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Vaillant flexoTHERM exclusive VWF 57/4 230V User manual

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en Installation and maintenance instructions
flexoTHERM exclusive
VWF 57 - 117/4 230V
0020213395_04 - 26.01.2023
2Installation and maintenance instructions 0020213395_04
Installation and maintenance
instructions
Contents
1 Safety .................................................................... 4
1.1 Intended use .......................................................... 4
1.2 General safety information .................................... 4
1.3 Regulations (directives, laws, standards) .............. 6
2 Notes on the documentation .............................. 7
2.1 Observing other applicable documents ................. 7
2.2 Storing documents................................................. 7
2.3 Validity of the instructions...................................... 7
3 System overview.................................................. 7
3.1 Heat pump system design ..................................... 7
3.2 Functionality........................................................... 7
3.3 Safety devices ....................................................... 9
4 Product description........................................... 10
4.1 Product design..................................................... 10
4.2 Information on the data plate............................... 10
4.3 Explanation of product stickers............................ 11
4.4 Type designation and serial number ................... 11
4.5 CE marking .......................................................... 11
4.6 Benchmark........................................................... 11
5 Set-up.................................................................. 11
5.1 Checking the scope of delivery............................ 11
5.2 Selecting the installation site ............................... 12
5.3 Dimensions .......................................................... 13
5.4 Minimum clearances............................................ 14
5.5 Transporting the heat pump ................................ 14
5.6 Installing the product............................................ 15
5.7 Removing the carrying straps.............................. 15
5.8 Removing the front casing................................... 15
5.9 Removing the casing top and side casings ......... 16
5.10 Removing the refrigerant circuit cover, if
required................................................................ 16
6 Carrying out the hydraulics installation.......... 17
6.1 Requirements for the heating circuit.................... 17
6.2 Connecting the heat pump to the heating
circuit ................................................................... 17
6.3 Connecting the heat pump to the brine circuit ..... 17
6.4 Hydraulic wiring in the system ............................. 18
7 Filling and purging the installation.................. 18
7.1 Filling and purging the heating circuit .................. 18
7.2 Filling and purging the brine circuit...................... 19
8 Electrical installation......................................... 21
8.1 Routing eBUS lines.............................................. 21
8.2 Opening the electronics box ............................... 21
8.3 Electronics box .................................................... 22
8.4 Establishing the power supply ............................. 22
8.5 Power supply PCB............................................... 24
8.6 Control PCB......................................................... 25
8.7 Connection terminals........................................... 26
8.8 Connecting the system control and
accessories to the electronics system ................. 26
8.9 Carrying out the wiring......................................... 26
8.10 Installing the VRC DCF........................................ 26
8.11 Installing optional accessories............................. 26
8.12 Connecting the circulation pump ......................... 26
8.13 Connecting the heat pump system to the
photovoltaic installation........................................ 26
8.14 Checking the electrical installation ...................... 27
8.15 Completing installation......................................... 27
9 Start-up ............................................................... 27
9.1 Operating concept ............................................... 27
9.2 Starting up the heat pump system....................... 27
9.3 Running the installation assistants ...................... 28
9.4 Calling up the installer level................................. 28
9.5 Changing the set language.................................. 28
9.6 Heating mode flow temperature control............... 29
9.7 Activating cooling mode....................................... 29
9.8 Calling up statistics.............................................. 29
9.9 Checking that the product works correctly........... 29
10 Adapting the unit to the heating
installation.......................................................... 29
10.1 Setting parameters .............................................. 29
10.2 Setting the high-efficiency pumps........................ 29
10.3 Setting the flow temperature in heating mode
(with no control connected) ................................. 31
10.4 Setting the flow temperature in cooling mode
(with no control connected) ................................. 31
10.5 Handing the product over to the end user ........... 31
11 Troubleshooting ................................................ 31
11.1 Displaying the Live Monitor (current product
status) .................................................................. 31
11.2 Checking fault codes ........................................... 32
11.3 Querying the fault memory .................................. 32
11.4 Resetting the fault memory.................................. 32
11.5 Restarting the installation assistant ..................... 32
11.6 Using check programmes.................................... 32
11.7 Carrying out the actuator test .............................. 32
11.8 Electric back-up heater circuit breaker ................ 32
12 Inspection and maintenance ............................ 32
12.1 Inspection and maintenance information............. 32
12.2 Procuring spare parts .......................................... 32
12.3 Checking maintenance messages....................... 33
12.4 Inspection and maintenance check-list................ 33
12.5 Checking and correcting the filling pressure of
the heating installation......................................... 33
12.6 Checking and correcting the brine circuit's
filling pressure...................................................... 33
12.7 Carrying out a restart and test operation ............. 33
13 Decommissioning.............................................. 34
13.1 Temporarily decommissioning the product.......... 34
13.2 Decommissioning the product ............................. 34
14 Recycling and disposal..................................... 34
14.1 Disposing of the brine fluid .................................. 34
14.2 Arranging disposal of refrigerant ......................... 34
15 Customer service............................................... 34
Appendix ............................................................................ 35
A Heat pump schematic........................................ 35
0020213395_04 Installation and maintenance instructions 3
B Circuit diagram .................................................. 37
C Power supply 1~/N/PE 230 V (wiring
diagram 1 = ).................................................. 38
D Power supply 3~/PE 230 V (wiring diagram
2 = ) ................................................................. 38
E Installer level overview...................................... 39
F Status codes –Overview .................................. 43
G Maintenance messages .................................... 45
H Fault codes......................................................... 45
I Characteristic values, external cylinder
temperature sensor ........................................... 51
J Characteristic values, internal temperature
sensors (refrigerant circuit).............................. 51
K Characteristic values for the VRC DCF
outdoor temperature sensor............................. 52
L Commissioning Checklist................................. 53
M Commissioning Checklist................................. 56
N Check conditions for determining the
performance data in accordance with EN
14511................................................................... 61
N.1 Building circuit (heat distribution side in
heating mode)...................................................... 61
O Technical data.................................................... 61
O.1 General ................................................................ 61
O.2 Brine heat source................................................. 63
O.3 Ground water heat source ................................... 65
P Rated currents = In[A]....................................... 67
Index ................................................................................... 69
4Installation and maintenance instructions 0020213395_04
1 Safety
1.1 Intended use
There is a risk of injury or death to the user or
others, or of damage to the product and other
property in the event of improper use or use
for which it is not intended.
The heat pump system is intended exclus-
ively for domestic use.
The heat pump system is intended as a heat
generator with cooling function for closed
heating installations and for domestic hot wa-
ter generation. Operating the pump outside
the application limits results in the heat pump
being switched off by the internal control and
safety devices.
Cooling mode with radiator heating systems
is not permitted since radiators do not have
an adequate heat transfer surface area.
Intended use includes the following:
–observance of accompanying operating,
installation and maintenance instructions
for the product and any other system com-
ponents
–installing and setting up the product in ac-
cordance with the product and system ap-
proval
–compliance with all inspection and main-
tenance conditions listed in the instruc-
tions.
Intended use also covers installation in ac-
cordance with the IP code.
Any other use that is not specified in these
instructions, or use beyond that specified in
this document, shall be considered improper
use. Any direct commercial or industrial use
is also deemed to be improper.
Caution.
Improper use of any kind is prohibited.
1.2 General safety information
1.2.1 Risk caused by inadequate
qualifications
The following work must only be carried out
by competent persons who are sufficiently
qualified to do so:
–Set-up
–Dismantling
–Installation
–Start-up
–Inspection and maintenance
–Repair
–Decommissioning
▶Proceed in accordance with current tech-
nology.
1.2.2 Risk of injury due to the heavy weight
of the product
The product weighs over 50 kg.
▶Make sure that the product is carried by at
least two people.
▶Use suitable transport and lifting equip-
ment, in accordance with your job safety
analysis.
▶Use suitable personal protective equip-
ment: Gloves, safety footwear, protective
goggles, protective helmet.
1.2.3 Risk of death due to lack of safety
devices
The basic diagrams included in this docu-
ment do not show all safety devices required
for correct installation.
▶Install the necessary safety devices in the
installation.
▶Observe the applicable national and inter-
national laws, standards and directives.
1.2.4 Risk of death from electric shock
There is a risk of death from electric shock if
you touch live components.
Before commencing work on the product:
▶Disconnect the product from the power
supply by switching off all power supplies
at all poles (electrical partition in over-
voltage category III for full partition, e.g.
fuse or circuit breaker).
▶Secure against being switched back on
again.
0020213395_04 Installation and maintenance instructions 5
▶Wait for at least 3 minutes until the capa-
citors have discharged.
▶Check that there is no voltage.
1.2.5 Risk of burns due to hot and cold
components
There is a risk of burns from any uninsu-
lated pipelines and from the electric back-
up heater.
▶Only carry out work on the components
once they have reached environmental
temperature.
1.2.6 Risk of material damage due to an
unsuitable installation surface
An uneven installation surface may cause
leaks in the product.
If the installation surface does not have suffi-
cient load-bearing capacity, the product may
topple.
▶Make sure that the product is positioned
flush against the installation surface.
▶Ensure that the installation surface has
sufficient load-bearing capacity to bear the
operating weight of the product.
1.2.7 Risk of material damage due to
malfunctioning
Not rectifying faults, changing the safety
devices and failing to carry out maintenance
can cause malfunctioning and pose safety
risks during operation.
▶Ensure that the heating installation is in a
technically perfect condition.
▶Ensure that no safety or monitoring
devices have been removed, bridged or
disabled.
▶Immediately eliminate any faults and dam-
age that may affect safety.
1.2.8 Risk of injury from freezing caused
by touching refrigerant
The product is delivered with an operational
filling of R410A refrigerant. Escaping refri-
gerant may cause freezing if the exit point is
touched.
▶If refrigerant escapes, do not touch any
components of the product.
▶Do not inhale any vapours or gases that
escape from the refrigerant circuit as a
result of leaks.
▶Avoid skin or eye contact with the refriger-
ant.
▶In the event of skin or eye contact with the
refrigerant, seek medical advice.
1.2.9 Risk of material damage caused by
using an unsuitable tool
▶Use the correct tool.
1.2.10 Risk of material damage caused by
condensate inside the house
In heating mode, the lines between the heat
pump and the heat source (environment cir-
cuit) are cold, which means that condensate
may form on the lines in the house. In cooling
mode, the lines in the building circuit are so
cold that condensate may form if the temper-
ature falls below the dew point. Condensate
may lead to material damage, for example
due to corrosion.
▶Ensure that you do not damage the heat
insulation on the lines.
1.2.11 Risk of material damage caused by
frost
▶Do not install the product in rooms prone
to frost.
1.2.12 Risk of environmental damage
caused by refrigerant
The product contains a refrigerant with con-
siderable GWP (GWP = Global Warming Po-
tential).
▶Ensure that the refrigerant does not es-
cape into the atmosphere.
▶If you are a competent person who is qual-
ified to work with refrigerants, you must
wear appropriate protective equipment
when servicing the product, and access
the refrigerant circuit, if required. Recycle
or dispose of the product in accordance
with the applicable regulations.
6Installation and maintenance instructions 0020213395_04
1.3 Regulations (directives, laws,
standards)
▶Observe the national regulations, stand-
ards, directives, ordinances and laws.
0020213395_04 Installation and maintenance instructions 7
2 Notes on the documentation
2.1 Observing other applicable documents
▶Always observe all the operating and installation instruc-
tions included with the system components.
2.2 Storing documents
▶Pass these instructions and all other applicable docu-
ments on to the end user.
2.3 Validity of the instructions
These instructions apply only to:
Product
VWF 57/4 230V
VWF 87/4 230V
VWF 117/4 230V
3 System overview
3.1 Heat pump system design
A
B
A
B
3 1 2
412
The heat pump system consists of the following components:
–Heat pump (1)
–System control (2) (from VRC 700)
–Outdoor temperature sensor with DCF receiver
–System sensor, if required
–With ground heat source: Ground collector (3)
–With well water heat source: Ground water module (4)
The heat pump system generates heat for heating installa-
tions and in domestic hot water generation by extracting the
thermal energy from a heat source circuit and releasing this
into the heating circuit via the internal refrigerant circuit. The
heat pump can be connected to two different types of heat
source (geothermal energy and ground water with a transfer
station between them). At the same time, there is an oppor-
tunity for active cooling to take place via circulation reversal.
3.1.1 Heat pump
–Fulfils the heating demand of the system control down to
a minimum outdoor temperature and up to a maximum
target flow temperature.
–Fulfils the cooling demands of the system control up to a
maximum source temperature.
–Domestic hot water generation with external domestic hot
water cylinder
3.1.2 Ground water module
Heat transfer from the ground water to the brine heat transfer
medium in the heat pump.
3.1.3 Passive cooling module (optional)
When using ground or ground water as a heat source, the
heat of the heating water is transferred to the heat source
medium purely using circulation pumps and valve switching.
3.2 Functionality
3.2.1 Heat pump
2
3
1
4
5
6
7
8
9
10
11
12
13
1 Heating installation 2 Domestic hot water
cylinder (optional)
8Installation and maintenance instructions 0020213395_04
3 Heating circuit
4 Compressor
5 Refrigerant circuit
6 Brine circuit
7 Heat source
8 Brine pump
9 Evaporator
10 Electronic expansion
valve
11 Condenser
12 Heating/cylinder char-
ging diverter valve
13 Electric back-up heater
The heat pump system uses geothermal energy or ground
water as the heat source.
The heat pump consists of the following separate circuits
which are coupled with one another by means of heat ex-
changers. These circuits are:
–The brine circuit, which extracts the heat energy from
the ground or the ground water and transfers it to the
refrigerant circuit
–The refrigerant circuit, which is used to bring the heat
energy from the heat source to a usable, higher temper-
ature level and deliver it to the heating circuit
–The heating circuit, which is used to heat up the living
rooms
The refrigerant circuit is connected via the evaporator to the
heat source, from which it extracts heat energy. At the same
time, the physical state of the refrigerant changes; it evapor-
ates. The refrigerant circuit is connected via the condenser to
the heating installation, to which it releases the heat energy
again. In so doing, the refrigerant becomes liquid again; it
condenses.
As heat energy can only pass from a body at a higher tem-
perature to a body at a lower temperature, the refrigerant in
the evaporator must have a lower temperature than the heat
source. On the other hand, the temperature of the refrigerant
in the condenser must be higher than that of the heating wa-
ter in order to be able to release the heat energy to it.
These different temperatures are produced in the refrigerant
circuit by means of a compressor and an expansion valve,
which are located between the evaporator and condenser.
The refrigerant flows in vapour form from the evaporator into
the compressor, where it is compressed. This causes the
pressure and temperature of the refrigerant vapour to rise
sharply. After this process, it flows through the condenser,
where it releases its heat energy to the heating water by
condensation. It flows as a liquid into the expansion valve,
where it expands significantly and, in so doing, loses much
of its pressure and temperature. This temperature is now
lower than that of the brine that flows through the evaporator.
The refrigerant can thus absorb more heat energy in the
evaporator, turning into vapour in the process and flowing
to the compressor. The cycle starts again.
The evaporator and parts of the refrigerant circuit inside the
heat pump are cold-insulated, meaning that no condensate
can accumulate. Any small amounts of condensate which
may form evaporate as a result of the heat generated inside
the heat pump.
The heating water, which, when supplied, is colder in the
flow than the room temperature, absorbs heat energy
from the rooms and is pumped by the heating pump to the
condenser (which works as an evaporator when in cooling
mode). This heat energy is absorbed by the refrigerant and
heated to a higher temperature level using the compressor.
The heat energy is then delivered to the brine in the evapor-
ator (which works as a condenser when in cooling mode).
The cooled refrigerant is guided to the expansion valve to
enable heat energy to be absorbed from the condenser
again. The brine pump transports the hot brine into the earth,
where the heat energy is dissipated.
During the installation, it may be useful to exclude some
rooms (e.g. the bathroom) from the cooling function and to
actuate isolation valves especially for this. The heat pump
electronics system emits a signal that can be used for actu-
ating these.
A passive cooling module is also available as an alternative,
whereby heat energy is transported via underfloor heating,
for example, from the rooms to the ground without the com-
pressor operating and therefore without the refrigerant circuit
operating.
If required, the integrated electric back-up heater can be
activated at different output levels via the heat pump display.
The electric back-up heater is then actuated by the system
control.
3.2.2 Weather-compensated system control
The heat pump system is equipped with a weather-com-
pensated system control that provides the heating, cooling
and domestic hot water mode depending on the control type
and controls this in automatic mode.
The control changes the target flow temperature based on
the outdoor temperature. The outdoor temperature is meas-
ured by a separate sensor which is installed outdoors, and
the results are transmitted to the control. The room temper-
ature depends only on the preset values. The system com-
pensates for the effect of the outdoor temperature. Domestic
hot water generation is not affected by the weather com-
pensation. The instructions for the system control describe
how to install and operate the product.
3.2.3 Display of the energy consumption, energy
yields and efficiencies
The product, the system control and the app show approx-
imate values for energy consumption, energy yields and ef-
ficiencies, which are extrapolated based on calculation al-
gorithms.
The values that are displayed in the app may differ from the
other display options due to staggered transfer intervals.
The determined values depend on:
–Installation and system of the heating installation
–User behaviour
–Seasonal weather effects
–Various tolerances of unit-internal components
The recording of the values only includes the product in the
factory-delivered condition. Supplementary accessories,
even if they are installed on the product, as well as any other
components in the heating system and other external con-
sumers, are not part of the data recording.
Deviations between the determined values and the actual
values may be significant. The determined values are there-
fore not suitable for creating or comparing energy billing, for
example.
When replacing the PCB, the values for energy consump-
tion, energy yields and efficiencies are reset in the heat
pump's control panel.
0020213395_04 Installation and maintenance instructions 9
3.3 Safety devices
3.3.1 Frost protection function
The frost protection function for the system is controlled via
the system control. If the system control fails, the heat pump
guarantees limited frost protection for the heating circuit.
3.3.2 Protection against low heating water
pressure
This function continuously monitors the pressure of the heat-
ing water in order to prevent a possible loss of heating water.
If the water pressure falls below the minimum pressure, an
analogue pressure sensor switches off the heat pump and
switches the other modules, where these exist, to standby
mode. The pressure sensor switches the heat pump on
again if the water pressure reaches the operating pressure.
–Min. heating circuit pressure: ≥0.05 MPa (≥0.50 bar)
–Min. heating circuit operating pressure: ≥0.07 MPa
(≥0.70 bar)
3.3.3 Brine pressure detector
The brine pressure detector continuously monitors the fluid
pressure in the environment circuit in order to prevent a pos-
sible shortage of fluid. If the fluid pressure falls below the
minimum pressure, an analogue pressure sensor switches
off the heat pump and switches the other modules, where
these exist, to standby mode. The pressure sensor switches
the heat pump on again if the fluid pressure reaches the op-
erating pressure.
–Minimum brine fluid pressure: ≥0.05 MPa (≥0.50 bar)
–Min. brine fluid operating pressure: ≥0.07 MPa
(≥0.70 bar)
3.3.4 Freeze protection
This function prevents the evaporator from freezing when the
heat source temperature drops below a certain value.
The outlet temperature of the heat source is constantly
measured. If the outlet temperature of the heat source falls
below a certain value, the compressor temporarily switches
off and displays a status message. If this fault occurs three
times in a row, it is switched off and a fault message is
displayed.
3.3.5 Pump- and valve-blocking protection system
This function prevents the pumps for heating water and
brine and all diverter valves from sticking. The pumps and
the valves, which were out of operation for 23 hours, are
switched on for 10 - 20 seconds, one after the other.
3.3.6 High-pressure pressure switch in the
refrigerant circuit
The high-pressure pressure switch shuts down the heat
pump if the pressure in the refrigerant circuit is too high. Fol-
lowing a waiting period, the heat pump attempts to start once
more. After three failed start attempts in succession, a fault
message is displayed.
–Max. refrigerant circuit pressure: 4.60 MPa (g) (46.00 bar
(g))
–Waiting period: 5 minutes (after the first occurrence)
–Waiting period: 30 minutes
(after the second and every further occurrence)
The fault counter is reset if both of the following conditions
are met:
–Heat requirement without switching off prematurely
–60 minutes of uninterrupted operation
3.3.7 Hot gas thermostat in the refrigerant circuit
The hot gas thermostat shuts down the heat pump if the tem-
perature in the refrigerant circuit is too high. Following a wait-
ing period, the heat pump attempts to start once more. After
three failed start attempts in succession, a fault message is
displayed.
–Max. refrigerant circuit temperature: 135 ℃
–Waiting period: 5 minutes (after the first occurrence)
–Waiting period: 30 minutes
(after the second and every further occurrence)
The fault counter is reset if both of the following conditions
are met:
–Heat requirement without switching off prematurely
–60 minutes of uninterrupted operation
3.3.8 Safety cut-out (SCO) in the heating circuit
If the temperature in the heating circuit of the internal elec-
tric back-up heater exceeds the maximum temperature, the
safety cut-out shuts down the electric back-up heater as a
securing measure. Following a waiting period, another at-
tempt is made to start the electric back-up heater. A fault
message is displayed that can only be reset by pressing the
Reset button or by switching the heat pump off and on again.
–Max. heating circuit temperature: 85 ℃
10 Installation and maintenance instructions 0020213395_04
4 Product description
4.1 Product design
4.1.1 Front view, open
1
2
3
4
1 Electronics box
2 Control panel
3 Heating/cylinder char-
ging diverter valve
4 4-port valve
1
2
3
4
5
11
12
9
10
8
7
6
1 Electric back-up heater
2 Condenser
3 Heating pump
4 Electronic expansion
valve EVI (intermediate
circuit injection)
5 Heating circuit
filling/draining cock
6 Data plate
7 Carrying straps for
transport
8 Compressor
9 Electronic expansion
valve
10 Brine circuit
filling/draining cock
11 Brine circuit pump
12 Evaporator (not visible)
4.1.2 Rear view
1
2
4
3
5
6
7
1 Connection: From the
heat pump to the heat
source (cold brine, B)
2 Connection: From the
heat source to the heat
pump (hot brine, A)
3 Hot water return
4 Heating circuit dia-
phragm expansion ves-
sel connection
5 Heating return
6 Heating flow
7 Recessed handles and
grommet
4.2 Information on the data plate
Information on the data plate Meaning
Rated voltage of the com-
pressor, pumps and control
Back-up heater rated voltage
P Max
Max. rated power of the
compressor, pumps and
control
P Max
Max. rated power of the
back-up heater
I +
30 A
+
In-rush current
Refrigerant type, fill quantity,
permissible rated excess
pressure
COP B0/W35 /W45 /W55 Coefficient of performance
at a brine temperature of
0 °C and a heating flow
temperature of 35/45/55 °C
B0/W35 /W45 /W55 Heat output at a brine tem-
perature of 0 °C and heat-
ing flow temperature of
35/45/55 °C
COP W10/W35 /W45 /W55 Coefficient of performance at
a ground-water temperature
of 10 °C and a heating flow
temperature of 35/45/55 °C