WATERKOTTE EcoTouch DS 5050T Technical manual

04.12..2015 / Z21974
Planning and installation
EcoTouch DS 5050T
2-power levels (0 % - 50 % - 100 %)
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: [phone], Service: 0049/(0)2323/9376-350
Fax: [phone], E-Mail: [email protected]
Internet: http://www.waterkotte.de
Z18494 / 20092012

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Copyright 2014 by: WATERKOTTE GmbH. Subject to changes.
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 pro-
gress.
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.

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Content
1Safety......................................................................................................................................... 6
1.1 Intended use..................................................................................................................... 6
1.2 Basic safety precautions................................................................................................... 6
1.2.1 Keep information available .................................................................................. 6
1.2.2 Before initial use.................................................................................................. 6
1.2.3 Environmental protection..................................................................................... 7
1.2.4 Modifications and repairs on the heat pump ....................................................... 7
1.3 Hazards ............................................................................................................................ 7
1.4 Specific types of hazards.................................................................................................. 9
1.5 Operator's duty of care..................................................................................................... 9
1.6 Other applicable documents............................................................................................. 9
2Functional principle of heat pump........................................................................................ 10
3Product description................................................................................................................ 11
3.1 Overview......................................................................................................................... 11
3.2 Overview (unit opened) .................................................................................................. 12
4Components and installation................................................................................................ 13
4.1 Heating system EcoTouch DS 5050T............................................................................ 13
4.2 Installation....................................................................................................................... 13
4.2.1 Heat pump system series EcoTouch DS 5050T ............................................... 13
4.2.2 Heat pump module ............................................................................................ 13
4.3 Electrical equipment....................................................................................................... 14
4.3.1 Electronic heat pump control............................................................................. 14
4.3.2 Sensors.............................................................................................................. 14
4.3.3 COP counter...................................................................................................... 14
4.4 Options ........................................................................................................................... 14
5Transport................................................................................................................................. 15
5.1 Transport to installation site............................................................................................ 15
6Installation............................................................................................................................... 16
6.1 Environmental conditions for installation........................................................................ 16
6.2 Creating the foundation and installing heat pump.......................................................... 17
6.2.1 Laying a foundation for acoustic heat pump...................................................... 17
6.3 Installation of the housing............................................................................................... 18
6.3.1 Removing the housing....................................................................................... 18
7Installation and connection................................................................................................... 19
7.1 Connections EcoTouch DS 5050T (rear side)................................................................ 19
7.2 Connection to heating system........................................................................................ 19
7.2.1 Heat pump with underfloor heating.................................................................... 20
7.2.2 Heat pump with radiators (no cooling mode)..................................................... 20
7.2.3 Heat pump with swimming pool......................................................................... 21
7.3 Connection to heat source.............................................................................................. 21
7.3.1 Water glycol systems......................................................................................... 21
7.3.2 Groundwater heat source.................................................................................. 21
7.3.3 Flow monitoring ................................................................................................. 23
7.3.4 Groundwater installation: Separating heat exchanger ...................................... 24

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8Electrical work ........................................................................................................................ 25
8.1 Electrical installation....................................................................................................... 25
8.2 Installation instructions for external sensor.................................................................... 26
8.3 Cabeling.......................................................................................................................... 26
8.4 Electrical connections..................................................................................................... 27
8.5 Controller WWPR 2........................................................................................................ 28
8.6 Connectors ..................................................................................................................... 29
9Pipe & instrumentation / measurement & control technology .......................................... 30
10 Commissioning....................................................................................................................... 31
10.1 Pre-startup checks.......................................................................................................... 31
10.2 Initial start-up of machine ............................................................................................... 32
10.3 Control of entire operation.............................................................................................. 33
10.4 Turning heat pump off .................................................................................................... 34
10.5 Taking heat pump out of operation for extended period ................................................ 34
11 Troubleshooting ..................................................................................................................... 35
11.1 Possible faults and solutions.......................................................................................... 35
11.1.1 Fault at input side (LP fault)............................................................................... 35
11.1.2 Fault at output side (HP fault)............................................................................ 35
11.1.3 Fault in circulation pumps.................................................................................. 35
11.1.4 Fault in compressor motor................................................................................. 35
12 Safety measures..................................................................................................................... 36
12.1 Pressure limits of compressor........................................................................................ 36
12.2 Motor protection against excessive temperature............................................................ 36
12.3 Refrigerator oil................................................................................................................ 36
13 Maintenance and care............................................................................................................ 37
14 Connection diagrams............................................................................................................. 38
14.1 Heat pump EcoTouch DS5050T with underfloor heating system, without single
room control.................................................................................................................... 38
14.2 Heat pump EcoTouch DS5050T with underfloor heating system and single room
control............................................................................................................................. 39
14.3 Heat pump EcoTouch DS5050T with underfloor heating system, without single
room control, with hygienic hot water heating................................................................ 40
14.4 Heat pump EcoTouch DS5050T ground water or ground –with connection
accessory F10815 (option)............................................................................................. 41
14.5 Heat pump EcoTouch DS5050T ground water or ground –with connection
accessory F10815 (option)............................................................................................. 42
14.6 Description of the parts in the connection diagram........................................................ 43
15 Technical data......................................................................................................................... 45

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Note: This symbol mark applies only to countries within the European Union
(EU).
This symbol mark is in compliance with Directive 2002/96/EG, Article 10.
The product has been designed and manufactured with high-quality mate-
rials 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 to conserve the envi-
ronment we live in!
Do not release R410A into the atmosphere:
R410A is a fluorinated greenhouse gas according to Kyoto Protocol and
has a global warming potential (GWP) of 1600.

Safety
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1Safety
1.1 Intended use
Your WATERKOTTE heat pump is used for space heating and cooling, and
heating of domestic water.
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 refrigerant connections are
completely filled, and the other hydraulic circuits are completely filled 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).
1.2 Basic 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 condi-
tion 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 work:
Ensure that all safety devices are installed and function as intended.
Check heat pump for visible damage. Remedy any detected defects
immediately.
Heat pump must be in perfect condition during operation!
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.

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, pollutants such as grease, oil, refriger-
ant, solvent- containing cleaning fluids, etc. do not contaminate the
ground or enter the sewer system!
These materials must be collected, stored, transported and disposed of
in appropriate 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 spare parts from WATERKOTTE.
Original spare parts are specially designed for your heat pump. Externally
procured parts provide no guarantee that they are designed and manufac-
tured 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.
1.3 Hazards
Observe the following points to avoid life-threatening injuries and damages
to the heat pump during operation:
Warning! Risk of electric shock!
Do not use water or other liquids to clean the unit!
Keep all electrical supply units locked at all times!
Any work on the electrical equipment of the heat pump shall only be per-
formed by professional electricians!
Discharging refrigerant can cause severe personal injury (suffocation or hy-
pothermia)!
Avoid contact with refrigerant!
Note the minimum volume of the installation room and consider the type of
the refrigerant (EN 378-1).
Warning! Risk of suffocation!
The packaging is not a toy! The packaging must be disposed of environ-
mentally acceptable.

Safety
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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 has a direct contact with lubricant leak.
Wear suitable clothing when performing maintenance work on the heat
pump!
Risk of injury in case of leakage in cooling circuit!
Skin contact with refrigerant may cause freezing of tissue and frostbites.
High vapour concentrations can cause headaches, dizziness, fatigue, nau-
sea and even unconsciousness. Irregular heartbeat (arrhythmia).
Avoid contact with refrigerant! Do not expose to heat, sparks, naked light or
other ignition sources!
Electrostatic charge!
Electronic components can be damaged by electrostatic processes.
Ground yourself before touching electronic components.
Risk of total loss!
Repeated restart of heat pump can result in total loss!
In case of heat pump failure, before restart an inspection by qualified
and authorised personnel must be performed.
Due to test bench operation, the heat pump can have ethylene glycol resi-
dues.

Safety
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1.4 Specific types of hazards
To avoid damage to machine or life-threatening injuries during installation of
machine, the following points must be observed:
Machine parts that are improperly placed or incorrectly attached can fall
down or overturn.
Sharp-edged machine parts that are still exposed and accessible can
result in injury.
Incorrectly installed lines (e.g. insufficient bending radius) can cause
smouldering and cable fires.
Risk of chemical burns when skin comes in direct contact with lubricant
leak.
Electronic components can be damaged by electrostatic processes.
During operation, surface temperatures (compressor and pressure line)
can climb above 100 °C or drop below 0 °C.
Serious burns/frostbites can occur. Before working on the compressor:
Switch off unit and allow to cool down.
1.5 Operator'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.
1.6 Other applicable documents
Operating manual: WWPR WATERKOTTE heat pump controller.

Functional principle of heat pump
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2Functional principle of heat pump
The heat pump is used to produce thermal energy for space heating and, if
required, domestic water heating. The medium used as heat source (WQ) is
the ground.
It is also possible to cool a building.
To utilise ground as thermal energy, for domestic water heating and cooling
in your home, you need the following:
a heat source (borehole with geothermal energy probes or groundwater
extraction / discharge)
heating system EcoTouch DS 5050T
domestic hot water tank
Figure 1: Energy share when using a geothermal energy pump
Heat source
Low temperature
Driving energy
Energy output
Heat pump

Product description
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3Product description
3.1 Overview
Figure 2: Heating system EcoTouch DS 5050T
1
ON / OFF switch
2
Control panel (electronic heat pump controller)

Product description
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3.2 Overview (unit opened)
Illustration 3: EcoTouch DS 5050T (top view, opened
1
Safety group with manometer: relief valve, bleeder
2
Connection terminal

Components and installation
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4Components and installation
4.1 Heating system EcoTouch DS 5050T
All components of the heating system are mounted in a protective steel
plate housing which is intended for installation inside. The base frame con-
sists of a bent, thick-walled sheet steel. Together with the rear panel frame,
which also consists of a thick-walled sheet steel, it forms a unit. Side pan-
els, cover, front and the tilt-mounted, ergonomic control panel can be re-
moved.
All enclosure components are reliably and permanently protected by pow-
der-coating and a stove enamel finish. A sound insulation ensures low noise
emissions.
4.2 Installation
4.2.1 Heat pump system series EcoTouch DS 5050T
The heat pump is designed as complete operational unit for thermodynamic
space heating, expandable to domestic hot water production.
Functions: Heat pump, domestic hot water heating system, natural cooling
(option), regulation and electrical control.
All dynamic components are located on an internal chassis (dual chassis
construction), separated from the external housing. The pipe joints between
internal and external chassis are flexibly mounted to prevent structure-born
noise transmission within the unit.
4.2.2 Heat pump module
The series 5050T is provided with two compressors (power level:
50 % or 100 %). The compressors feature a fully hermetic design in ap-
proved leading scroll technology (fig. left). Evaporator and condenser are
designed as soldered stainless steel plate packs with reverse flow circuits,
according to state-of-the-art development, tailored to the new non-
flammable safety refrigerants that will be required by law in the future. In
combination with ester oil (biodegradable), this guarantees optimum lubrica-
tion conditions, low friction losses and therefore the highest possible life ex-
pectancy for the compressor according to the latest industrial research
findings.
The cooling circuit is designed in accordance with the relevant safety regu-
lations. Manufacturing quality is carried out based on ISO 9000ff, supple-
mented by an automated computer-monitored quality test (pressure stress
and helium leak test) in addition to inspection of all parameters in a subse-
quent trial run.

Components and installation
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4.3 Electrical equipment
The electrical connections are made via the internal terminal (on the con-
struction profile). The implementation of the electrical cable is carried by the
rear wall (with the strain relief).
The internal terminal connects the entire sensor, all queries, all relay out-
puts, digital circuit, the compressor and the electrical heating element. The
WATERKOTTE WWPR-controller is supplied with a control panel mounted
on the 24 V AC transformer.
4.3.1 Electronic heat pump control
The heat pump control (control panel is pictured) is included in the scope of
delivery of the WATERKOTTE heat pump.
Use in other than WATERKOTTE heat pumps will void any warranty claim.
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.
The following tasks are performed: everything to do with regulation (de-
pending on the external temperature with pilot room guidance), control,
monitoring, self-diagnosis, saving of data in cases of breakdown.
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.
Info: Technical details, operation and warning messages (see Operating
manual for Heat pump control) .
4.3.2 Sensors
The control's sensor system consists of: Pressure transmitter for evapora-
tion and condensation pressure/temperature, 5 sensors for temperature
detection in all circuits. External wall sensor (accessories kit). Pilot room
sensor and hot water sensor: optional.
4.3.3 COP counter
A WATERKOTTE COP counter is already integrated in the heat pump con-
trol. For additional information, please refer to Operating manual for Heat
pump control.
4.4 Options
Domestic hot water production (heating-side vertical tank, hot
water heater, temperature sensor, three way valve), pilot room sensor,
natural cooling, WEB interface: for control and parameterization of the heat
pump via internet.

Transport
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5Transport
Exercise particular caution when transporting the units. Since the unit
weighs 232 kg or more, at least two people are required for transport.
Do not use the packaging straps to carry the unit. Wear protective
gloves for unpacking and transporting the unit to prevent hand injuries
from cooling fins or other parts.
Observe the transport information on the packaging.
Observe the specified storage requirements.
The units may not be stacked.
Machine may only be lifted at the provided attachment points.
Machine may only be transported in upright position.
Ensure proper disposal of packaging materials. Packaging materials,
such as nails or other metal or wooden parts, may cause injuries.
Please also read chapter "General safety information“.
5.1 Transport to installation site
Units of the EcoTouch DS 5050T series are delivered ready-to-connect with
separate metal cladding. For transport purposes, the metal cladding and
the heat pump are delivered in one carton on a palette. During transport it
must be ensured that appropriate means of transport are used (lift truck,
transport rollers, handcart).
Unit must be 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 during start-up.
After packaging is removed or opened it is not permitted to tilt the unit by
applying pressure to the pipelines or housing enclosure; this could result in
bent housing parts and pipelines.

Installation
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6Installation
Installation of the heat pump must be performed on a flat and horizontal
surface.
The unit should not be installed on a floating screed (structure-born
noise).
We recommend a concrete base.
Wall clearance left, right and on top must be at least 300 mm.
Wall clearance in rear must be at least 300 mm.
Wall clearance in front: at least 1,000 mm.
6.1 Environmental conditions for installation
Note the minimum volume of the installation room and consider the type of
the refrigerant (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. The
housing frame is to be completely supported. If support is only provided at
points, operating noise increases. To compensate for minor unevenness,
we recommend use of an approx. 10 mm thick rubber mat. Acoustics in in-
stallation rooms with rigid walls can noticeably increase operating noise.
Counter measure: acoustic insulation of one of the opposite wall or ceiling
surfaces.

Installation
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6.2 Creating the foundation and installing heat pump
- with best possible structure-borne noise insulation
6.2.1 Laying a foundation for acoustic heat pump
1
Heat pump
2
Noise-absorbent mat Polyethylen (PE)
3
Insulation material (3 layer, polyurethan rubber)
4
Supporting subsurface
5
Insulation material
6
Screed
7
Concrete plinth
Dimensions concrete plinth (mm):
Plinth
Width
x
Depth
x
High
EcoTouch
DS 5050T
850 mm
700 mm
150 mm

Installation
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6.3Installation of the housing
To avoid damage, the delivered housing parts are not installed.
After preparation of all connections, mount the housing parts to the intend-
ed positions (insert and press).
6.3.1 Removing the housing
A disassembly tool is delivered with the heat pump. Use this tool to avoid
damage while you are removing the housing parts.
Procedure:
Keep enough clearance with the tool to the upper and lower metal edge.
So you can’t damage the retaining bolts (see Figure).
The removal tool is driven with moderate force, by hand, into the gap
between the front and side panel.

Installation and connection
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7Installation and connection
7.1 Connections EcoTouch DS 5050T (rear side)
Figure 4: Connections EcoTouch DS 5050T heating and heat source( 2“ flat sealing)
7.2 Connection to heating system
The connected systems should be technically clean and free from air. Steel
pipes and other steel components in the water circuit shall not be used
when connecting diffusion-open surface heating system. In exceptional
cases an effective corrosion inhibitor must be added and a dirt trap (0.8
mm mesh) connected before entry into the unit.
The system must then be marked accordingly and the maintenance instruc-
tions of the supplier must be followed strictly. Designation for inlet and out-
let must be observed. When there is danger of frost, add antifreeze to pro-
tect against formation of ice.
To ensure tension-free connection of the heat pump, a flexible connection
is required!
Tip:
We recommend the use of external shut-off devices (ball valves) at all con-

Installation and connection
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nections. Thus, if service is required, only the minimum amount of heat
transfer medium has to be drained from the system and time-consuming
venting measures can be avoided.
In factory default setting, the pipe ends are closed with plastic caps. When
connection is performed, these caps must be removed and the connecting
unions screwed on with suitable gasket.
To tighten the screw connections, resistance at the cap must be provided
with suitable tool!
To prevent corrosion and scale formation in the heating system (circulating
pumps, radiators, etc.), the heating water must be treated according to VDI
2035 (e.g. with corrosion inhibitor).
To find the volume flow at heating side for the corresponding heat
pump, please refer to the performance table (5K spread).
The heating connections (2“) feature an external pipe thread for flat-
sealing connections with union nut and insert.
A circulation pump is installed at heating side. The circulation pumps are
offered with an internally coated housing (plastic).
7.2.1 Heat pump with underfloor heating
The use of steel pipes and other steel components is not permitted in
the heating circuit of underfloor heating systems. Use stainless steel,
copper, brass or plastic - such as PE - for instance.
In case of single room control, a buffer tank (corrosion-free) and a differ-
ential pressure overflow valve must be installed in the heating system
(see diagrams).
When the living space controlled by single room control is less than 1/3,
a buffer tank is not required if the remaining 2/3 floor circuits remain
open.
7.2.2 Heat pump with radiators (no cooling mode)
On systems with steel radiators an effective corrosion inhibitor must be
added and a dirt trap (0.8 mm mesh) connected before entry into the
unit. The system must then be marked accordingly and the mainte-
nance instructions of the supplier must be followed strictly.
Heating systems with radiators require the installation of a buffer tank
(connected in parallel) (see diagrams). The size of the tank must be cal-
culated. The heat pump control regulates the temperature of the buffer
tank. After the tank, the components (circulation pump, mixing valve ...)
must be controlled with an optional WATERKOTTE mixing control
(P11108).
If the formation of deposits is to be expected (e.g. strong contamination)
based on water quality, cleaning must be performed in regular intervals.
Cleaning can be performed by flushing.
Procedure: