WATERKOTTE EcoTouch Ai1 Geo Technical manual

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Planning and installation
Basic Line Ai1 Geo
Heating station
WATERKOTTE GmbH, Gewerkenstraße 15, D-44628 Herne
Tel.: [phone], Fax: [phone]
Service: [phone]
E-Mail: [e-mail] Internet: http://www.waterkotte.de

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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 pub-
lication, 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.

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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
1.3 Before initial use................................................................................................................. 6
1.3.1 Environmental protection ...................................................................................... 7
1.3.2 Modifications and repairs on the heat pump ......................................................... 7
1.4 Hazards ............................................................................................................................. 7
1.5 Specific types of hazards ................................................................................................... 9
1.6 Operator's duty of care...................................................................................................... 9
1.7 Other applicable documents.............................................................................................. 9
2Functional principle of an heat pump......................................................................................10
2.1 Description of operation Basic Line Ai1 Geo .................................................................... 10
3Product description...............................................................................................................11
3.1 Overview.......................................................................................................................... 11
4Components and installation..................................................................................................13
4.1 Heating system Basic Line Ai1 Geo ................................................................................. 13
4.2 Structure.......................................................................................................................... 13
4.2.1 Heat pump module ............................................................................................. 13
4.2.2 Compressor........................................................................................................ 13
4.3 Electrical equipment......................................................................................................... 14
4.3.1 Electrical resistance heating ................................................................................ 14
4.3.2 Domestic hot water heating system .................................................................... 14
4.3.3 Heat source ........................................................................................................ 14
4.3.4 Electronic heat pump control .............................................................................. 14
4.3.5 Sensors .............................................................................................................. 14
4.3.6 COP-counter ...................................................................................................... 15
4.3.7 Options............................................................................................................... 15
4.4 Hydraulical equipment ..................................................................................................... 15
4.4.1 Domestic water heating technology .................................................................... 15
4.4.2 Domestic hot water tank ..................................................................................... 15
5Transport..............................................................................................................................16
6Installation ............................................................................................................................18
6.1 Environmental conditions for installation .......................................................................... 18
6.2.1 Heat pump base ................................................................................................. 19
7Installation of heat pump and tank .........................................................................................20
7.1 Accessories (scope of delivery) ........................................................................................ 20
7.2 Installation........................................................................................................................ 21
7.2.1 Dismantlement/ Assembly of the heat pump (service event)................................ 22
7.2.2 Temperature sensor............................................................................................ 23
7.2.3 Removing of the housing .................................................................................... 23
8Installation und connection ....................................................................................................24
8.1 Connection (rear) ............................................................................................................. 24

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8.2 Connecting dimensions ................................................................................................... 25
8.3 Connection to heating system ......................................................................................... 26
8.3.1 Installations provided by customer ...................................................................... 26
8.3.2 Heat pump with underfloor heating ..................................................................... 26
8.3.3 Heat pump with radiators (natural cooling not possible) ...................................... 27
8.4 Connection to heat source............................................................................................... 27
8.4.1 Residual head ..................................................................................................... 29
8.4.2 Water glycol systems .......................................................................................... 30
8.4.3 Groundwater heat source ................................................................................... 30
8.4.4 Groundwater quality............................................................................................ 30
8.4.5 Water-Glycol mixture in the installation................................................................ 31
8.4.6 Flow Monitoring .................................................................................................. 32
8.4.7 Filter.................................................................................................................... 32
8.4.8 Cleaning.............................................................................................................. 32
9Electrical work.......................................................................................................................34
9.1 Electrical installation......................................................................................................... 34
9.2 Electrical heat generator for startup and standby............................................................. 35
9.2.1 Initial heating of buildings during winter months .................................................. 35
9.2.2 Startup of electrical heat generator (EWE) ........................................................... 36
9.2.3 Parallel operation: Heat pump and electrical heat generator................................ 36
9.3 Heat generator, thermostat settings................................................................................. 36
9.4 Installation instructions for an external sensor .................................................................. 36
9.4.1 Instalation of the cabling ..................................................................................... 37
9.5 Electrical connection........................................................................................................ 38
9.5.1 Electrical wiring diagram (3x 400 V)..................................................................... 38
9.5.2 Electrical wiring diagram (1x 230 V)..................................................................... 39
9.6 Controller......................................................................................................................... 40
9.7 Terminals ......................................................................................................................... 41
10 Plan and MSR-equipment......................................................................................................42
11 Hydraulic diagramm Basic Line Ai1 Geo.................................................................................43
12 Commissioning .....................................................................................................................44
12.1 Pre-startup checks .......................................................................................................... 44
12.2 Initial start-up of the machine........................................................................................... 45
12.3 Control of the entire operation ......................................................................................... 46
12.4 Turning off the heat pump................................................................................................ 46
12.5 Turning off the heat pump for a longer time ..................................................................... 46
13 Troubleshooting ....................................................................................................................47
13.1 Possible faults and solutions............................................................................................ 47
13.1.1 Fault at input side (LP fault) ................................................................................. 47
13.1.2 Ausgangsseitige Störung (HD-Störung)............................................................... 47
13.1.3 Fault in compressor motor .................................................................................. 47
14 Safety measures ...................................................................................................................48
14.1 Pressure limits of compressor.......................................................................................... 48
14.2 Motor protection against excessive temerpature.............................................................. 48
14.3 Refrigerator oil ................................................................................................................. 48
15 Maintenance and care...........................................................................................................49

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16 Connection diagram..............................................................................................................50
16.1 Basic Line Ai1 Geo with underfloor heating...................................................................... 50
16.2 Basic Line Ai1 Geo with underfloor heating and individual room control........................... 51
16.3 Basic Line Ai1 Geo with hydraulical deflector ................................................................... 52
16.4 Basic Line Ai1 Geo with radiators .................................................................................... 53
16.5 Legend hydraulic schemes .............................................................................................. 54
17 Technical data ......................................................................................................................56
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 use-
ful 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 environment 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 1980.

Safety
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1Safety
1.1Intended use
Your WATERKOTTE heat pump is used for space heating and cooling, and heat-
ing of domestic water.
Project planning of the heat source system must be performed in compliance with
the technical information provided by WATERKOTTE for layout of heat source sys-
tems.
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 elec-
trical 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).
Risk of total loss!
The device may only be switched on when the hydraulic circuits are completely
filled and vented, and all electrical connections are properly.
The commission may only be performed by trained specialist staff. Damages
resulting from failure to observe the points above, are not in the scope of the
warranty (see attached warranty-exclusion).
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.
1.3Before 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. Remedy any detected defects immedi-
ately. 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.

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Remove all objects and other materials that are not required for operation of
the heat pump from the work area of the heat pump
1.3.1 Environmental protection
Observe the regulations regarding waste avoidance and proper waste recy-
cling 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, refrigerant, sol-
vent- 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.
1.3.2 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 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 approved for
use on the heat pump.
1.4Hazards
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 performed by
professional electricians!
Attention! Risk of suffocation!
The packing is not a toy. The packaging must be disposed of environ-mentally
acceptable.
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.

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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!
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, nausea and
even unconsciousness. Irregular heartbeat (arrhythmia).
Avoid contact with refrigerant! Do not expose to heat, sparks, naked light or
other ignition sources!!!
Risk of total loss!
The heat pump is not a toy!
Keep children away from the heat pump, in particular from the operating input
device (touch screen). Read the accompanying technical manual.
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.
Leaking Liquids!
Due to test bench operation, the heat pump can have ethylene glycol residues.
Risk of total loss!
The device may only be switched on when the hydraulic circuits are completely
filled and vented, and all electrical connections are properly.

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1.5Specific types of hazards
To avoid damage to machine or life-threatening injuries during installation of ma-
chine, 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 smoulder-
ing and cable fires.

1.6Operator'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 quali-
fied and authorised personnel.
None of the safety and warning notices on the heat pump are removed or
damaged.
1.7Other applicable documents
Operating manual: WWPR WATERKOTTE heat pump controller.

Functional principle of an heat pump
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2Functional principle of an heat pump
The heat pump is used to produce thermal energy for space heating and domes-
tic water heating if required. 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 ex-
traction / discharge)
heating system Ai1 QE
domestic hot water tank
Figure 1: Energy share while using a geothermal energy pump
2.1Description of operation Basic Line Ai1 Geo
The WATERKOTTE heating central Basic Line Ai1 Geo uses a heat pump as heat
generator. At the heat source side the medium is cooled down in the vaporizer
about 3 to 4K with the help of this device. The hereby won energy is made usable
for heating purposes by transport through the cooling circle up to a higher tem-
perature level.
Heating energy is given to the medium about the liquefier at the heating side, so a
temperature rise about 5K is reached.
On this way building heating and domestic water heating can be done.
The configuration of the heat source system must be planned in accordance with
the technical information of WATERKOTTE GmbH heat source installation instruc-
tions.

Product description
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3Product description
3.1Overview
Figure 2: Basic Line Ai1 Geo (closed)
1
Display
2
ON/ OFF-switch

Product description
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Figure 3: Basic Line Ai1 Geo (open)
1
Tank for domestic hot water
2
Control board
3
Connecting terminal (400 V –series)

Components and installation
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4Components and installation
4.1Heating system Basic Line Ai1 Geo
All components of the heating system are mounted in a protective steel plate
housing which is intended for installation inside. The base frame consists of a
bent, thick-walled sheet steel. Together with the rear panel frame, which also con-
sists of a thick-walled sheet steel, it forms a unit. Side panels, cover, front and the
tilt-mounted, ergonomic control panel can be removed.
All housing parts are optionally available in high-gloss white or stainless steel fin-
ish. Sound insulation ensures low noise emissions.
4.2Structure
Complete hot water heating system with integrated central hot water supply run,
consisting of: heat generator (heat pump), heat-source technology, electrical re-
sistance heating for start-up and stand-by, control and electrical control, storage
stainless steel integral foam insulation), full-constant Electrical and Control En-
gineering, touch display with BASICPRO software, Smartphone Control with
BASICPRO Mobile Software, diagnostic system.
All hydraulic connections positioned on the back. All units within the scope Vice-
mounted with removable, all-round heat and sound insulated lining, colour sig-
nal white (RAL 9003).
4.2.1 Heat pump module
The heat pump unit includes the whole hydraulic technology. The built-in con-
sole consists of compressor and heat exchanger.
4.2.2 Compressor
The compressor features a fully hermetic design in approved leading scroll tech-
nology (fig. left). Evaporator and condenser are designed as soldered stainless
steel plate packs with reverse flow circuits, according to state-of-the-art develop-
ment, 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 op-
timum lubrication conditions, low friction losses and therefore the highest possible
life expectancy for the compressor according to the latest industrial research find-
ings.
The cooling circuit is designed in accordance with the relevant safety regulations.
Manufacturing quality is carried out based on ISO 9001ff, supplemented by an au-
tomated computer-monitored quality test (pressure stress and helium leak test) in
addition to inspection of all parameters in a subsequent trial run.

Components and installation
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4.3Electrical equipment
The electrical connections are made via the internal terminal (on the construction
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 outputs, digi-
tal circuit, the compressor and the electrical heating element. The WATERKOTTE
WWPR-controller is supplied with a control panel mounted on the 24 VAC trans-
former.
An integrated web interface is available for remote monitoring via the Internet.
4.3.1 Electrical resistance heating
Located in the heating flow, power 6 kW. Used to support initial heating in the
winter and during the standby function; automatic or independent control via the
built-in mechanical thermostats.
4.3.2 Domestic hot water heating system
Consisting of: heating circulation pump (speed-controlled / energy class A), air
separator with automat. air diverter, connections for heating flow and return are fit-
ted externally to facilitate installation in the rear panel frame.
4.3.3 Heat source
Consisting of: heat source circulator speed controlled (energy efficiency class A),
connections for ahead and return facilitates installation in the rear wall frame out-
wards.
4.3.4 Electronic heat pump control
The heat pump control (control panel is pictured) is included in the delivery scope
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 operated with
WATERKOTTE compact heat pumps according to technical guidelines of
WATERKOTTE head pump GmbH.
The following tasks are performed: everything to do with regulation (depending 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 consequential 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) .
4.3.5 Sensors
The control's sensor system consists of: Pressure transmitter for evaporation and
condensation pressure, sensors for temperature detection in all circuits, external
wall sensor in accessories kit, pilot room sensor and hot water sensor (optional).

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4.3.6 COP-counter
A WATERKOTTE COP counter is already integrated in the heat pump control. For
additional information, please refer to Operating manual for Heat pump control.
4.3.7 Options
Mixer accessories: sensor, three ways valve, additional control module.
Expansion kit: for pool heating, mixer circuits.
Pool accessories: sensor, additional control module.
Buffer tank: standard tank
Heat source accessories: heat exchanger for ground water, flow rate monitoring,
antifreeze concentrate, heat source distributor.
Heating accessories: underfloor heating system, underfloor heating head station,
distribution cabinet, convectors.
Heat pump accessories: Digital soft starter (for retrofitting at 3 x 400 V compres-
sor design), basement pad.
4.4Hydraulical equipment
4.4.1 Domestic water heating technology
Stainless-steel plate heat exchanger made in high vacuum solder technology that
works with counter flow and bronze charge pump for indirect water heating up to
60 °C.
4.4.2 Domestic hot water tank
In system-specific design,volume 170 l, test pressure 12 bar. tank made of stain-
less steel, insulated with Neopor RG, (heat loss < 80 W at 60 °C). Connections for
cold and hot water in the rear. An automatic legionella protection circuit ensures
hygienic quality of drinking water.
Note: Accessories as fittings, additions and security group and expansion vessel
are not included. They are optionally available.
4.4.3 Heat transfer medium
The unit may only operate with heat transfer media approved by Waterkotte.
These are Water-Glycol-mixes:
25 Vol. % Waterkotte-Ethylen-Glycol or
33 Vol. % Waterkotte-Propylen-Glycol

Transport
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5Transport
For easy transport the heat pump will be supplied in two packaging: heat pump
unit and housing.
Exercise particular caution when transporting the units. The unit weighs 245 kg
depending on model. Do not use the packaging straps to carry the unit. Wear
protective gloves for unpacking and transporting the unit to prevent hand inju-
ries 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 by the proposed construction struts (left and right
side outside).
Figure 4: Installed machine (delivery status)
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“.

Transport
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5.1Transport to installation site
Units of the Basic Line Ai Geo series are delivered ready-to-connect with separate
metal housing. For transport purposes, two people are required because the head
pump unit weights about 125 kg. During transport it must be ensured that appro-
priate 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 insertion.
Horizontal transport results in oil displacement in compressor and can cause
damage during start-up.
After carton 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 sur-
face.
We recommend a concrete base
Recommendation:
Wall clearance left, right and on top must be at least 400 mm.
Wall clearance in rear must be at least 200 mm.
Figure 5: Recommendation - wall clearances
6.1Environmental conditions for installation
The room must be dry. Room temperature should be between
+10 °C and +30 °C.
To facilitate maintenance, the use of a base plate is recommended. Acoustics in
installation rooms with rigid walls can noticeably increase operating noise.
Counter measure: acoustic insulation of one of the opposite wall or ceiling surfac-
es.
6.2Creating the foundation and installing heat pump
Within the device an electrically driven air compressor is used, causing the vibra-
tion. For the best attenuation of the vibration it gets placed on rubber mounting
feet, the weight and the excitation get balanced on. The hydraulic connections are
also connected with flexible hoses. In this way the transmissions of the vibrations
is reduced to a minimum. An additional improvement can be obtained by creating
an heat pump size corresponding base (see below), are achieved with an insulat-
ing pad made of polyurethane rubber.

Installation
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6.2.1 Heat pump base
1
Heat pump
2
Insulation strip (polyethylen / PE)
3
Insulation material (3 layer, polyurethan rubber)
4
Supporting subsurface
5
Insulation material
6
Screed
7
Concrete plinth
Dimensions concrete plinth (mm)
Series
Width
x
Depth
x
High
Basic Line Ai1
Geo
850
x
880
x
150

Installation of heat pump and tank
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7Installation of heat pump and tank
7.1Accessories (scope of delivery)
Piece
Item No.
Description
1
Z21241
Installation manual Basic Line Ai1 Geo
1
Z21327
User manual: Control
1
Z15312
Installation document: Acceptance and Installation Data
1
Z20086
Isolated removing Tool (for the removing of the housing)
1
Z13122
Outdoor wall mounted sensor (accessories box heat pump)