ESP Classic 15kW, 17kW and 25kW Installation ... - Heat & Plumb

ESP Classic15kW, 17kW and 25kWInstallation ManualEarth Save Products Ltd©ESP Oct2009

CONTENT1 Preface 22 Safety Precaution 3(1) Mark notes 3(2) Icon notes 3(3) Warning 4(4) Attention 43 Specification 5(1) Appearance and Structure of the heat pump 5(2) Specification data 5(3) Unit dimension 64 Installation 6(1) Application of heat pump 6(2) Choose a right heat pump unit 7(3) Installation place 7(4) Installation method 7(5) Water loop connection 7(6) Power supply connection 7(7) Location of the unit 8(8) Transit 8(9) Trial running 85 Usage 9(1) Wire controller function 9(2) How to use the remote controller 96 Maintenance 12(1) Maintenance 12(2) Ordinary malfunctions and solution 127 Appendix 14(1) Appendix 1 14(2) Appendix 2 14(3) Appendix 3 14(4) Appendix 4 14(5) Appendix 5 14(6) Appendix 6 15Preface Congratulations on purchasing your ESP Classic Series air source heat pump (“ASHP”) fromEarth Save Products Ltd. (“ESP”) and thank you for entrusting the heat of your home to one ofour units. In line with our policy of providing high quality, durable products with market leading technology,the ESP Classic Series air source heat pumps has been developed using strict design andmanufacturing standards. This manual incorporates the information necessary to install, operateand maintain the units. Please read this manual carefully before you start to install and/or operatethe ASHP and follow the instructions carefully.Please note that we do not accept any liability if loss or damage is caused as a result of improper/inappropriateinstallation or operation of the unit and that the warranty for the unit willbe invalidated in the event that it is not installed and operated in accordance with this manualand any separate written instructions supplied with the unit.It is extremely important that the unit is installed by a suitably qualified person. For the warranty on the unit to remain valid you must ensure that:- The unit is installed and any maintenance or repair is carried out by a suitably qualified engineer.Please call ESP if you are unsure about the qualifications of your installer.- Installation, operation and maintenance must be carried out according to the information inthis Manual – if you are at all unsure, please call ESP for advice prior to proceeding.- Any repairs must be done using spares that ESP will supply or using genuine “like for like”makers parts.Failure to follow these recommendations will invalidate the warranty. Our ESP Classic series of ASHP units have the following features:1. Advanced controlThe microcomputer based controller is supplied with the unit and allows you to review orset the unit running parameters.2. AppearanceThe heat pump is designed to be discrete and attractive.3. Flexible installationThe unit has a well protected frame and cabinet – all galvanised and powder coat painted forlong life and easy cleaning.(7) Appendix 7 152©ESP Oct2009

Preface4. Quiet runningOur high quality and efficient compressors, fans and water pump ensure that the unit runs withvery low noise levels. The unit also has sound insulation to make the unit one of the quieteston the market.5. Heat exchange rate.Our units are designed and equipped with highly efficient heat exchangers to provide maximumheat exchange efficiency.6. Large working rangeThe ESP Classic Series units are designed to work in wide temperature ranges. The units willwork very effectively and efficiently down to as low as -15 degrees in heating mode.InstallationOur units are all designed with ease of installation in mind. Most of our units are“hydraulically complete” which ensures that installation is quick and easy, thus keepinginstallation costs low.Safety PrecautionTo prevent the users and others from the harm of this unit, and avoid damage on the unit or otherproperty, and use the heat pump properly, please read this manual carefully and understand thefollowing information correctly.PLEASE REMEMBER – We are here to help you and your installer in any way that wecan. It is important to us that your installation goes smoothly and that you have many yearsof trouble free operation. We prefer you to call and ask us for assistance whenever you needit rather than struggling along – no question is unimportant and you will receive our immediateattention and support. We recognise that no Manual can give all the answers and thatinstallations may be done at any time of the day/evening or weekends, so please call any time(01235 815569, 07860 422 996 or 07990 903 751).3©ESP Oct2009

Safety PrecautionSafety Precaution4©ESP Oct2009

1. Appearance and structure of the unitSpecificationSpecificationUnit Model ESP Classic 15kW 17kW 25kWCooling capacityHeating capacitykW 11.0 13.0 22.0BTU/h 40000 45000 75000kW 14.0 16.0 24.0BTU/h 48000 55000 82000Cooling power input kW 4.0 4.6 6.9Heating power input kW 4.2 4.9 7.4Running current (Cooling/Heating) A 17.4/18.3 20.0/21.3 30.0/32.2Power supply V/Ph/Hz 230/1/50 230/1/50 230/1/50Compressor quantity 2 2 3Compressor Rotary Rotary Rotary2. The data of unitFan quantity 2 2 2Fan power input W 120 x 2 120 x 20 200 x 2Fan rotate speed RPM 850 850 750Noise dB(A) 56 56 59Water pump input kW 0.2 0.2 0.75Water head m 10 10 24Water connection inch 1 1 1.5Water flow volume m²/h 2.3 2.8 3.8Water pressure drop kPa 34 34 36Unit net dimensions mm See the drawing of the unitsUnit shipping dimensions (L/W/H) mm See package labelNet weight kg See nameplateShipping weight kg See package label5Cooling: Ambient temperature: 35°C/24°C, Inlet/outlet water temperature: 12°C/7°CHeating: Ambient Temperature: 7°C/6°C, Inlet/outlet water temperature: 40°C/45°C(Above information just for your reference only. Please subject to nameplate on the unit)PLEASE NOTE: Tested under EN14511 test conditions the units heating outputis 15kW, 17kW and 25kW respective ly with correspondingly higher COPs.©ESP Oct2009

SpecificationInstallation3. Unit Dimension1 Application of heat pump1.1 Only for air-con1.2 Air-con and super heater (for hot water)6

Installation2. Choose a right heat pump unit2.0 Choosing the right sized heat pump is critical to the efficiency of the system – if it is toosmall, it may cause the heat pump to operate outside its design cases and, if too large, theunit will cycle too often. If you have any doubt about the size of you unit, please consultyour system designer before installing the unit.2.1 Based on the local climatic conditions, construction methodology, size of property, insulationlevel (floor, walls, roof and windows), your system designer should have calculated the requiredheating capacity per square meter.2.2 Based upon your heating requirement per square meter, you can calculate the size of theASHP required to heat the desired “Heating Envelope” (the areas within your house that is tobe heated by your system).2.3 Air source heat pumps (“ASHP”) are suitable for domestic and commercial buildings.3. Installation place The unit can be installed on any level and stable site outside. If you do not have a level/stablesite that the ASHP can be fixed to, you can prepare a concrete plinth to site the unit on –make sure that you make the plinth about 10cm larger than the ASHP dimensions so thatlocating the unit is easy. As the units are heavy, it is best not to have to move the unitaround to small measuring tolerances.Further installation/location considerations are as follows: The location must be well ventilated. The unit must not be exposed to flames or very hot radiated temperatures (e.g. Bonfires in thegarden). The unit must be kept clear of deep settled snow and ice around it. The plinth that the ASHPsits on should be raised 150mm from general ground level to keep the unit above snowfall.If snow is higher than the plinth, you need to clear snow around the unit. There must not be any obstacles near the air inlet and outlet of the heat pump – obstacles willdisrupt air flow to and from the unit and this can have an adverse impact upon efficiency. The installation site should be sheltered from direct high winds as this can adversely impactupon the performance of the unit. You should make provision for full and appropriate drainage of condensate water produced bythe unit and be sure to not drain the condensate to surfaces that could freeze over and be ahazard. There must be adequate space around the unit for maintenance.Installation4. Installation methodThe heat pump should be fixed to the base such that it is level. Rubber anti-vibration pads aresupplied with most ASHP units and can be purchased from the supplier as an extra in all othercases.5. Water loop connectionPlease NOTE the following: Install all pipe work in a manner that minimizes resistance/back pressure – otherwise theflow switch may trigger and shut down the unit. Make sure that all system pipe work is clear of obstructions or blockage. The water leakpressure test must be carried out to ensure there is no water leaking – the leak test shouldbe carried out before the heat pimp is connected in to the system. Once the leak test hasbeen successfully completed, insulation may be installed on all exposed pipe work. Where not fitted with a pressurization vessel as standard, an ancillary pressure vessel shouldbe fitted to the un-vented loop. The expansion vessel should be installed in accordancewith local/national Regulations or recommendations made by suitably qualified Authorities. The pressurised heating loop will need to be purged of air and it is critical that all air is expelledfrom the system – otherwise, the intelligent controller may prevent the systemoperating in order to protect key components. To assist in this process, auto air ventsshould be fitted in the loop at the highest points or “dead legs” within the system. Air inthe system will show as system error Code 003. A thermometer and pressure meter must be fitted as close as reasonably possible at the waterinlet and outlet of the unit for easy inspection during operation.6. Power supply connection Open the front panel and open the power supply access. The power supply must go through the supply wire access point and be connected to thepower supply terminals provided within the unit. Then connect the controller block/clipconnector signal wires of the remote controller to the main controller. If an external water pump is needed, please insert the power supply wire for the externalwater pump into the unit via the same wire access and connect to the water pump terminalson the Chiller 300 Control inside the unit.7©ESP Oct2009

Installation If an auxiliary heater is required and it is to be controlled by the heat pump controller, therelay (or power) of the auxiliary heater must be connected a to the relevant output of thecontroller.NOTE – The unit needs to be wired back to the consumer unit via a 32 A, type C MCB. Pleaseensure that all electrical work is carried out by a suitably qualified electrician.7. Location of the unitInstallation9. Trial runningInspection before trial running: Check and make sure that the pipe connections are right and the relevant valves are open. Check the water loop, to ensure that the water inside of the expansion vessel is adequate,the water supply is good and that the water loop is full of water and without any air in it.Also make sure there is suitable and adequate insulation for the water pipes. Check the electrical wiring again to make sure that all wires are securely in place and connectedwhere they should be. Make sure that the wiring has been installed in line with thediagram provided and that the earthing is properly connected. Check the heat pump unit over thoroughly, including all of the screws and parts of the heatpump to see if they are in good order, secure and suitable to be commissioned. When thepower is switched on, review the unit status noted on the remote controller to see if thereis any error message showing. [The gas gauge can be connected to the check valve to seethe high pressure (or low pressure) of the system during trial running.Trial running8. TransitWhen the unit need to be hung up during installation, a 8meters cable is needed, and there must be soft materialbetween the cable and the unit to prevent damage tothe heat pump cabinet. (See picture 1)Pic 1 Start the heat pump by pressing " or " key on the remote controller. Check whetherthe water pump is running - if it runs normally there will be 0.2 MPa on the water pressuremeter. When the water pump has been running for 1 minute, the compressor will start. Listen tomake sure that on start up the compressor(s) do not make any unusual sounds. If you hearanything abnormal please stop the unit and check the compressor for any obvious problems.If the compressor runs well check the pressure meter of the refrigerant. Then check whether the power input and running current is in line with this manual. If notplease stop and check over the installation work again. Adjust the valves on the water loop, to makes sure that the hot water supply to each dooris good and meet the requirement of heating (or cooling). Check that the outlet water temperature is stable. Please note that running parameters are factory set and may not be altered by the end user– parameter settings must be locked.8©ESP Oct2009

UsageUsage1) Wire controller functions instruction2) How to use the remote controller:r9©ESP Oct2009

UsageUsage10

UsageUsage11

MaintenanceMaintenance Check the water supply and air vent once a quarter to prevent there being inadequate water availableor not enough air circulating around the Unit.Clean the inline water filter as required as is sensible based upon your water supply. The above inimportant as a lack of water and/or dirty water in the system can damage the unit.The heat pump will start run the water pump once every 72 hours when it is not in regular use.This is to try and avoid freezing the system. Keep the unit in a place which is dry and clean and has good ventilation all round – the front andback of the unit are of particular importance.You should also clean the evaporator to the rear and side of the unit every in 1 or 2 month(depending on the time of year – leaves can affect performance) in order to keep the maximumheat exchange surface. During maintenance, check each part of the unit and the pressure of the system (water side andrefrigerant). Replace parts as necessary and recharge the refrigerant if needed. Check the power supply and the electrical system - make sure that the electrical components arefree and clear of any foreign matter and check that wiring appears intact and free of any problems. If the heat pump is not in use for a long period, please drain out all the water in the unit and sealthe unit to keep t good. Please drain the water from the lowest point of the heat exchanger toavoid freezing in winter. Water recharge and inspection of the heat pump is needed before it isrestarted. Please drain out the water in the super heater of the heat pump unit in winter, when the superheater is not used. The water loop of the heat pump MUST be protected from freezing in late Autumn/winter/earlySpring . Please note the recommendations below - If not followed the warranty for the heat pumpwill be invalidated.(1) Please do not shut off the power supply to the heat pump in Winter. When the ambienttemperature outside is below 0°C and if, the inlet water temperature is 2°C (or lower), theheat pump will run to provide heat to prevent frosting.(2) Use anti-freezing liquid (glycol/water mix 25/75)1) look for below table for the volume of the glycol water2) The glycol water can be added into the system via the expansion tank of the water loopor the filling loop.NOTE: If glycol water is too much, the water flow and water pump will be influenced and the heat exchangerate will be decreased. This table is for reference , please use anti-freezing water according to the real conditionof the local climate.2. Ordinary malfunction and solutionMalfunction Running lamp Reason ResolutionWater in 1 Flash The water inlet sensor is disengaged orshort circuitWater out 2 Flash The water outlet sensor is disengaged orshort circuitPipe temp. 1 3 Flash The pipe temp sensor is disengaged orshort circuitPipe temp. 2 4 Flash The pipe temp sensor is disengaged orshort circuitAmbient temp. 5 Flash The ambient temp sensor is disengaged orshort circuitTemp. difference ProtectFrost protectionFrost protectionWater flow volume not inadequate, waterpressure difference is too lowAmbient or inlet water temp. is too lowAmbient or inlet water temp. is too lowCheck or change the sensorCheck or change the sensorCheck or change the sensorCheck or change the sensorCheck or change the sensorCheck the water flow volume, or system obstructionSystem 1 System 1 protection was failed Check each protection point of system 1 removethe malfunction according to System ProtectionBoard malfunction tableSystem 2 System 2 protection was failed Check each protection point of system 2 removethe malfunction according to System ProtectionBoard malfunction tableWater flow 8 Flash No water/little water in water system Check the water flow volume or water pumpfailurePower phase (systemprotect)High/low pressureWrong electricity phase used or lack ofgood connectionGas charge too low or high. Possiblesystem blockageCheck connections of power cable and phase ofelectricity supplyCheck through each pressure switch and returncircuitTemp. difference error Water flow rate not high enough Check the water flow rate and identify whichcomponents has failed and replace accordingly12Communication problembetween unit and PCBController, unit and the PCBconnection failureCheck the connection

Maintenance(2) You can judge and remove the malfunctions according to the malfunction code display on thePROTECT 300 (only for 3 phase units).Maintenance(3) Look over and clear the failure according to below information.Failure Possible causes for the failure SolutionsDisplay Name Reason Action Recover(yes or no)RevolutionHeat pump cannot bestarted1. Incorrect power supply2. Power supply cable loose3. Circuit breaker open/failed1. Shut off the power and check power supply2. Check power cable and re-make connection3. Check for cause and replace the fuse or circuit breaker1 Cooling water freezing Cooling water temp. toolow2 Cooling water anti freezingfailureCooling water temp. aftertube inlet too low3 Low pressure Low pressure switchaction4 Compressor exhaust temp toohighCompressor exhaust temptoo high5 Over-current on compressor Current through compressortoo high6 High pressure High pressure switchaction7 Temp. sensor before tubefailure8 Tube outlet temp. sensorfailureTemp. disengaged sensoror short circuitTemp. disengaged sensoror short circuit9 Exhaust temp. sensor failure Temp. disengaged sensoror short circuitUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmUnit stopsand alarmYesYesYesYesYesYesYesYesYesCheck water flow volume and tempsetting and controllerCheck the water systemCheck through the pressure switchand systemCheck through therefrigerant system for faults andoverloadingCheck through the power supply tocompressor or for short circuitCheck through the pressure switchand systemCheck and renew the sensorCheck and renew the sensorCheck and renew the sensorNoisy water pump whenrunning or no watercirculatingHeat pump capacity islow or compressorrunning continuouslyHigh temperature atcompressor exhaustLow pressure in refrigerantsystemCompressor not runningNoisy compressor1. Lack of water in the system2. Air in the system3. Water valves closed4. Dirt blocking the water filter1. Lack of refrigerant2. Inadequate insulation on water pipes3. Low heat exchange rate on air side exchanger4. Lack of water in the system1. Too much refrigerant2. Low heat exchange rate on air side exchanger1. Lack of refrigerant2. Block on filter or capillary1. Power supply failure2. Compressor contactor failed3. Power cable loose4. Automatic protection implemented on compressor5. Wrong setting on return water temp.6. Lack of water flow1. Refrigerant carry over to compressor2. Compressor failure1. Check the water supply and charge system fully2. Bleed the air from the system3. Open the valves4. Clean the water filter1. Check for refrigerant leakage and recharge the refrigerantafter repairing any leak2. Improve insulation on water pipes3. Clean the air side heat exchanger4. Clean the water filter1.Discharge the excess refrigerant2. Clean the air side heat exchanger1. Check for gas leakage and recharge refrigerant2. Replace filter or capillary1. Check the power supply to the compressor2. Replace compressor contactor3. Tighten the power cable4. Check the compressor exhaust temp.5. Reset the return water temp6. Clean the water filter and discharge any air in the system1.Evaporation rate low – check and repair as appropriate2. Install new compressorEPower supply wrongconnectionWrong connection or lackof connectionUnit stopsand alarmYesCheck the connections and powersupply being used (i.e. single or 3phase)Fan not runningThe compressor runs butheat pump has no heatingor cooling capacity1. Failure of fan relay2. Fan motor broken1. No refrigerant in the heat pump2. Heat exchanger failure3. Compressor failure1. Replace the fan relay2. Replace fan motor1. Check system for leakage, repair as appropriate andrecharge refrigerant2. Establish the cause of the failure and repair. Replace theheat exchanger3. Replace compressorLow outlet waterTemperature1. Low water flow rate2. Setting for water temp. too low.1. Clean the water filter and discharge any air in system2. Reset the desired water temperatureLow water flow protection1. Lack of water in the system2. Failure of flow switch1. Clean the water filter and discharge any air in the system2. Replace the flow switch13

AppendixAppendix 1Installation request1. The Manual covers only the units supplied by Earth Save Products Limited and not any othersystem components.2. Water pump is fitted inside the heat pump.3. Auto bleed vents must be is installed at the highest point(s) of the water system.4. The flow and return configuration should be installed in a manner that is suitable for any boiler –i.e. A “Y” water strainer must be fitted to the return pipe work with full isolation valves eitherside so that removing the filter for cleaning is a simple exercise – please note that failing to fit a“Y” strainer will invalidate the unit guarantee/warranty. Further, the system should be fitted witha Magnatec/boiler buddy scale inhibitor.You will also need to install a pressurization vessel and filling loop.AppendixThe way to install auxiliary heating in the system is as follows:1) Heat pump + auxiliary heating from a gas-fired boiler:2) Heat pump + auxiliary in-line electric boiler:Appendix 2NOT IN USEAppendix 3The heat pump unit is supplied with a blow off valve that will release pressure should the systemreach a pressure higher than 3 bar.Appendix 5Unit parameter settings:Please set unit running parameters according the following table:Appendix 4Fitting auxiliary heating to the heat pump system:The Unit allows for the addition of auxiliary heating in the system – this can be auxiliary electricalheating or gas boiler.14

AppendixAppendixPlease note:Connections explanation:Setting 00 relates to cooling mode only.Settings 01-08 relate to heating mode only. You can change these parameters according to yourpreference.Parameter Sub-Settings:Parameter 06 sub-settings:1: the unit has 1 compressor.2: the unit has 2 compressors.Parameter 07 sub-settings:0: the unit will restart automatically;1: the unit will not restart automatically.Appendix 7:Connections of PROTECT 300Parameter 08 sub-settings:0: Cooling mode only.1: Heat pump mode (heating and cooling, as required).2: Electrical auxiliary heating activated.3: Heating mode only.Parameter 09 sub-settings:For the ESP XK range, the parameter should be set as follows:1: 60 second delay before compressors start.30 second delay after compressors stop.Connections explanation:Appendix 6:Connections code of the main PCB15