WATERKOTTE EcoTouch Ai1 Air Technical manual

Planning and installation
EcoTouch Ai1 Air
Zubadan and Power Inverter
Electrical connection types: 230 V, 400 V, 230 V/400 V
Heating station
EcoTouch Ai1 Air, Indoor unit
Outdoor units: EcoTouch Ai1 Air
(Zubadan and Power Inverter)
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: [phone], Fax: [phone], E-Mail: [e-mail]
Internet: http://www.waterkotte.de
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Copyright 2013 by: WATERKOTTE GmbH. Subject to changes.
Copyright 2013 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 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
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
recycling 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 vet 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.....................................................................................................................................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............................................................................................................................. 8
1.4 Operator's duty of care...................................................................................................... 9
1.5 Other applicable documents.............................................................................................. 9
2Functional principle of heat pumps.........................................................................................10
3Product description and scope of delivery ..............................................................................11
3.1 Overview.......................................................................................................................... 11
3.2 Scope of delivery ............................................................................................................ 12
3.2.1 Heat distribution station EcoTouch Ai1 Air .......................................................... 12
3.2.2 Domestic hot water tank..................................................................................... 12
4Components and setup.........................................................................................................13
4.1 Heat distribution station EcoTouch Ai1 Air ....................................................................... 13
4.2 Construction and Controlling ........................................................................................... 13
4.3 Electronic heat pump control........................................................................................... 13
4.4 Outdoor unit (heat source) ............................................................................................... 14
4.5 Overview: ECOTouch Ai1 Air ........................................................................................... 14
4.5.1 Connection accessories...................................................................................... 15
4.6 Sensor system................................................................................................................. 15
4.7 Heat meter (optional) ....................................................................................................... 15
5Transport..............................................................................................................................16
6Installation and connection ....................................................................................................17
6.1 Installation and connection of indoor unit......................................................................... 17
6.2 Environmental conditions for installation .......................................................................... 18
6.2.1 Installation of the heat pump............................................................................... 18
6.2.2 Preparation of the assembly ............................................................................... 18
6.2.3 Assembly of the heat pump ................................................................................ 19
6.2.4 Connection tube of the tank (at the top).............................................................. 20
6.2.5 Connection tube of the tank (bottom).................................................................. 20
6.2.6 Connection terminal............................................................................................ 21
6.2.7 Installation of the temperature sensor ................................................................ 22
6.2.8 Installation of the Touch Display......................................................................... 23
6.2.9 Installation of the housing ................................................................................... 24
6.2.10 Removing the housing ........................................................................................ 25
7Installation and connection ....................................................................................................26
7.1 Connections (rear) ........................................................................................................... 26
7.2 Connection measurements.............................................................................................. 27

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8Installation and connection of outdoor unit .............................................................................28
8.1 Selecting a location for outdoor unit ................................................................................ 28
8.1.1 Dimensions of outdoor unit ................................................................................. 29
8.1.2 Clearance for ventilation and operation ............................................................... 30
8.1.3 Mounting on base plate or on the wall ................................................................ 30
8.1.4 Installation and space requirement...................................................................... 31
8.2 Connection outdoor unit / indoor unit (refrigerant lines).................................................... 32
8.2.1 Installation of refrigerant lines .............................................................................. 32
8.2.2 Connections indoor unit (refrigerant line) ............................................................. 33
8.2.3 Connections outdoor unit (refrigerant line)........................................................... 33
8.2.4 Installation of a LOKRING coupling (example) ..................................................... 34
8.2.5 Tube airtight testing method (recommended procedure)..................................... 36
9Refrigerant ............................................................................................................................37
9.1 Requirements on handling of R410A refrigerant............................................................... 37
9.2 Safety information on handling of refrigerant .................................................................... 37
9.3 Refrigerant charge and additional charge –EcoTouch Ai1 Air (Zubadan) ......................... 38
9.4 Refrigerant charge and additional charge –EcoTouch Ai1 Air (Power Inverter) .............. 39
9.5 Charging refrigerant circuit............................................................................................... 40
9.5.1 Adding refrigerant ............................................................................................... 41
9.5.2 Insulation ............................................................................................................ 41
10 Electrical work.......................................................................................................................42
10.1 Electrical connection outdoor unit.................................................................................... 43
10.2 Electrical connection indoor unit ...................................................................................... 44
10.2.1 Connection Temperature sensor......................................................................... 44
10.2.2 Connection Touch Display .................................................................................. 44
10.2.3 Installing external wall sensor .............................................................................. 44
10.2.4 Adjustment of the electrical heating element ....................................................... 44
10.3 Connection diagram ........................................................................................................ 45
10.3.1 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps (400 V) .......... 45
10.3.2 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps (230 V) .......... 46
10.3.3 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps
(Compressor 230 V / Electrical resistance heating 400 V) ................................... 47
10.3.4 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps X1 (all models)48
10.3.5 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps X2 (all models)49
10.3.6 EcoTouch Ai1 Air Zubadan and Power Inverter: Overview clamps X4 (all models)50
10.3.7 EcoTouch Ai1 Air Zubadan and Power Inverter: Input (400 V) ............................. 51
10.3.8 EcoTouch Ai1 Air Zubadan and Power Inverter: Input (230 V)............................. 52
10.3.9 EcoTouch Ai1 Air Zubadan and Power Inverter: Input (Compressor 230 V /
Electrical resistance heating 400 V)..................................................................... 53
10.3.10 EcoTouch Ai1 Air Zubadan and Power Inverter: Electric heating insert (400 V).... 54
10.3.11 EcoTouch Ai1 Air Zubadan and Power Inverter: Electric heating insert (230 V).... 55
10.3.12 EcoTouch Ai1 Air Zubadan and Power Inverter: Control power (all models) ........ 56
10.3.13 EcoTouch Ai1 Air Zubadan and Power Inverter: Control source and heating
pump (400 V and 230 V) .................................................................................... 57
10.3.14 EcoTouch Ai1 Air Zubadan and Power Inverter: Switched output extern (400 V
and 230 V) .......................................................................................................... 58
10.3.15 EcoTouch Ai1 Air Zubadan and Power Inverter: Digital output extern (400 V
and 230 V) .......................................................................................................... 59
10.3.16 EcoTouch Ai1 Air Zubadan and Power Inverter: Analoque signals extern (400 V

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and 230 V) .......................................................................................................... 60
10.3.17 EcoTouch Ai1 Air Zubadan and Power Inverter: Expansion valve, BUS
and Display (230 V and 400 V)........................................................................... 61
10.3.18 EcoTouch Ai1 Air Zubadan and Power Inverter: Intern control board (400 V
and 230 V) .......................................................................................................... 62
10.3.19 EcoTouch Ai1 Air Zubadan and Power Inverter: WWPR 2 (400 V and 230 V) ..... 63
10.4 DIP switch of motherboard (indoor unit)........................................................................... 64
11 Silent Mode (option) ..............................................................................................................65
11.1 Connecting „ Silent Mode “................................................................................................ 66
11.2 Silent mode (only the fan speed reduction) ...................................................................... 67
11.3 Step mode (speed reduction of fan and compressor) ...................................................... 67
12 Start-up ................................................................................................................................68
12.1 Pre-startup checks .......................................................................................................... 68
12.2 Initial start of the heat pump ............................................................................................ 71
12.3 Control of entire operation ............................................................................................... 71
12.4 Turning heat pump off ..................................................................................................... 72
12.5 Taking heat pump out of operation for extended period .................................................. 72
13 Defrost operation ..................................................................................................................72
13.1 Start ................................................................................................................................ 72
14 Maintenance and care ...........................................................................................................73
15 Technical Data ......................................................................................................................74
15.1 EcoTouch Ai1 Air (Zubadan) ............................................................................................ 74
15.2 EcoTouch Ai1 Air (Power Inverter).................................................................................... 75
16 Connection diagram..............................................................................................................76
16.1 EcoTouch Ai1 Air with underfloor heating (Basic circuit diagram) ..................................... 76
16.2 EcoTouch Ai1 Air with underfloor heating and single room control (Basic circuit diagram) 76
16.3 EcoTouch Ai1 Air with radiators or fan convectors (Basic circuit diagram) ....................... 77
16.4 EcoTouch Ai1 Air with hydraulic filter (Basic circuit diagram)............................................ 77
16.5 Overview EcoTouch Ai1 Air.............................................................................................. 78

Safety
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1Safety
1.1 Intended use
Your WATERKOTTE heat pump of the EcoTouch Ai1 Air series is used for
space heating and cooling, and heating of domestic water.
An outdoor unit, 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 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.

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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.

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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).
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!
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 heat pump breaks down, an inspection by qualified and authorised
personnel must be performed before restart.

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1.4 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 properly
qualified and authorised personnel.
None of the safety and warning notices on the heat pump are removed
or damaged.
1.5 Other applicable documents
Installation manual: Air-Conditioner
Zubadan : Air-Conditioners PUHZ-SHW HA
Power Inverter : Air-Conditioners PUHZ-SW HA..
Operating manual: WWPR WATERKOTTE heat pump controller.

Functional principle of heat pumps
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2Functional principle of heat pumps
The heat pump is used to produce thermal energy for space heating and
domestic water heating. The medium used as heat source
is air.
By means of reverse cooling it is also possible to cool a building.
Figure 1: Heating system with domestic hot water production and heat source air
To utilise air as thermal energy and for domestic water heating in your
home, you need the following:
Outdoor unit.
Indoor unit with domestic hot water tank (not WPQLN(i)) and heat distri-
bution station.
Buffer tank (only in connection with fan convector, radiators or under-
floor heating with single room control).