Altherma Commission Tips en

Altherma System Setup & Commissioning Guide


Outdoor Unit.
Installation Location
Check that the outdoor unit is installed in a location where the following
can be achieved:

a) Adequate air flow around the heat exchanger this will include
any obstructions in front of the fan outlet.
b) Adequate service space around the machine that will enable
components to be removed and the unit to be correctly serviced
and maintained i.e cleaning of heat exchanger.

It is also important that the outdoor unit is raised from a solid surface
and provisions are made for drainage of water produced during defrost
operation. Failure to do this can result in this volume of water freezing
inside of the outdoor unit which will affect performance and
component reliability.


The example above will allow the water to drain away from the base of
the outdoor unit the example below shows the effects of mounting the
machine on a solid surface with no provision for drainage the ice has
built up inside of the unit and is protruding from the air outlet grille.


Electrical installation
The outdoor unit must be connected to the hydrobox in the following way:

Refer to the following electrical information and check that a correct
M.C.B/Fuse has been installed to protect the outdoor unit.

Note These are for single phase models only.
Possible total
current draw on
sizes 006-008
Recommended fuse
size on sizes 006-008
Possible total
current draw on
sizes 011-016
Recommended fuse
size on sizes 011-016
18Amp 20Amp 28.2Amp 32Amp

Mechanical installation
The refrigeration piping for Altherma should be sized at 5/8 gas and 3/8
liquid for the size 011 to 016 models and 5/8 gas and liquid for the size
006 to 008 models.
This piping must be insulated and the piping lengths kept within the following
guidelines:

Size 006-008
Max length 30m, (20m Height diff)
Min length 3m
Pre Charged For 10 m
g/m Additional 20 g/m over 10m
Std Liquid pipe 6,4mm (1/4 inch)
Piping
Std Gas pipe 15,9mm (5/8 inch)


Size011-016
Max length 75m, (30m Height diff)
Min length 5m (3m*)
Pre Charged For 30 m
Additional 30 - 40m add 0.5Kg
Additional 40 - 50m add 1Kg
Additional 50 - 60m add 1.5Kg
Additional 60 - 70m add 2Kg
Std Liquid pipe 9.5mm (3/8 inch)
Piping
Std Gas pipe 15,9mm (5/8 inch)

Additional refrigerant will be required after the pre charged piping length is
exceeded. Add the additional refrigerant volume according to the charts
above. The refrigerant type is R410a and must be charged in its liquid phase.

NOTE For the 011-016 models if the hydrobox is installed above the
outdoor unit an oil trap should be used on the gas pipe at 10 metre intervals.


Hydrobox.

Check the installation location of the hydrobox complies with the
following:

The space around the unit is adequate for servicing
The space around the unit allows for sufficient air circulation
There is a provision for condensate drain (only for EKHBX models)
and pressure relief valve blow-off
The installation surface is a flat and vertical non-combustible
wall, capable of supporting the operation weight of the unit
All piping lengths and distances have been taken into consideration

Electrical installation

The hydrobox will require either one or two power supplies. The first supply is
for the backup heater which is located inside of the box, the second supply is
for the booster heater which is in the DHW tank. For installations where no
DHW tank is installed only one power supply is required to the hydrobox.
The size of the supply depends on the size of the backup heater these
come in 3,6 & 9KW versions.
The booster heater for the tank is always rated at 3KW.

Before initial switch on check the following components are connected to the
relevant electrical connections in the hydrobox.

Terminal block X1M terminals 1,2 & 3 These are the cables from the
outdoor unit.

Terminal block X1M terminals L&N This is the power supply
connections for the back up heater.

Terminal block X2M terminals 1,2,3 & 4 These are to be connected to
an external thermostat (if one is required). These must be volt free switches.
Connecting terminal 4 to 1 will force heating and connecting terminal 4 to
terminal 2 will force cooling.

Terminal block X2M terminals 5,6 & 7 These connections are used if a
cooling/heating system is installed. The purpose is to interlock the cooling
and heating emitters from operating at the same time. Example CWFC, and
under floor heating.


Terminal block X2M terminals 9,10 & 11 These connections are used
for the three port valve (this needs to be installed if there is a DHW
connected) this will then decide whether to circulate the water through the
tank or the space heating circuit.
For the ESBE valves terminal 9 is black, terminal 10 is blue and terminal 11 is
brown. For further information see ESBE valve details document.
Terminal block X2M terminals 13 &14 To be connected to Q2L (thermal
protector) inside of DHW tank. This is only to be connected with systems with
a tank connected.

Terminal block X3M terminals L&N These are the power supply
connections for the booster heater.

Terminal block X4M terminals L &N These are the connections that the
heater from the tank connects to. This is the switched output from the
hydrobox to the heater.

Plug X9A This is the plug for the thermistor that connects to the DHW tank
to sense the DHW temperature.

SOLAR THERMAL CONNECTIONS

KRP1B option PC board terminals YC & Y3 This is an input from the site
supplied solar pump station. This input is 230Vac and should be present
when the pump station pump operates.

Terminal block X2M terminals 19&20 These are the connections that
power the Daikin Altherma solar pump. EKSOLHAV1.

Terminal block X7M terminals L&N this is to be used if a solar system is
installed, this is to comply with G3 regulations. X7M is an additional connector
that needs to be installed by the installation company.


Mechanical Installation
Size 008

Size 016 Hydrobox

To avoid big temperature change when
switching from DHW to cooling
(hot draft)
To guarantee a minimum temperature
difference between outlet plate heat
exchanger and inlet tank
To avoid big temperature change when switching from
DHW to cooling
(hot draft)
To guarantee a minimum temperature difference between
outlet plate heat exchanger and inlet tank
Standard minimum
5m

3 m in case
recharging on outdoor
is performed


Ensure that the piping connected to the hydrobox complies with the charts
above.

NOTE MINIMUM FLOW RATES AND WATER VOLUMES

It is vital that the minimum water volume for the systems is obeyed, it is also
important to ensure that an automatic bypass valve is connected to the
system for installations that have thermostatically controlled regulating valves
such as TRVs.
It is also necessary to allow for a minimum of 10L water volume (for the size 8
unit) and 20L (for the size 16 unit). This volume must be in the system at all
times even when in full bypass operation (to prevent damage to the PHE)

EKHBH008
ERHQ006
EKHBH008
ERHQ007
EKHBH008
ERHQ008
EKHBX008
ERHQ006
EKHBX008
ERHQ007
EKHBX008
ERHQ008
Cooling
(Nom)
14.7 16.5 17.6
Heating
(Nom)
16.5 19.6 24.2 16.5 19.6 24.2

Water
flow
rate
(l/min)
Minimum 12

EKHBH016
ERHQ011
EKHBH016
ERHQ014
EKHBH016
ERHQ016
EKHBX016
ERHQ011
EKHBX016
ERHQ014
EKHBX016
ERHQ016
Cooling
(Nom)
28.7 35.8 37.6
Heating
(Nom)
32.1 40.1 45.9 32.1 40.1 45.9

Water
flow
rate
(l/min)
Minimum 16


DHW Tank


If the system is unvented please check the diagram below for conformity
with G3 regulations.

B
C
D
A
E

A Pressure/Temperature Relief Valve Installed? Yes No
B Combination Valve Installed? Yes No
C Tundish Installed? Yes No
D Expansion Vessel Installed? Yes No
E - Safety Solenoid Valve Installed* Yes No

* Required if the hydrobox is model EKHBH(X)007AC or if a solar system has
been installed to work with the Altherma system.


D1 15mm pipe must be of a suitable material to
withstand a temperature of 95C and a maximum
length of 500mm from the discharge device to the
tundish

D2 22mm pipe must be of a suitable material to
withstand a temperature of 95C and have a
minimum vertical drop of 300mm and must not
exceed an equivalent length of 9m from the tundish
to drain off where it has to be visible but will not
cause danger to persons (equivalent length is taking
into account the bends within the pipe work).
Pipe work must have a continuous drop of at least
1:200mm

Electrical Installation

If there is a domestic hot water tank installed without solar then the system
should be wired in this configuration:

1
1
1
2
E
X
4
M
X
2
M4
3
1
2
E
X 6 M
Q2L
Q3L E4H
HYDROBOX
DHW TANK
OVERVIEW
OF TANK
ELECTRICAL
LAYOUT


If a solar system has been installed the tank should be wired in this
configuration:

Ensure that the thermistor that connects to the DHW tank is tightly fixed and is
located at the very back of the pocket. Heat conductive paste can be used to
guarantee a good contact. This plugs into X9a on the hydrobox.

1
2
X
7
M

2
3
1
E
1 1 2 2
E
SAFETY
SOLENOID
VALVE
Q2L Q2T
EKUHW2
1
2
E
X
4
M

1
2
E
X
6
M

Q2L
Q3L E4H
1
1
X
2
M

4
3 3
1
4 3
Q3L Q3T
1
2
X
2
M

4
3
2
1
1 2 1 2
X
8
M

SOLAR
PUMP
EKSOLHWAV
DHW
TANK
E
Pre Wired
X
5
M

HYDROBOX


Switches & Settings

The Dip switches on the hydrobox need to be set if a) a thermostat is
connected or b) a domestic hot water tank is installed.
Ensure that the power is switched off when making adjustments.

Operating the system

Note:
Before operating the system please ensure that the water circuit is filled
to approx 1.0-2.0BAR and that all air is removed from the system.
The pressure can be obtained from the manometer.

After initial power on of the system you may notice that the system
operates in cooling operation. This is part of the start up sequence and
is not a malfunction of operation.

Operate the system in space heating operation.
To do this either push the ON/OFF key OR if there is a thermostat
connected ensure that the stat is ON. At this time ensure that the
shower head symbol (for DHW) is not on the controller display.


Then set the temperature for the target water flow using the keys below:

The target flow should be set according to the type of heat emitter.
Button
ON/OFF Button

Check points

The system will now operate in heating, ensure that the heating system
is balanced allowing equal T across the connected heat emitters.

Check the T between the water flow and return pipes on the hydrobox.
After the system has been operating for a while the ideal differential
would be approx 5C.
If the temperature difference is too small or too large then changing the
pump speed may be beneficial.
If the temperature difference is too low then decrease the pump speed.
If the temperature difference is too high then increase the pump speed.
These settings can be done by altering the dial on the side of the pump.

Once the system has been balanced and pump speeds set leave the
system to operate and then take the following readings:

*Please take note of the minimum water flow rate for the machine, this is
stated in the installation manual.


Hydrobox in space heating:

Water flow set point C
Leaving water temp
(hydrobox)
C
Return water temp
(hydrobox)

Pump speed
selected
1 2 3
Approx flow rate* L/Min

To calculate approx flow use the following formula:
(KW) / (C T) / 4.2(Clean water) = L/Sec X 60 = Litres per min.


Domestic hot water heating

Disable the space heating function and push the shower head ON button.

Use the shower head up & down temperature keys to program DHW set
temperature.

Record the following data:

DHW tank temperature before
switch on*
C
DHW set point temperature C

To obtain the DHW tank temperature follow instructions below:


Reading system temperatures

To read system temperatures push and hold the
Automatic button for 5 seconds then use the
timer up and down buttons to show the following
temperature readings

Sanitary water temperature sensing off sensor
R5T

Outdoor ambient temperature sensor

Flow water temperature for space heating or
cooling sensor R1T

Once the heat pump has been operating for a while (approx 30 mins)
record the following data.

DHW temperature (30 mins after
initial switch on)
C

If the booster heater has not yet operated please push and hold the
shower head on key. The showerhead symbol will now flash and an
image of a heater will appear on the screen.

Current of Booster heater Amps

Cooling Operation

If the system has chilled water devises installed please complete the
following:

Operate the system in cooling mode by turning on the controller or
thermostat and ensuring that the snowflake symbol is present. Make
sure the showerhead symbol is off.

A cooling set point will need to be set similar to the heating water flow
set point.


Water flow set point C
Leaving water temp (hydrobox) C
Return water temp (hydrobox) C

Service Codes.

To maximise the systems capabilities special attention must be given to the
service codes. These parameters can effect the time the heat pump is
allowed to operate, and the temperature in which the electrical heater is used
to assist the space heating requirements etc.
Refer to the service settings document for further information.

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Altherma System Setup & Commissioning Guide

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