L)
Heating Capacity(Unit: ×100W)
Heat Pump Water Heater model
R S J
-
1 5
/
1 9 0
R
D
N 3
-
D

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2. Combo Type Heat Pump Water Heater
2.1Features
 Safety:
1. Complete isolation between water and electricity
without electric shock problem, more safety.
2. No fuel tubes and storage, no potential danger
from oil leakage, fire, explosion, and so on.
3. No cross contamination potential, the condenser coil
is wrapped around the enameled inner tank.
 Minimal leakage: With 15°C of ambient temperature and 43°C of average temperature in tank, the
inner tank temperature decrease only of 2,2°C.
 Maximum outlet water temperature: 70 ° C . The system makes the water be heated stably and
quickly with innovative heating methods of combination the electric heating and heat pump heating
properly.
 Flexible installation achieves by long air inlet and outlet duct with pressure. 15Pa air flow pressure
enables ducted length up to 5 meters .
Note: A≤5m or A+B≤5m
 Automatic startup and shutdown, automatic defrosting by revising refrigerant cycle to save the extra
operation.

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 According to the heat pump principle, the unit absorbs heat from outdoor air and
produce heat water, thermal efficiency can be approximately 3.6
(Under the condition A15/12 W15/45).
 Within the temperature range from -20 °C to 43 °C , the unit will not be affected by
night, cloudy sky, rain even snow weather.
2.2 Refrigerant circuit
Compressor: PJ125G1C-4DZDE, R134a compressor, supplied by GMCC.
Evaporator: copper tube and aluminum fin type heat exchanger.
EXV: electronic expansion valve, the opening is regulated according to the discharge air temperature
of compressor.
Fan: centrifugal fan, there is three speeds. The motor is supplied by Welling.
ATCO (Temperature Switch): If the water temperature is too high, or higher than 78 °C, the ATCO
will automatically shut off the compressor and E-heater’s power supply, and turn it on if the
temperature falls down below 68 °C.
TCO (Temperature Switch): If the water temperature is higher than 85 °C , the TCO will
automatically shut off the compressor and E- heater’s power supply, it must turn on by manual.
High Pressure Switch: When the discharge pressure of compressor is 2.76MPa or higher, the
protection switch will be triggered, and if the discharge pressure is down to 2.07MPa, the protection
switch will be recovered.

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2.3 Unit structure
NOTE:
When ordering repair parts please always give the following information:
- Model, serial and product number.
- Parts name.

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2.4 Specifications
Model Calor Top 200D
Running mode Economy E-heater
Running ambient temperature °C -7
~ 43 -20 ~ 45
Output water temperature °C Default 60°C,38°C
~ 70°C
Power supply Ph, V, Hz
1, 220-240~, 50
Storage size Ltr 190
Water heating
Capacity W 1500 3000
C.O.P. 3.60 1.00
Max. current A 6.5 13.0
Unit
Dimension (D×H) mm
Ф560 × 1680
Packing (W×H×D) mm 695 × 1725 × 685
Net/gross weight kg 94 / 110
Sound pressure level dB(A) 41
Sound power level dB(A) 53
Refrigerant type/quantity kg R134a / 0.9
Refrigerant design pressure MPa 3.0 / 1.2
Throttling type Electric expansion valve
System protection
TCO1, TOC2, PT valve, automatic defrosting, over-load
protector, etc.
Air flow m
3
/h 218 / 202 / 178
Compressor
Model PJ125G1C-4DZDE
Type Rotary
Brand GMCC
Capacity W 1390 / 1405
Input W 515 / 540
Rated current(RLA) A 2.32 / 2.24
Locked rotor Amp(LRA) A 17.6
Thermal protector B135-135-241 Eor BF-580MA (External)
Capacitor
25µF / 450V
Refrigerant oil ml ESTEL OIL VG74 / 400ml
Evaporator coil
Number of rows 3
Tube pitch(a) x row pitch(b) mm 21×13.37
Fin spacing mm 1.5
Fin type (code) Hydrophilic aluminum
Tube outside dia. and type mm
φ7 Inner groove copper tube
Coil length x height mm 402 × 294
Number of circuits 3
Fan motor
Model YDK12-6A
Brand Welling
Input W 28 / 26 / 26
Speed r/min 900 / 815 / 680

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Output W 9
Locked rotor Amp(LRA) A 0.19
Capacitor 1.2µF/450V
Water pipeline
Water inlet pipe DN20
Water outlet pipe DN20
Drainage pipe DN20
PT valve joint DN20
Max. operating pressure MPa 1.0
Heat exchanger Dividing wall type heat exchanger
E-heater W 3000 × 1
Hot water yield m
3
/h 0.043 0.086
Loading Quantity 20'/40'/40H Pcs 24 / 51 / 51
Notes:
1. The test conditions: outdoor temperature 15/12°C (DB/WB), inlet water temperature 15°C, outlet water
temperature 45°C.
2. Sound pressure value test conditions: four side of the unit, distance is 1m, and height is 1m + half of the unit’s
height. The sound pressure level is following this procedure:
3. The specification may be changed for product improvement, please refer to the nameplate.
2.5 Dimension (Unit: mm)

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2.6 Performance diagram
The unit has two modes: E-heater and Heat pump. Modes will be automatically selected by unit, and
manually mode selection is unavailable.
Operation range
E-heater running ambient temperature range: -20~45 °C.
Heat pump running ambient temperature range: -7~43 °C.
Setting water temperature target range: 38~70°C.
Unit: °C
Ambient temperature (T4) T4 ≤ -7 -7 ≤ T4<-2 -2 ≤ T4<2 2 ≤ T4<43 43 ≤ T4
Max. temperature (Heat pump)
- 45 60 70 -
Max. temperature (E-heater) 70 70 70 70 70
The curve between capacity and ambient temperature
The curve between COP and ambient temperature

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2.7 Wiring diagram

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2.8 Installation
Transport
The unit is so heavy that it should be carried by two or more
persons. Otherwise, it might cause injury and damage.
Location of installation
_ Enough space for installation and maintenance shall be preserved.
_ The air inlet and outlet should be free from obstacles and strong wind.
_ If the unit has to be installed in the indoor space, the unit might cause indoor temperature
decreased and noise, please take preventive measures for this.
_ If the unit has to be installed on a metal part of building, make sure the well electric
insulation which should meet the relevant local electric standard.
Maintenance space (Unit: mm)
•The site contains mineral oils such as cutting lubricant.
•Seaside where the air contains much salt.
•Hot spring area where corrosive gases exist, e.g., sulfide gas.
•Factories where the power voltage fluctuates seriously.
•Inside a car or cabin.
•Place like kitchen where oil permeates.
•Place where strong electromagnetic waves exist.
•Place where flammable gases or materials exist.
•Place where acid or alkali gases evaporate.
•Other special environments.

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Water system piping
 In case of installing the unit at a place where outside temperature below freezing point,
insulation must be provided for all hydraulic components.
 Water inlet or outlet pipes: The specification of the water inlet or outlet thread is RC3/4",
which is external thread. Pipes should be heat-insulated well.
 Installation of the one way valve: The specification of the valve thread in accessories is
RC3/4". It is used to prevent water from flowing backwards.
 The drainage pipe should be insulated to prevent water inside pipe from freezing in cold
weather.
 Do not dismantle the PT Valve, and do not block off the drainage pipe.
 After water system piping connection, turn on the inlet and outlet valve to effuse the tank.
When water flow smoothly out from outlet pipe, the tank is full, turn off all valves to check
the pipeline leakage.
 If the inlet water pressure is less than 0.15MPa (1,5atm), a pump should be installed at
the water inlet. If the water supply hydraulic is higher than 0.65MPa (6,5atm), a reducing
valve should be installed at the water inlet pipe.
 Condensate may be leaked from unit if drainage pipe is blocked, so a drainage pan should
be installed.

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 To smoothly drain condensate, the unit should be installed at a horizontal floor. Otherwise, the drain
vent is ensured at the lowest place, and recommending the inclination angle of unit to the ground
should be no more than 2°.
Air duct connection
A B C
A
Air inlet and outlet with
duct A+B
≤ 5m
B
Only air outlet with duct A ≤ 5m It is recommended to install unit by this way
in winter
,
where there is other heat source in the room.
C
Only air inlet with duct A ≤ 5m It is recommended to install unit by this way
in
summer
that could charge fresh air into room.

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Duct description Round duct Rectangle duct
Dimension (mm) Ф160 160×160
Straight-line pressure drop (Pa/m) ≤ 2 ≤ 2
Straight-line length (m) ≤ 5 ≤ 5
Bent pressure drop (Pa) ≤ 2 ≤ 2
Bent’s quantity ≤ 5 ≤ 5
 The duct’s resistance will decrease air-flow-rate, and capacity of unit will be decreased.
 It is recommended to install the unit in the indoor space. It is not allow installing the unit at
the rainy space.
 In terms of the unit connect with duct reaching to outdoor, and then a reliable water-resistant
measure must be conduct on the duct, to prevent water from dropping into internal of the unit.
 Filter should be installed at the unit inlet, if the air inlet is not connected with duct. In terms of
the unit with duct, filter should be put on the position of duct inlet.
ATTENTION!
Do not dismantle the PT Valve or block off the Drainage pipe, It will cause
explosion and injury

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Electric connection
 If the power supply is not earthed well, the unit should be not installed.
 The reliable earthing connection and the installation of the unit should be done by a
qualified person.
 The power supply should be an independent circuit with rated voltage.
 An all-pole disconnection device which has at least 3mm separation distance in all pole and
a residual current device (RCD) with the rating of above 10mA shall be incorporated in the
fixed wiring according to the national rule.
 Set the electric leakage protector according to the relevant electric technical standards of
the local.
 The power cord and the signal cord shall be laid out neatly and properly without mutual
interference or contacting the connection pipe or valve.
 After wire connection, check it again and make sure the correctness before power on.
Specifications of power supply
Model name Calor Top 200D
Power supply 220-240V~, 50Hz, 1Ph
Min. diameter of power supply cord (mm
2
) 4
Earth cord (mm
2
) 4
Manual switch capacity (A)/Fuse (A) 25/20
Creepage breaker 30Ma, ≤0.1sec
 Choosing the power cord according to above table, and it should comply with local electric
standard.
 The power cord model, recommended power cord mode is H05RN-F.

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PCB I/O Ports description
Remark:
SW1 and SW2: Default factory setting is all ‘OFF’, it is not allowed to alter.

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2.9 Water affusion and effusion
Water affusion: If the unit is used for the first time or used again after emptying the tank, please
make sure that the tank is full of water before turning on the power.
1) Open the cool water inlet valve and the hot water outlet valve.
2) When water flows out from the water outlet, the tank is full. Turn off the hot water outlet
valve and water affusion is finished.
Caution:
Operation without water in water tank may result in the damage of auxiliary E-heater.
Due to such damage, manufacturer will not be liable for any damages caused by this issue.
Water effusion: If the unit needs cleaning, moving etc, the tank should be emptied.
1) witch off the unit, and close the cool water inlet valve, open the hot water outlet valve and
open drainpipe.
2) After emptying, the nut of drainpipe should be replaced and closed.
Note: The outlet water temperature maybe very high when emptying, beware of your body for burns.

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2.10 Trial run
Checking list before trial- running:
 Correct installation of the system.
 Correct connection of water piping and wiring.
 Correct connection of air inlet and outlet.
 Condensate draining smoothly well.
 All the insulation work for all hydraulic part.
 Correct power supply.
 No air in the water pipeline and all valves opened.
 Effective electric leakage protector installation.
 Sufficient inlet water pressure, between 0.15MPa and 0.65Mpa (1,5 ~ 6,5 atm).
Water temperature display
 The temperature shown of the display depends on the upper sensor.
 It is normal that the display temperature has reached to target temperature.
 Compressor still running, because the lower water temperature does not get to target
temperature.
Heat source shift
 The default heating source is heat pump. If the ambient is range out of heat pump, heat
pump will stop running, and the unit will shift automatically to activate E-heater and show
the icon ‘ LA ’ on the display, then if the ambient temperature goes into the running range of
heat pump again, it will stop E-heater and shift automatically to heat pump again, and the
icon ‘ LA ’ will be extinguished.
 E-heater will be activated once for the current heating progress, if want to apply E-heater
again, the button of ‘ E-HEATER ’ should be pressed once.
 If the target setting water temperature is higher than the maximum temperature (Heat
pump), the unit will activate heat pump firstly to the maximum temperature, then stop heat
pump, activate E-heater to continually heat water to the target temperature.
 If manually activate the E-heater running mode when heat pump running, E-heater and heat
pump will work together until the water temperature gets to target temperature. So if want to
heat quickly, E-heater should be activated manually.
2.11 Maintenance
Recommended regular maintenance table
Checking
item Checking content Checking frequency Action
1 Air filter (inlet/outlet) Every month Clean the filter.
2 Anode rod Every half year Replaced if it has been used out.
3 Inner tank Every half year Clean the tank.
4 E-heater Every half year Clean the E-heater.
5 PT valve Every year Operate the hander of PT valve to
ensure that waterways are clear.
If water dose not flow freely when operating the hander, replace PT vale with a
new one.

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 Check the connection between power supply plug and socket and ground wiring regularly.
 In some cold area (below 0 °C ), if the system will be stopped for a long time, all the water
should be released in case of freezing of inner tank and damage of E-heater.
 It is recommended to set a lower temperature to decrease the heat release, prevent scale
and save energy if the outlet water volume is sufficient.
 Before shutting the system down for a long time:
Shut down the power supply;
Release all the water in the water tank and pipeline, and close all the valves.
 Check the inner components regularly.
Anode rod replaced
 Turn off the power supply and water inlet valve.
 Open hot water tap, and decrease the pressure of the inner
container.
 Open the drainage valve, and drain out the water, until there is no
water flow out.
 Get off the anode rod.
 Replace with a new one, and make sure effective sealed.
 Open cold water inlet tap until water flows out from outlet tap, then
turn off water outlet tap.
 Power on, and then restart the unit.
PT Valve
 The handle of PT Valve should be pulled out once per half a
year to make sure that there is no jam of the valve. Please
beware of burn by hot water from the valve.
 The drainage pipe should be well insulated in order to prevent
water inside pipe from freezing in cold weather
Filter cleaning
 In terms of the air filter set in air inlet direct.
 Anti-clockwise unscrew the air inlet ring.
 Take out the filter and clean it completely.
 Remount it to the unit.
Restart after a long term stop
When the unit is restarted after a long term stop (include trail running), it is normal that outlet
water is unclean. Keep the tap on and the water will be clean soon.
2.12 Trouble shooting
Error phenomenon Possible reason Solution
Cold water tapped out and
display screen extinguished.
Bad connection of power supply wire. Connection well
Setting water temperature too low. Setting water temperature higher.
Temperature sensor broken.
PCB of indicator broken. Replace the sensor or PCB.
No hot water tapped out.
Public water supply ceased. Waiting for water supply recover.
Water inlet pressure too low. Waiting for the pressure increase.
Water inlet valve closed. Open water inlet valve.
Water leakage Hydraulic pipeline joints are not sealed well. Check and reseal all joints.
Handle
Drainage
pipe