ecodan installation manual - e-si ltde-si.com/downloads/ecodan manual v1-2 feb 2009.pdf · ecodan...

EcoDan Installation Manual Version 1.0 (26/01/09) Ice Energy Heat Pumps Ltd © 2008

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Ecodan Installation Manual


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Contents

Contents .................................................................................................................................................. 2 For The User ........................................................................................................................................... 4 Heat Pump Control and operating principles........................................................................................... 4 First Months of Use ................................................................................................................................. 4 Maintenance ............................................................................................................................................ 5 Heating System Maintenance Advice...................................................................................................... 5 Components ............................................................................................................................................ 6 Items Included: ........................................................................................................................................ 6 Not Included: ........................................................................................................................................... 6 For The Installer ...................................................................................................................................... 7 Specifications .......................................................................................................................................... 7 Installation Process (also see Mitsubishi Manual) .................................................................................. 9 Finding a suitable position for the EcoDan.............................................................................................. 9 For Ice Energy Engineer or approved Sub Contractor.......................................................................... 10 Securing the unit to the floor.................................................................................................................. 10 Internal Plumbing................................................................................................................................... 11 Internal Wiring ....................................................................................................................................... 14 Mitsubishi Flow Temperature Controller (FTC) ..................................................................................... 15 Detailed Honeywell wiring diagram ....................................................................................................... 16 EcoDan Main Supply ............................................................................................................................. 16 Sentinel X500 ........................................................................................................................................ 19 Features & Benefits ............................................................................................................................... 19 Dosing & Feeding .................................................................................................................................. 19 X500 Physical Properties ...................................................................................................................... 19 Technical Specification.......................................................................................................................... 20 Commissioning ...................................................................................................................................... 21 General Notes ....................................................................................................................................... 21 Pre-Commissioning Check List ............................................................................................................. 23 Photos.................................................................................................................................................... 25


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Important Information Please read the whole of this document before starting the installation. There are parts you will need to buy to complete the installation successfully, see page 6 If you have any questions, please telephone 01865 882202, and ask for Technical Support. Pre commissioning check sheet is included that should be completed correctly and sent back to us prior to commissioning (see page 22) Ensure that this manual is left with the householder after installation.


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For The User

Heat Pump Control and operating principles

The Ecodan air source heat pump system consists of an external box which is fitted to your outside wall. It harvests renewable, low grade energy from the outdoor air and upgrades this into useful heat to supply a home with hot water and heating. For every 1kW of electricity fed into Ecodan, you will get at least 3kW of heating energy.

The outdoor unit is a bit like your fridge in that it has a circuit of factory-sealed copper piping containing ozone-friendly refrigerant, which is continually compressed and expanded to extract the free, renewable energy from the air.

Your fridge extracts heat from the box inside (to keep food cold) and rejects it at the back. The air source heat pump works a bit like this but in reverse in that it extracts heat from the outdoor air and upgrades it to heat up your hot water supply.

It can work efficiently all year round even if the outdoor temperature should drop to -15ºC.

The Ecodan range of air source heat pump systems have been developed by Mitsubishi Electric specifically for the UK and bring advanced, inverter-driven technology refined in the commercial heating sector to your home.

Ecodan in Operation:

Ecodan heat pumps are ideal for use in a variety of house sizes or styles and it’s carefully developed control system is designed to work perfectly to provide hot water to either traditional radiators or under floor heating systems.

Traditionally heat pumps have been seen as only suitable for under floor heating, however with the advanced control system of Ecodan and it’s ability to provide optimum variable flow temperature control, radiators can now be easily provided with the hot water they need and prove to be a very efficient option.

Capacity control in radiator systems, with a fixed flow temperature is controlled by Thermostatic Radiator Valves (TRV). These operate by turning the radiators on and off to maintain the desired comfort level. For example at 2°C, with 55°C flow temperature, the radiators will be on 50% of the time and off for the other 50% of the time.

First Months of Use

The Ecodan will vary the flow temperature automatically, based on the ambient temperature to keep the house warm. Operating at these lower flow temperatures significantly improves efficiency.


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The heat pump has been designed to supply enough heat to make up for the heat loss from the building. If the heat pump is commissioned in the winter it may be found that the electric consumption is high for the first few months. This would be due to the initial first start heat load and, on new builds, the building being ‘wet’.

Maintenance

Your heat pump will operate efficiently for many years with minimal attention. An annual check to clean the heat exchanger from debris is all it will require.

Heating System Maintenance Advice

Please consult the heating system installers as to any recommended maintenance requirements. Safety valves fitted to the hot water and central heating systems should be checked annually.


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Components

Items Included:

Ecodan External Unit

Hot Water Tank with immersion heater & temp sensor

Hot Water Expansion vessel & tundish etc…

Flexible hoses

Boiler buddy

Mitsubishi Flow Temperature Controller

Flow setter

Flow temperature sensor

Not Included:

Cables

Honeywell S-Plan control pack or equivalent

Any pipework insulation

Heating System pressure & safety kit

System Pump 1 x 15/60

2 x 22mm zone valves

X500 antifreeze (20ltrs)

2 x 22mm full bore isolation valves


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For The Installer

Specifications

Cylinder

Cylinder Capacity Height Diameter Weight (full)

AUI 180 180 1281 550 225

AUI 210 210 1469 550 260

AUI 250 250 1719 550 305


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EcoDan 5kW EcoDan 9kW

EcoDan 14kW


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Installation Process (also see Mitsubishi Manual)

Finding a suitable position for the EcoDan

The unit must be bolted into place on a stable platform. The unit must also have free air flow as per the diagram below.


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For Ice Energy Engineer or approved Sub Contractor

Securing the unit to the floor

The unit should be mounted on anti-vibration pads, and bolted to the floor using M10 bolts as shown below.


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Internal Plumbing The EcoDan will be installed onto a standard Honeywell S-Plan system. For details on the installation of hot water cylinder please refer to the manufactures literature include in packaging. The only additions to this are a Boiler Buddy and Flow Setter, seen on the following pages.


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Boiler Buddy

1 ¼” BSP fittings. 2 x pump unions with isolators are used to fit the Boiler Buddy to the return pipe.

(fittings not supplied)


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Flow Setter

The ‘flow setter’ is as shown above the circulating pump, and is to be fitted to the return pipe.

When we arrive to install the external unit we would expect to see the primary flow and return on the outside of the building within 1m of the external unit. These should be sleeved and insulated as they go through the wall using 19mm Armaflex. Each pipe should terminate at a Ball Valve and the heating system should be filled and pressurised to this point with water and antifreeze. Ice Energy can supply Sentinel X500 anti-freeze. Please contact us for more information. More information on Sentinel X500 is available later in this manual. (see pages 19,20)


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Internal Wiring Prerequisites:

A qualified part P certified Electrician is required to install the power supply

Nominal current draw ~ 10.3A heating, Maximum current draw ~ 23A

Care should be taken to ensure the power supply is weather proof

Supply cable should be either armoured cable, or twin + earth protected in conduit

Power should be isolated locally within 1.5 metres, minimum 3mm contact gap in isolator

An RCD (residual current device) should fitted in the supply to the Ecodan this should have a tolerance of 30mA or more

The Honeywell S-Plan system will have to be wired to the Honeywell wiring centre as per the instructions included. This will include:

Hot Water Zone Valve

Heating Zone Valve

Heating Thermostat

Hot Water Thermostat

Circulating Pump

5 Amp fuse spur supply

Timer

The Honeywell wiring center will need a 5 core 1mm² cable run to the intended position of the Mitsubishi Flow Temperature Controller (FTC).

Where more than one Heat pump is installed we will commission a bespoke controls system called a step controller, this box will be located near to the hot water cylinder and is approximately the same size as a consumer unit.

Hot water pasteurisation In order to reach a temperature of 65 degrees to pasteurise the hot water to reduce the risks of legionella, we recommend that the immersion heater is wired to a seven day timer and set to come on once every seven days for approx 1hr to achieve this temperature.


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Mitsubishi Flow Temperature Controller (FTC) Also refer to the Mitsubishi Manual. The FTC is wall mounted and should be placed near to the cylinder. See ‘FTC wiring’ installation details included in the box with External Ecodan Heat Pump.

To allow the home owner to continue to operate both their central heating and hot water time clocking using a commonly available two-channel controller, we have introduced the Flow Temperature Controller (FTC) interface.

The FTC will accept signals from a standard "S-Plan" piping configuration and operate the Ecodan in either a Space or Water heating mode, as required. In a Space Heating mode the FTC will ensure that Ecodan operates at optimum efficiency, varying the flow temperature to either the radiator or under floor heating system to meet a homes heating requirements. In a Water Heating mode the FTC will allow the Ecodan to work with leading brands of water storage tanks. It is, however, important to consider that the overall performance of the system in Water Heating mode will be very dependant on the thermal performance of the storage tank's heat exchanger Note: You should always wait at least two days when increasing or decreasing the heating before making a new adjustment.


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Detailed Honeywell wiring diagram

EcoDan Main Supply The main supply for the EcoDan should be installed to the exterior wall within 1m of the EcoDan. The supply should terminate at a waterproof isolator, and should be to the right hand side of the unit.


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5 KW

Circuit Breaker size 16 Amp

Cable size 1.5mm

Maximum Running Current 13 Amp

Maximum Starting Current 3 Amp

9KW


Cable size 4mm



14 KW


Cable size 6mm




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ESTIMATING THE VOLUME OF WATER SYSTEMS

Useful conversion factors:

1kW : 3,412 BTU's 1m3 : 1000 litres 4.546 litres : 1 gallon

The following guide to estimating system volumes has been developed from field experience over many years. Multiply the boiler output rating in kWs by the figure given below for the relevant type of system to give an estimate of the total system volume.

Commercial systems (pressurised):

Systems comprising of perimeter heating, convectors, etc.

: 6 litres/kW

Ventilation systems (air handling units, fan coils, etc.)

: 8 litres/kW

Steel panel radiators : 11 litres/kW

Cast iron radiators : 14 litres/kW

'Distant' heating systems in large sprawling buildings

: 20 litres/kW

Underfloor heating : 23 litres/kW

Domestic systems:

All small & microbore domestic installations

: 6 litres/kW

Allow an additional 10% (multiply by 1.1) for open vented systems of all types.


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Sentinel X500 Sentinel X500 is an Inhibited Antifreeze for Central Heating Systems.

Features & Benefits

Suitable for all metals including aluminium

Manufactured under a quality system con-forming to ISO9001

Effective frost protection

Easy to handle

Helps prevent the formation of hydrogen gas

Effectively controls corrosion and scale Application Sentinel X500 is a multipurpose inhibited anti-freeze formulated to help control corrosion, scale, boiler noise and hydrogen gassing in all types of indirect heating systems including those containing aluminium components. If minimum levels are maintained the product ensures a permanent protection and does not need to be replaced. Sentinel X500 is suitable for use in all waters, both hard and soft. The low toxicity formulation is colourless and easy to handle.

Dosing & Feeding

The dosage of Sentinel X500 will depend on the level of frost protection required. One 20L pail of Sentinel X500 added to a typical domestic sys-tem of 8 to 10 radiator panels will provide the minimum concentration of corrosion and scale inhibitor and also protection from freezing down to approximately -6°C. Two 20L pails will provide protection to -20°C. Further information is avail-able upon request.

For best results, it is recommended that systems are cleansed and flushed in accordance with BS7593; new systems and those up to 6 months old with Sentinel X300, existing systems with Sentinel X400. If the system is already noisy due to lime scale deposits in the heat exchanger, Sentinel X200 should be added together with Sentinel X500.

Open Systems: Dose via F&E cistern, via a by-pass feeder or use a Sentinel Dosing Vessel.

Sealed Systems: If the system is empty, add to any convenient point before filling. If full, use a Sentinel Dosing Vessel to inject via the filling loop or other access point.

X500 Physical Properties

Appearance: Clear colourless liquid

Odour: Mild slightly sweet

Specific gravity: 1.03 (20°C)

pH in aqueous solution (5%): 7.3 (approx)

Freezing point: -58°C Packaging

5 litre bottle

200 litre plastic drum Safety Precautions The information provided overleaf enables compliance with the Control of Substances Hazardous to Health Regulations Full Material Safety Data Sheets are available upon request.


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Technical Specification

X500 is an Inhibited Antifreeze for Central Heating Systems. X500 is a solution of inorganic and organic corrosion and scale inhibitors in propylene glycol. Health Hazards: Not for use in potable water systems. Not considered hazardous to health. Handling: Avoid contact with skin and eyes. Keep out of reach of children and animals. Wash out empty container thoroughly with water before disposal. Storage: Keep container tightly closed. Store in cool, well ventilated area. Spillage: Flush spillage with plenty of water and wash to waste. Spillage on Soil: Absorb on to inert material and dispose of according to Controlled Waste Regulations. Fire/Explosion Risks: Non-flammable. Oxides of carbon and nitrogen evolved in fire. First Aid Skin Exposure: Wash immediately with plenty of water. Eye Exposure: Rinse immediately with plenty of water. Seek medical attention. Ingestion: Rinse mouth with water. Do NOT induce vomiting! Seek medical attention.


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Commissioning When all the relevant first fix work has been completed and the system correctly filled with anti-freeze. Our Engineer will visit in order to carry out the final electrical/plumbing connections and to commission your heat pump. Prior to this, please ensure that you have informed Ice Energy that all is ready and given at least three weeks notice for a commissioning date ASWELL AS COMPLETING AND SENDING BACK THE PRE COMMISSIONING CHEK LIST ON PAGES 36. Upon arrival our Engineer will inspect the installation to ensure that the all works carried out have been done correctly. The next job is to install the heat pump and to remove any air. Our Engineer will bring all the required equipment. The final electrical connections to the heat pump (sensors etc.) are then made. The heat pump can now be put into operation. The control circuits will be tested and the Mitsubishi flow temperature controller programmed. The flow rate will be checked and adjusted if needed. The Engineer will explain the operation of the heat pump and how to make operational adjustments. Throughout the commissioning process, please feel free to ask questions and even to help if needed. If our Engineers attend and find that the installation is not ready to be commissioned, and another commissioning date has to be made – THIS WILL BE CHARGEABLE TO THE CUSTOMER. There may also be a 3 week lead time for a re commissioning date.

General Notes

If the house is newly built and ‘wet’ then the heat pump will not be able to provide enough heat to dry it out. In this case additional heat sources/dehumidification will be required.


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Pre-Commissioning Check List


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Time clock pattern setup Each channel on the time clock should be programmed to meet the demands of the home occupier in the most efficient way.

For example

If an owner wakes up in the morning and wants a shower at 7am and the property takes an hour to raise to the required room temperature then both channels should be set to 5 am as the vessel will take approximately 1 hour to achieve temperature before switching to space heating.

If they don’t require hot water again until later in the evening then the time clock should be programmed to heat up approximately one hour prior. This is the most efficient pattern to use rather than maintaining a high storage temperature constantly.

If economy 7 tariffs are available then the initial hot water heat up and as much space heating as possible should programmed to coincide with these times.


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Photos

First fix completed

Rear of unit showing lagged pipework


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Typical finished installation


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ecodan installation manual - e-si ltde-si.com/downloads/ecodan manual v1-2 feb 2009.pdf · ecodan...

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