WATERKOTTE Basic Line BS 7010 Technical manual

Planning and installation
Basic Line Ai1 Air
Air to water heat pump
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: [phone], Fax: [phone], E-Mail: [e-mail]
Internet: http://www.waterkotte.de
21.10.2015 / Z21437
Basic Line Ai1 Air –Indoor unit
Basic Line BS7010 –Hydraulikstation
- Indoor unit
Basic Line Ai1 Air /Basic Line BS 7010
- Outdoor unit
Basic Line Ai1 Air /Basic Line BS 7006
- Outdoor unit

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Copyright 2014 by
WATERKOTTE GmbH
Gewerkenstraße 15, 44628 Herne, Germany
All rights reserved. Reproduction, duplication as well as translation of this
publication, or excerpts therefrom, require prior written approval by
WATERKOTTE GmbH.
Illustrations and diagrams serve as explanatory description and shall not be
used as drawings for construction, offers or installation.
All specifications comply with the state of technology at time of printing; we
reserve the right to make changes that serve technical progress.
This publication has been prepared with all reasonable care.
WATERKOTTE GmbH does not assume any liability for remaining errors or
omissions, or for possible damages.
Note: This symbol applies only to countries within the European Union (EU).
This symbol is in compliance with Directive 2002/96/EC, Article 10. The
product has been designed and manufactured with high-quality materials
and components which are suitable for recycling.
This symbol means that electrical and electronic equipment, at the end of
its useful life, shall be disposed of separately from household waste. Please
dispose of this equipment at your designated collection point or local recy-
cling centre.
In the European Union, different collection systems are available for used
electrical and electronic equipment. Please help us conserve the environ-
ment we live in!
Never vent R410A into the atmosphere:
R410A is a fluorinated greenhouse gas according to Kyoto Protocol and
has a global warming potential (GWP) of 1975.

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Content
1Safety.....................................................................................................................................5
1.1 Intended use...................................................................................................................... 5
1.2 Basic safety precautions.................................................................................................... 5
1.2.1 Keep information available .................................................................................... 5
1.2.2 Before initial use.................................................................................................... 5
1.2.3 Environmental protection ...................................................................................... 6
1.2.4 Modifications and repairs on the heat pump ......................................................... 6
1.3 Hazards............................................................................................................................. 6
1.4 Operator's duty of care...................................................................................................... 8
1.5 Other applicable documents.............................................................................................. 8
2Product description and scope of delivery ................................................................................9
2.1 Overview............................................................................................................................ 9
2.1.1 Basic Line Ai1 Air /BS 7010 (outdoor module) .................................................... 10
2.1.2 Basic Line Ai1 Air (indoor module)....................................................................... 10
2.1.3 Basic Line BS Hyd 5010 hydraulic station........................................................... 10
3Components and installation..................................................................................................11
3.1 Heating system Basic Line Ai1 Air BS 7010 / BS 7006.................................................... 11
3.2 Structure and control....................................................................................................... 11
3.2.1 Electronic heat pump control .............................................................................. 11
4Transport to installation site ...................................................................................................12
4.1 Environmental conditions for installation (indoor module) ................................................. 12
4.2 Residual head circulation pump (heating)......................................................................... 12
5Installation and connection ....................................................................................................13
5.1 Installation and connection of indoor unit......................................................................... 13
5.2 Environmental conditions for installation .......................................................................... 13
5.3 Dimensions and connections outdoor module BS 7010 (5010.5) .................................... 14
5.4 Dimensions and connections outdoor module BS 7006 (5006.5) .................................... 15
5.5 Dimensions and connections (indoor module) Basic Line Ai1 Air ..................................... 16
5.6 Dimensions and connections (indoor module) BS Hyd 5010 hydraulic station ................. 17
5.7 Installation of cover and cladding panels.......................................................................... 18
5.8 Disassembly of cladding panels....................................................................................... 18
5.9 Disassembly of cover and cladding panels (outdoor module)........................................... 18
6Installation and connection of the outdoor module ..................................................................19
6.1 Selecting a location for outdoor module .......................................................................... 19
6.2 Clearance for ventilation and operation............................................................................ 20
6.3 Installation in base plate or on the wall............................................................................. 20
6.4 Installation and space requirement .................................................................................. 21
7Connection lines ...................................................................................................................22
7.1 Refrigerant charge and additional charge ........................................................................ 22
7.2 Oil traps........................................................................................................................... 23
7.3 Insulation ......................................................................................................................... 23
7.3.1 Tube airtight testing method (recommended procedure), test equipment nitrogen24
7.4 Connection outdoor module / indoor module (refrigerant lines) Basic Line Ai1 Air............ 25
7.5 Connections (refrigerant and heating) indoor module hydraulic station............................. 26

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7.6 Connections outdoor module (refrigerant line).................................................................. 27
8Refrigerant ............................................................................................................................28
8.1 Requirements on handling of R410A refrigerant............................................................... 28
8.2 Safety guidelines for the handling of refrigerants .............................................................. 28
8.3 Charging refrigerant circuit............................................................................................... 29
8.4 Mounting (heating /domestic water side) ......................................................................... 30
9Electrical work.......................................................................................................................31
9.1 Electrical connection outdoor module.............................................................................. 32
9.1.1 Cable cross sections/types................................................................................. 32
9.2 Electrical connection (indoor module) (hydraulic station / control module)........................ 32
9.2.1 Installing external wall sensor .............................................................................. 32
9.2.2 Power supply- Heating element.......................................................................... 32
9.2.3 Heating element - thermostat setting .................................................................. 32
9.3 Electrical and BUS connection (outdoor module BS 7010.5) ........................................... 33
9.4 Electrical and BUS connection (outdoor module, BS 7006.5) .......................................... 34
9.5 Electrical connection Basic Line Ai1 Air (5010.5) (indoor module)..................................... 35
9.6 Electrical and BUS connection Basic Line BS Hyd 5010 hydraulic station ....................... 35
9.6.1 DIP-Switch (outdoor module).............................................................................. 35
9.7 Electrical wiring diagram Basic Line Ai1 Air / BS 7010 (outdoor module) ......................... 36
9.8 Electrical wiring diagram - Basic Line Ai1 Air (indoor module) .......................................... 37
9.9 Electrical wiring diagram - Basic Line BS Hyd 5010 hydraulic station (indoor module) ..... 38
9.10 WWPR2 Controler - connections..................................................................................... 39
9.11 Electrical connections ...................................................................................................... 40
10 Commissioning .....................................................................................................................41
10.1 Pre-startup checks .......................................................................................................... 41
10.2 Initial start of heat pump .................................................................................................. 43
10.3 Control of entire operation ............................................................................................... 44
10.4 Turning heat pump off ..................................................................................................... 44
10.5 Taking heat pump out of operation for extended period .................................................. 44
11 Technical data ......................................................................................................................45
12 Connection diagram..............................................................................................................46
12.1 Basic Line Ai1 Air with underfloor heating, without single room control............................ 46
12.2 Basic Line Ai1 Air with underfloor heating, with single room control ................................ 47
12.3 Basic Line Ai1 Air with radiators / fan convectors ........................................................... 48
12.4 Basic Line Ai1 Air with hydraulic compensator................................................................ 49
12.5 Basic Line Ai1 Air hydraulic compensator and additional heater ...................................... 50
12.6 Basic Line BS 7010 with underfloor heating, without single room control ........................ 51
12.7 Basic Line BS 7010 with underfloor heating, without single room control, decentral domestic
hot water preparation................................................................................................................. 52
12.8 Legend (hydraulic schemes) ............................................................................................ 53
13 Refrigeration circuit Basic Line Ai1 Air / BS 7010 ....................................................................55
14 Maintenance and inspection ..................................................................................................57

Safety
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1Safety
1.1Intended use
Your WATERKOTTE heat pump of the Basic Line series is used for space
heating and cooling, and heating of domestic water.
An outdoor module, which is coupled to a heat source (air) that is available
year-round, serves as heat generator.
Project planning of the heat source system must be performed in compli-
ance with the technical information provided by WATERKOTTE for layout of
heat source systems. Heat pump shall only be turned on after the refriger-
ant connections are completely charged, and the other hydraulic circuits
are completely charged and vented, and all electrical connections are
properly completed.
Commissioning may only be carried out by trained professionals. Damages
caused by non-compliance with above mentioned items are not covered by
the warranty (see enclosed Exclusion of Warranty).
1.2Basic safety precautions
1.2.1 Keep information available
In addition to the operating manual, also furnish operating instructions in
terms of Labour Protection Law and Work Equipment ordinance. Keep all
safety and operating signs on the heat pump in fully legible condition at all
times. Replace damaged or illegible signs immediately.
1.2.2 Before initial use
Before initial use of your WATERKOTTE heat pump, familiarise yourself with:
Operating and control elements of your WATERKOTTE heat pump
Equipment of heat pump
Operation of heat pump
Immediate surroundings of heat pump
Safety devices of heat pump
Before initial start, perform the following steps:
Ensure that all safety devices are installed and function as intended.
Check heat pump for visible damage. Eliminate any detected defects
immediately. Heat pump may only be operated in perfect condition!
Ensure that only authorised personnel is in the work area of the heat
pump and that no other persons are endangered when heat pump is
started.
Remove all objects and other materials that are not required for opera-
tion of the heat pump from the work area of the heat pump.
Activate the electrical connection; the module must be in standby mode
(oil sump heater active).
Check heating circuit temperature: Temperature heating circuit below
16 °C.

Safety
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1.2.3 Environmental protection
Observe the regulations regarding waste avoidance and proper waste
recycling or disposal when performing any kind of work on and with the
heat pump.
Ensure that particularly during installation and maintenance work, as well
as when placing out of operation, groundwater pollutants such as
grease, oils, refrigerants, solvent-containing cleaning fluids, etc. do not
contaminate the ground or enter into the sewer system!
These substances must be collected, stored, transported, and disposed
of in suitable containers.
1.2.4 Modifications and repairs on the heat pump
For safety reasons, no unauthorised modifications shall be performed on
the heat pump.
Thus, all intended modifications are subject to written approval by
WATERKOTTE.
Use only original WATERKOTTE spare parts.
Original parts are specifically designed for your heat pump. Externally pro-
cured parts provide no guarantee that they are designed and manufactured
in compliance with relevant usage and safety requirements.
Parts and special equipment not delivered by WATERKOTTE are not ap-
proved for use on the heat pump.
1.3Hazards
Observe the following points to avoid life-threatening injuries and damages
to the heat pump during operation:
Risk of death by electric shock!
Do not use water or other liquids to clean the system!
Keep all electrical supply modules locked at all times!
Any work on the electrical equipment of the heat pump shall only be per-
formed by professional electricians!

Safety
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Leaking refrigerant can result in severe personal injuries (suffocation or hy-
pothermia)!
Avoid direct contact with refrigerant!
When selecting the installation site, observe the minimum volume under
consideration of the refrigerant applied (as per EN 378-1).
Risk of burns!
During operation, surface temperatures (compressor and pressure line) can
climb above 100 °C or drop below 0 °C.
Do not remove housing cover during operation!
Allow heat pump to cool down before removing cover.
Risk of injury!
Risk of chemical burns when skin comes in direct contact with lubricant
leak.
Wear suitable clothing when performing maintenance work on the heat
pump!
Do not put your fingers or others into the fan, or evaporator.
The inside parts of the heat pump may run at high speed or high tempera-
ture, they could cause serious injury. Do not remove the grills on the fan
outlet and top cover.
The hot water probable need to mix with cold water for terminal usage, too
hot water (over 50 °C in the heating module may cause injury.
The installation height of power supply should be over 1.8m, if any water
may spatter, the module can be safe from water.
Electrostatic charge!
Electronic components can be damaged by electrostatic processes.
Ground yourself before touching electronic components.
Risk of total loss!
Repeated restart of the heat pump can result in total loss! In case of heat
pump failure, an inspection by qualified and authorised personnel must be
performed before restart.

Safety
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1.4Operator's duty of care
Your WATERKOTTE heat pump has been designed and built on the basis
of a risk analysis and after careful selection of standards to be observed.
Thus, your heat pump is state-of-the-art and provides for maximum safety.
In practice, however, this safety can only be ensured by taking all necessary
measures. As operator of the heat pump it is your responsibility to plan
these measures and oversee their implementation.
You must ensure that:
The heat pump is only used as intended (see also chapter 1.1,
"Intended use").
The heat pump is only operated in perfect, fully functional condition and
safety devices are checked regularly to ensure that they are working
properly.
The operating manual is available in perfect condition at the heat pump
at all times.
The heat pump is operated, maintained and repaired only by adequately
qualified and authorised personnel.
None of the safety and warning notices on the heat pump are removed
or damaged.
1.5Other applicable documents
Operating manual: WATERKOTTE heat pump controller.
WATERKOTTE technical information

Product description and scope of delivery
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2Product description and scope of delivery
2.1Overview
1
Basic Line Ai1 Air /BS 7010 - (outdoor module)
2
Basic Line Ai1 Air /BS 7006 - (outdoor module)
3
Basic Line Ai1 Air - (indoor module)
4
Basic Line BS Hyd 5010 hydraulic station –(indoor
module)
4
3
1
2

Product description and scope of delivery
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2.1.1 Basic Line Ai1 Air /BS 7010 (outdoor module)
The device contains:
Compressor, inverter controlled
Evaporator
Fans
Inverter board, EVD
2.1.2 Basic Line Ai1 Air (indoor module)
The indoor module contains:
Integrated hot water tank 170 l
Monochrome, semi-graphic, 8-line display
Central power switch
6 convenient buttons and 3 indicator LEDs
Intuitive control software BasicPro
Speed-controlled circulation pump, efficiency class A
Integrated electrical heating element 6 kW
Combination fitting with safety valve
Air vent
3-way motor ball valve
membrane expansion tank
2.1.3 Basic Line BS Hyd 5010 hydraulic station
The hydraulik station contains:
Monochrome, semi-graphic, 8-line display
Central power switch
Outdoor temperature sensor
6 convenient buttons and 3 indicator LEDs
Intuitive control software BasicPro
Speed-controlled circulation pump, efficiency class A
Integrated electrical heating element 6 kW
Combination fitting with safety valve
Metal housing (W x H x D) 743 x 750 x 303 mm
Docking features for 1 additional module: e.g. domestic hot water tank,
living area ventilation
Series options
Hydraulic station incl. control (only heating)
- Art. Nr.: BS701059CH
Hydraulic station incl. control (heating and domestic hot water)
- Art. Nr.: BS701059CHW

Components and installation
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3Components and installation
3.1Heating system Basic Line Ai1 Air BS 7010 / BS 7006
The newly developed heating system was designed as a compact air
source heat pump for outdoor installation. It is suitable for heating and
cooling low-energy buildings.
Thanks to the inverter-controlled compressor, the Basic Line Ai1 Air and BS
7010 operate extremely energy-efficiently. Due to the infinitely variable
adjustment of the power it impresses with high performance. Even at
outdoor temperatures of -15 °C, flow temperatures of 55° C are possible
The outdoor module contains all the heat pump technology (nicht der not
the condenser). The control moduel with the tank (Ai1 Air) or the hydraulic
module BS Hyd 5010 are installed in the building.
3.2Structure and control
Complete hot water heating system with integrated central hot water supply
(option), consisting of: heat generator (heat pump), regulation and electrical
control, complete electrics and control system, semi-graphic display.
3.2.1 Electronic heat pump control
The heat pump control is included in the delivery scope of the
WATERKOTTE heat pump. Use in other than
WATERKOTTE heat pumps will void any warranty claim.
Info: Technical details, operation and warning messages (see Operating
manual for heat pump control ).
The control is used to control and monitor heating systems that are operat-
ed with WATERKOTTE compact heat pumps according to technical guide-
lines of WATERKOTTE Wärmepumpen GmbH. All tasks to do with control
are fulfilled (depending on the external temperature, control, monitoring,
self-diagnosis, saving of data in case of breakdown, etc.
WATERKOTTE explicitly states that function warranty will become void if
used on systems not approved by WATERKOTTE. Any liability for conse-
quential damages due to incorrect function within these systems shall be
explicitly excluded.

Transport to installation site
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4Transport to installation site
Modules of the Basic Line 7010 series are delivered ready-to-connect with
metal cladding. The Basic Line Ai1 Air / Basic Line 7010 are delivered ready
for connection.
Since the heat pump module weighs 120 kg or more, for instance, at least
two people are required for transport.
The devices are mounted on top of each other only at the installation site.
During transport it must be ensured that appropriate means of transport are
used (lift truck, transport rollers, handcart).
It is crucial that the heat pump is transported upright!
Transport in tilted position (45°) is permitted only temporarily during inser-
tion. Horizontal transport results in oil displacement in compressor and can
cause damage to the heat pump during start-up.
After carton is removed or opened it is not permitted to tilt the module by
applying pressure to the pipelines or housing enclosure; this could result in
bent housing parts and pipelines.
4.1Environmental conditions for installation (indoor module)
The room must be dry. Room temperature should be between +5 °C and
+25 °C.
4.2Residual head circulation pump (heating)
Residual head circulation pump (heating)
- Hydraulic station BS Hyd 5010
- Indoor module Basic Line Ai1 Air
10 kW ∆t=5K
6 m

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5Installation and connection
5.1Installation and connection of indoor unit
To make hydraulic connections, you must use the supplied material (con-
necting lines and gaskets).
During assembly of connecting lines, use an according tool as brace to
prevent damage to the heat distribution station.
Installation of the indoor unit must be performed on a flat and horizontal
surface.
Wall clearance (free space) in front: at least 1000 mm.
Due to the connections on the rear of the unit, the mounting distance to
the wall (rear, right side, left side) must be selected in such a way that
access is ensured in case of repairs.
Recommendation for good service accessibility: Wall clearance (free
space), left, right 400 mm. Wall clearance rear at least
300 mm.
Figure 1: Recommendation - wall clearance for installation
5.2Environmental conditions for installation
When selecting the installation site, observe the minimum volume under
consideration of the refrigerant applied (as per EN 378-1).
The room must be dry. Room temperature should be between +5 °C and
+25 °C. To facilitate maintenance, the use of a base plate is recommended.
To compensate for minor unevenness, we recommend use of an approx.
10 mm thick rubber mat.

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5.3Dimensions and connections outdoor module BS 7010 (5010.5)
Figure 2: Dimensions outdoor module BS 7010 (all dimensions mm)
A
Cable entries, electrical connection
B
Cover: connection refrigerant line
A
B

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5.4Dimensions and connections outdoor module BS 7006 (5006.5)
Figure 3: Dimensions outdoor module BS 7006 (all dimensions mm)
A
Cable entries, electrical connection
B
Cover: connection refrigerant line

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5.5Dimensions and connections (indoor module) Basic Line Ai1 Air
Figure 4: Dimensions indoor module Basic Line Ai1 Air (all dimensions mm

Installation and connection
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5.6Dimensions and connections (indoor module) BS Hyd 5010 hydraulic station
Figure 5: Dimensions indoor module (buttom)

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5.7Installation of cover and cladding panels
To prevent transport damage, the cover, front and side panels of the heat
pump are enclosed separately.
After establishing all connections, mount them to the required positions (in-
sert and press).
5.8Disassembly of cladding panels
The heat pump is provided with a disassembly tool. Use this tool to remove
the cladding panels to prevent damage.
Procedure:
Keep enough distance with the disassembly tool to the upper/lower
panel edge so as not to damage the retaining bolt (see figure).
The disassembly tool is manually driven into the gap between the front
and side panel with moderate force.
5.9Disassembly of cover and cladding panels (outdoor module)
Cover and cladding panels are fixed with screws. In the case of a disas-
sembly the screws must be removed with an appropriate screwdriver.

Installation and connection of the outdoor module
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6Installation and connection of the outdoor module
6.1Selecting a location for outdoor module
Select a location permitting easy wiring and pipe access to the power
source and indoor module.
Avoid locations exposed to direct sunlight / other heat sources.
Select a location from which noise emitted by the module will not incon-
venience neighbours.
Avoid locations where combustible gases may leak, be produced, flow /
accumulate.
Please note that water may drain from module during operation. Ensure
unobstructed condensation drain.
Select a level location that can handle the weight and vibration of the
module.
Avoid locations where the module could be covered by snow. To pre-
vent snow from blocking / blowing against the air intake in regions sub-
ject to heavy snowfall, special precautions are required (selecting a
higher installation location / installing a protective cover in front of the air
intake). This can reduce airflow and cause malfunctions.
Avoid locations exposed to oil, steam, or sulphuric gas.
To ensure stability, we recommend the use of two concrete brackets in
combination with a gravel bed for condensed water drainage.
Select an installation site where the module is largely protected from for-
eign objects (leaves, etc.). In this connection observe the recommenda-
tions in chapter Maintenance and inspection.
Select an installation site where no foreign material (leaves, etc.) get into
the module.
Do not exceed permissible line length between indoor and outdoor
module.
Risk of injury!
When carrying the module at the bottom there is a risk of crushing the
hands / fingers.

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6.2Clearance for ventilation and operation
When installing outdoor module on a rooftop / other location unprotected
from the wind, align air outlet opening in such a way that it is not directly
exposed to strong winds. Strong wind blowing directly into the air outlet
opening may impede normal airflow and thus cause malfunctions.
Precautions against strong winds can be seen in the following examples:
Align air outlet to nearest wall with a distance of about 50 cm.
Air guide: Position the module in such a way that the air discharged
from the air outlet is guided perpendicular to the direction from which
seasonal strong winds usually blow.
6.3Installation in base plate or on the wall
Secure the base of the module firmly with four M10 screws to a proper
base plate (screws and nuts are not included in delivery). Please note:
Connection directions: The connection (piping and wiring) is performed
from below.
Ensure that water can drain off during defrosting. This can be accom-
plished by excavating the ground.
The installation height depends on the climate conditions at the site. In-
stall the module at a height that takes possible flooding or heavy snow
into account, but at least about 40 cm to 60 cm above the ground to al-
low unobstructed drainage of condensation. This ensures trouble-free
operation even in case of snow.
Note: Ice formation can occur particularly during the cold season. In ex-
treme cases, this can block the fans. Remedial action: Ensure unob-
structed drainage of melted water and remove excessive ice build up
below the module manually if necessary.
Figure 6: Securing in base plate
WATERKOTTE GmbH offers a wall mounting set.
Ensure that the melted water can drain off. Ensure that the entire drain is
frost-free to prevent freezing in the winter. For this purpose, a trace
heating could be applied.
Base plate