Master Therm AirMaster aku, Installation And Operating Manual

Page 1: ...D OPERATING MANUAL BoxAir BoxAir Inverter EasyMaster EasyMaster IndoorSplit AirMaster aku AirMaster mini AquaMaster AquaMaster Inverter AquaMaster Inverter Combi DirectMaster Catalog AM AQ EM BA Documentation IOM Edition 28 07 2014 Czech Product ...

Page 2: ...5 1 Units MINI with In built Liquid Receiver 21 2 6 Circuit Connection 21 2 6 1 Opening the ROTALOCK valve 21 2 6 2 Covers and Caps of the Ball Valves and the ROTALOCK Valve 21 2 7 Thermal Insulation 21 3 Earth Exchanger for Direct Evaporating AQxxD 22 3 1 Principle of Operation 22 3 2 Collector Piping 22 3 2 1 Distributor and Collector 22 3 2 2 Distributor and Collector for AQ9Z1D 23 3 2 3 Liquid...

Page 3: ...Single loop heating system 46 5 6 2 BoxAir and BoxAir Inverter multi circuit system with DHW 47 5 6 3 BoxAir BoxAir Inverter multi circuits charging pump DHW 48 5 6 4 Heating system charge for BoxAir and BoxAir Inverter 48 5 6 5 Venting the system for BoxAir a BoxAir Inverter 48 5 7 ASW units connection 49 5 8 Heating Circuits 50 5 8 1 Manifolds 50 5 8 2 Pump heating circuits 51 5 8 3 Mixing heati...

Page 4: ...ction 60 8 2 Piping Network Inspection 60 8 3 Electrical wiring check 60 8 4 Start up and Filling of Start up Protocol 60 9 Maintenance 61 9 1 Introduction 61 9 2 Personnel Qualification 61 9 3 Quarterly Maintenance 61 9 4 Annual Maintenance 61 9 5 Warranty 62 10 Legislation 62 11 Revision history 62 ...

Page 5: ...ordance with the presented drawings Using other handling methods may damage the unit 1 3 Location of the indoor unit 1 3 1 Working environment and clearances Indoor units are dedicated for indoor installation in dry non explosive and non corrosive environment at temperatures 5 30 C without free public access There must be a sufficient clearance around the unit for the antifreeze heating water refr...

Page 6: ...AM EM AQ BA ASW IOM page 6 64 Ing Jiří Jiránek Clearances AquaMaster EasyMaster AirMaster MINI AquaMaster x 2 AirMaster x 2 ...

Page 7: ...o tube 400mm 25mm PUR inlet grille PMR 400W SONOFLEX 406mm pipe draining 40mm flexi outlet grille gravity valve PMR 400W PER 400W fan motor access panel access panel electric fan propeller Clearances and installation 1OEM26 45VK evaporator indoor split ...

Page 8: ...ng Jiří Jiránek Spiro tube 400mm 25mm PUR inlet grille PMR 400W SONOFLEX 406mm tube fan access panel electric access panel XPS 40mm outlet grille gravity valve PMR 400W PER 400W compressor access panel Clearances and installation ASW ...

Page 9: ...nstallation in the lowest floor on solid ground Installation in higher floors can cause transfer of vibrations to the heated building The units have adjustable legs which allow for balancing of minor uneveness and inclination up to 20 mm of the floor 1 3 3 Minimum Inner Volume of the Machinery Room Each area for installation has to be inspected with regard to the refrigerent charge of the Heat Pum...

Page 10: ...lding wall Do not install the outer unit underground or in partly or completely enclosed spaces except in the case of the targeted use of waste heat Under the unit must be installed a condensate and melted water drain with a sufficient height reserve for frosty periods when percolation is problematic 1 4 2 Positioning with regard to noise When selecting the place of installation you must observe t...

Page 11: ...AM EM AQ BA ASW IOM page 11 64 Ing Jiří Jiránek Two reflecting walls d 3m FU 6dBA Between reflecting walls FU 6dBA ...

Page 12: ...OINT EVALUATION POINT BUILDING CORNER AS A NOISE BARRIER EVALUATION POINT EVALUATION POINT BARRIER NOISE SOURCE L L1 L2 D L1 L2 Distance between the noise source and evaluation point around a barrier D Direct distance between the noise source and evaluation point FB Attenuation factor L m 0 15 0 3 0 6 0 9 1 8 3 7 FB dBA 4 7 10 12 15 17 ...

Page 13: ...ting noise level represents the plain sum of the acoustic output level and all the factors Sound Power Level dBA Noise source position factor dBA dBA Barrier attenuation factor dBA dBA Evaluation point factor dBA dBA Distance factor dBA dBA Sound Pressure Level at evaluation point dBA This approach leads to an ESTIMATE of the resulting noise level This estimate assumes the usual installation condi...

Page 14: ...AM EM AQ BA ASW IOM page 14 64 Ing Jiří Jiránek Layout drawing for the noise evaluation ...

Page 15: ...e bracket is placed on the wall For attaching use chemical anchors and stainless screw rod only or use stainless screw rod and screw it through the wall The bracket has 4 holes of 10mm DIA for attachment to the wall The chemical anchors and stainless screw rods are not a part of the supply Vertical and horizontal on legs The outer unit is supplied with 4 pcs of stands for positioning on a suitable...

Page 16: ...Jiří Jiránek EM60Z EM75Z outdoor unit 4 legs are delivered with the outdoor unit for location on a suitable basement Recommended basement is on picture below wall plastic tube concrete 100 150mm like casing terrain draining acc snow base ...

Page 17: ...e RCD circuit breaker or additional earth wiring Minimum free area around unit is neccessary for sufficient air flow heating water piping and electrical connection Minimum clearances are shown on the picture below Clearances BoxAir We recommend preparing of following basement before unit installation Height of the basement should be corresponding to the ussual snow height during winter PLASTIC PIP...

Page 18: ... recommend using pre insulated piping The connection comprises always of the steam piping and liquid piping Never use piping dedicated for water Piping dimensions of different types of heat pumps see table below typ TČ D vapour line mm d liquid line mm max length m max height m AM3015 18x1 3 4 12x1 1 2 15 10 AM3021 18x1 3 4 12x1 1 2 15 10 AM3030 22x1 7 8 12x1 1 2 15 10 AM3038 22x1 7 8 12x1 1 2 15 ...

Page 19: ...concrete etc Holes under the ground must be waterproofed to prevent the humidity and water from penetrating the building 2 2 2 Horizontal Parts of the Vapour line The horizontal parts of the vapour piping must be descended by 1 100 toward the coolant flow in the heating mode always in direction from the outer toward the inner unit 2 2 3 Vertical Parts of the Vapour line In the case the piping is v...

Page 20: ...ng the body of the valve Proceed with care no moisture must get into the cooling circuit under any circumstances Instructions for ball valve welding Removing the core of the service valve of the outer unit Inspect visually after welding and cooling of joints 2 4 Leak Test After welding put the core back to the service valve of the outer unit and pressurize it using nitrogen to 10 bars 1 0MPa Inspe...

Page 21: ...alves and the ROTALOCK valve must be screwed back on When manipulating with the ball valve caps special attention must be paid to the Teflon sealing so it is not lost The plastic cap of the ROTALOCK valve is sealed by the coned surfaces and no sealing is used Tighten the valve cap manually Then tighten by wrench 2 7 Thermal Insulation Both the liquid and steam piping must be insulated to prevent c...

Page 22: ...ged Cu piping with PE or PVC coating and certification for cooling equipment must be used for installation The piping must be certified per EN12735 1 Usually piping of 12mm DIA 65m long or 14mm DIA 75m long are available Never use piping designed for water The following table lists numbers of earth collector loops piping Cu12x65m piping Cu14x75m Typ TČ heat capacity kW E0W35 land area m2 loops len...

Page 23: ...ed for distribution and collection of 2 refrigerant lines Vertical inlet orientation is required for refrigerant distribution vapor and liquid mixture If elbow is used in front of the distributor it must be oriented perpendicularly to the loop lines There is no direction limitation for collector fitting cause vapour inside only ...

Page 24: ...ust be installed in such direction that from a half of its length it is descending in the direction from the distributor toward the collector to make sure the oil returns to the compressor Always use only the Cu roller type pipe cutter for cutting the piping never use a saw Cut the piping immediately prior to connecting operation Remove the plugs no sooner than immediately prior to connecting weld...

Page 25: ...ur line liquid line shaft collector min 50cm distributor ground loop lines Ground loop and heat pump piping 3 3 Brazing Please see chapter 2 3 3 4 Leak Test Please see chapter 2 4 3 5 Vacuuming Please see chapter 2 5 3 6 Circuit Connection Please see chapter 2 6 3 7 Thermal Insulation Both liquid and vapour lines must be insulated inside the building Insulation between the building and the collect...

Page 26: ... system and thus the needed area of land depend on the heat loss of the building power of the heat pump and the heating capacity of the soil Following table lists approximate values of various types of soil Type of soil Yield on m2 of land Area needed for 1kW of building peak heat demand dry non cohesive 10W m2 70m2 moist cohesive 20 30W m2 40 26m2 wet loose 35W m2 20m2 The main requirement of the...

Page 27: ...300m Loops Spacing m Pipe Length m Circuit Volume l AQ17 6 6 300 PE32 3 0 6 600 318 AQ22 AQ22I 7 8 350 PE32 3 0 6 600 318 AQ26 10 1 450 PE32 4 0 6 800 425 AQ30 AQ30I 11 4 500 PE32 5 0 6 1000 531 AQ37 14 1 600 PE32 5 0 6 1000 531 AQ45 17 2 700 PE32 6 0 6 1200 637 AQ50 18 5 750 PE32 7 0 6 1400 743 AQ60 AQ45I 22 8 950 PE32 8 0 6 1600 849 AQ75 27 8 1150 PE32 10 0 6 2000 1061 AQ90 AQ60I 33 2 1350 PE32 ...

Page 28: ...ts for excavation works but it is necessary to use more piping and thus the total volume of anti freeze mixture is increased 4 2 3 SLINKY V Horizontal Loop The principle is the same as the previous type with the difference that it allows for high savings on excavation works in the case suitable mechanization and suitable subsoil are available SAND BED WARNING FOIL MODULES ASSEMBLY 1 circuit length...

Page 29: ...6 150 PE32 2 400 212 AQ22 AQ22I 7 8 200 PE32 3 600 318 AQ26 10 1 250 PE32 4 800 425 AQ30 AQ30I 11 4 250 PE32 4 800 425 AQ37 14 1 300 PE32 5 1000 531 AQ45 17 2 350 PE32 6 1200 637 AQ50 18 5 400 PE32 7 1400 743 AQ60 AQ45I 22 8 500 PE32 8 1600 849 AQ75 27 8 600 PE32 10 2000 1061 AQ90 AQ60I 33 2 700 PE32 10 2000 1061 4 2 4 Vertical Ground Loop This is an earth heat exchanger in the shape of single or ...

Page 30: ...ircuit 10m Vertical ground loop Drilling position The following table lists recommended configurations of vertical collectors drills dry subsoil 25m kW No of Drills Loop type HP Type H Cap B0W35 kW Total Depth m Pipe Dimension 4x 2x Depth 1 Drill m Pipe Length m Circuit Volume l AQ17 6 6 166 PE25 2 83 664 208 AQ22 AQ22I 7 8 196 PE32 2 98 784 416 AQ26 10 1 254 PE32 3 85 1016 539 AQ30 AQ30I 11 4 286...

Page 31: ...E32 2 57 456 242 AQ37 14 1 142 PE32 2 71 568 301 AQ45 17 2 172 PE32 3 57 688 365 AQ50 18 5 186 PE32 3 62 744 395 AQ60 AQ45I 22 8 228 PE40 3 76 912 484 AQ75 27 8 278 PE40 4 70 556 447 AQ90 AQ60I 33 2 332 PE40 4 83 664 534 4 3 Caution This dimensioning of heat exchangers assumes standard heating season for a family house in CR of average length 230 days and a year round preparation of domestic hot w...

Page 32: ... distributor collector body should be dimensioned for max flow speed 0 5m s 4 6 Manifolds Location There are 2 kinds of distributor positions 4 6 1 Manifolds in the Collection Shaft It is usually used in places where there is a big distance between the collector system and the heat pump unit or in places with lack of space inside the building The advantage is that only 1 pair of piping is connecte...

Page 33: ...W35 kW PE32 PE40 PE50 PE63 AQ17 6 6 12 40 120 300 AQ22 AQ22I 7 8 10 30 100 250 AQ26 10 1 3 20 60 180 AQ30 AQ30I 11 4 20 60 150 AQ37 14 1 10 30 120 AQ45 17 2 4 20 80 AQ50 18 5 20 70 AQ60 AQ45I 22 8 12 50 AQ75 27 8 6 30 AQ90 AQ60I 33 2 4 25 4 8 Hydraulic system schematic venting valves expansion vessel with fitting set ball valve with filter filtrball ball valve heat pump with internal source pump d...

Page 34: ...urer After the system completion the leak test of the whole unit is performed by surplus pressure of 2 5 bars The test is performed by filling the system with water and pressuring it by air The heat pump is disconnected during the test by closing the valves A written report about the test is made out 4 11Heat Insulation After the Pressure and Leak Test is performed heat insulation of earth collect...

Page 35: ...eave to run the pressed out water outside the barrel turn the pump off after filling the measured volume Close the loop and open the next one in line repeat the process above After filling the required volume of concentrate for the entire collector app 1 3 of loops refill the barrel with water only as much as we need refilling as needed Close all loops and return to the 1st loop open it Put the wa...

Page 36: ...al capacity and relative volume Capacity kW relative volume l kW Maximum Hardness dH pH value 50kW 20l kW 16 8 9 50kW 20l kW 11 8 9 50 200kW 11 8 9 200 600kW 8 8 9 600kW 0 11 8 9 5 2 1 Corrosion Inhibitors It is neccessary to check water quality before filling the system and add corrosion inhibitors Type of heating system components material muts be taken into consideration and use suitable corros...

Page 37: ...g system already installed Their connection is thus easy and fast The AKU unit must be connected as per the following scheme electrical supplementary hot water heater safety valve DN25 1 8bar pump loop mixing loop shut off valves tap water inlet filter ball valve filterball draining valve expansion vessel Hydraulic scheme of AKU unit connection ...

Page 38: ... In the case of usage for radiators it is also necessary to comply with the requirement of minimum heating water volume of 15 l kW of the heating output of the heat pump at B0W35 The DHW heating is provided by a 3 way switching valve Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water tap water inlet DHW outlet desuperheater optional pump loop pump HC so...

Page 39: ...of the heat pump for B0W35 Heating of DHW is also provided by a 3 way switching valve Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water desuperheater optional pump loop all year pump HC venting valves tap water inlet DHW outlet solar system pump HC 3 way valve filtrball check valve safety valve mixing DN25 2 5bar hc heating system buffer DHW tank expan...

Page 40: ...ermined for 15 l kW of heating output of the heat pump for B0W35 Heating of DHW is provided by a charge circulation pump from the accumulation vessel of the heating system Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water tap water inlet DHW outlet venting valves mixing HC pump HC DHW charging pump filtrball safety valve DN25 2 5bar expansion vessel he...

Page 41: ...irement of minimum heating water volume of 15 l kW of the heating output of the heat pump at B0W35 Unit is equipped with stainless steel DHW tank volume 170l Important Note Due to the stainless steel DHW tank maximum Cl content of the tap water could be 250ppm DHW outlet tap water inlet max 250ppm Cl solar inlet solar outlet solar pump solar system expansion vessel and safety valve venting valves ...

Page 42: ...rvoir to which the pump heating circuits are connected Each circuit has its own spatial thermostat which switches the circulation pump The vessel temperature is maintained equithermally depending on the outside temperature The DHW is flow through heated in the Cu exchanger of the accumulation vessel with subsequent electric accumulation after heating venting valves electric DHW tank DHW outlet tap...

Page 43: ...way switching valve Regarding the type of DHW tank follow instructions in the chapter Preparation of Domestic Hot Water Warning for good operation 10 15 propylene glycol is required due to the 20 C antifreeze protection of the heat pump inlet when pure water is used venting valves tap watet inlet DHW outlet pump HC desuperheater pump group solar pump 3 way group valve DHW venting valves filterball...

Page 44: ... of DHW is also provided by a 3 way switching valve Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water Warning non direct heating boiler for DHW cannot be used venting valves tap watet inlet DHW outlet pump HC pump HC desuperheater pump group solar pump 3 way group valve filterball safety valve DN25 2 5bar mixing HC expansion vessel tank in tank DHW ves...

Page 45: ...ut of the heat pump for A7W35 Heating of DHW is provided by a charge circulation pump from the accumulation vessel of the heating system Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water tap water inlet DHW outlet venting valves DHW charging pump mixing HC pump HC desuperheater pump group ball valves filterball safety valve DN25 2 5bar expansion vessel...

Page 46: ...stem maximally 30 of the heating system can be equipped by local regulation In the case of usage for radiators it is also necessary to comply with the requirement of minimum heating water volume of 15 l kW of the heating output of the heat pump at B0W35 Heating of DHW is provided by a 3 way switching valve Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Wa...

Page 47: ...ng output of the heat pump for A7W35 Heating of DHW is provided by a 3 way valve Regarding the type of DHW tank follow instructions in Chapter Preparation of Domestic Hot Water venting valves tap water inlet DHW outlet pump HC pump HC solar pump 3 way group valve DHW safety valve DN25 2 5bar flexible fittings filterball mixing HC expansion vessel tank in tank DHW vessel heating system buffer with ...

Page 48: ...ter tap water inlet DHW outlet DHW venting valves charging pump mixing HC venting valves pump HC safety valve DN25 2 5bar filtrball flexible fittings expansion vessel heating szstem buffer with integrated manifold DHW tank with heat exchanger BoxAir BoxAir Inverter machinery room for multiple circuits and charging DHW 5 6 4 Heating system charge for BoxAir and BoxAir Inverter Antifreeze mixture of...

Page 49: ...d for connection to the DHW tank and heating system buffer Controller is not designed for heating circuits control tap water inlet DHW outlet tank in tank DHW vessel heating system buffer 3 way valves DHW safety valve 2 5bar pump HC outlets condensate draining filterball expansion vessel flexible fittings ASW machinery room with tank in tank DHW configuration ...

Page 50: ...distributor collector should not exceed 0 5m s The distributors can be independent with integrated thermohydraulic distributor or integrated in the accumulation vessel We recommend using manufactured distributors which make the installation faster and easier Typical implementation in the following images heating circuits outlets inlets from energy source inlets from energy source combined manifold...

Page 51: ...ets which make the installation faster and easier 5 8 3 Mixing heating circuits Typical usage is in projects where more heating circuits with different operating temperatures need to be combined Typical application is thus floor heating The following image describes the components of a typical mixing circuit which are required for flawless operation and maintenance return line from heating circuit...

Page 52: ...ll MINI units The advantage is higher temperature of DHW achieved than in the non direct heating boiler typically 50 to 55 C Another advantage is easy connection to hot water solar collectors and using the higher temperature of heating water for the circuit of towel radiators or seasonal heating of a pool tap water inlet DHW outlet DHW internal tank optional high temperature pump circuit 3 way val...

Page 53: ... pumps The Charge Pump draws heating water from accumulation boiler of the heating system and heats DHW Recommended heat transfer area of the exchanger is 2m2 300l of the boiler volume During preparation of DHW the control system automatically cancels the equithermal control and sets the required value of heating water to maximum tap water inlet DWH outlet charging pump heat source outlet indirect...

Page 54: ...f through flow afterheating to required temperature is performed Typical area of exchanger is 4 to 5m2 This kind of heating does not cause bacterial risk in the low temperature part of heating This system requires no control it is self regulating DHW outlet tap water inlet electric DHW tank optional circulation return heat source heating system outlets copper stainless steel heat exchanger 4 5m 2 ...

Page 55: ...ritten report about the test is made out 5 12Heat insulation After the Pressure and Leak Test is performed heat insulation is performed Unlike for the ground loop common insulation materials based on PE mirelon or mineral wool isover can be used for heating system 5 13General Instructions After connecting the heating system the following instructions need to be followed Filter with 0 5mm sieve mus...

Page 56: ...of power supply is in the following table heat pump type no aux heater aux heater kW 3x400V 4 5 6 7 5 AQ9Z1 16A B AQ17Z 9A C 16A B 16A B 20A B AQ22Z 9A C 16A B 20A B 20A B AQ22I 20A B 20A B AQ26Z 13A C 20A B 20A B 20A B AQ30Z 13A C 20A B 25A B 25A B AQ30I 20A B 20A B AQ37Z 16A C 25A B 25A B 25A B AQ45Z 16A C 25A B 25A B 25A B AQ45I 16A B 25A B 25A B 25A B AQ60Z 25A C 32A C 32A C 32A C AQ75Z 25A C ...

Page 57: ...B 63A B BA37Z1 63A B 63A B BA22I and BA30I it is possible to use 1x230V N PE and 3x400V N PE as well 6 2 Tariff signal remote on off signal Units with pCO5 controller are equipped with digital input for dry contact external relay used for remote on off We recommend to use relay with manual control Please check wiring diagram delivered with heat pump for terminals location and connection example 6 ...

Page 58: ...not used pump could be used solar panel probe is not the part of delivery and it must be ordered separately Pt1000 whes solar control is used 1 pump circuit is lost 7 2 Optional Expansion Card It is optional equipment It must be ordered together with heat pump Expansion card is delivered like separated wall mounted box including all probes and terminals heat pump type main HC buffer mixing pump HC...

Page 59: ...g diagram delivered with heat pump for terminals numbers and connection examples 7 5 Circulating pumps Pumps are wired to heat pump terminals or X3 terminals in case of expansion card Please see wiring diagram delivered with heat pump for terminals numbers and connection examples 7 6 pAD room terminals We recommend to use of pAD room active communicating terminals pAD could be used for each heatin...

Page 60: ...ting inspection liquid must flow through all loops inspection by closing the ball valve of each loop immediately before closing a strong hydraulic noise is heard inspection of mixing of anti freeze mixture by closing one loop at a time for half the time required for a full circle of the entire volume of anti freeze mixture flow sensor inspection or modification of its setting inspection of hydraul...

Page 61: ...uit inspection of overpressure and sufficient filling of hydraulic circuits inspection and cleaning of filter sieves inspection of anti freeze mixtures if used as the filling inspection of venting 9 4 Annual Maintenance inspection of refrigeration circuit during operation temperatures and operating pressures condensation pressure evaporating pressure expansion valve setting compressors suction tem...

Page 62: ...and hydraulic calculations in accordance with applicable standards must be performed and operating project documentation prepared for each installation European and national standards and other locally applicable regulations must be observed during design and installation Building permit is usually required for installation of the heat pump The Master Therm company is not liable for proper operati...

Page 63: ...AM EM AQ BA ASW IOM page 63 64 Ing Jiří Jiránek NOTES ...

Page 64: ...h Republic Tel 420 311 516 567 Zelená linka 800 444 000 info mastertherm cz www mastertherm cz Head office and billing address Master Therm tepelná čerpadla s r o Václavské náměstí 819 43 110 00 Praha 1 Czech Republic IČ 288 922 75 DIČ CZ 288 922 75 E55 D8 R7 E48 E50 D5 E50 D1 E50 E65 D11 R10 E65 R1 R1 R1 R1 ...