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Heat Pump Manual

6

MARKING

The units have various markings on them. There is a marking plate on the unit, an example is
shown below giving regulatory requirements. There will be a wiring diagram as shown in the
wiring diagram section of this document provided in a larger scale for ease of maintenance.

A four digit serial number sticker will also be placed under the marking plate. With this number
Thermex can trace the date of manufacture of the product and details on the unit.

The wiring diagram will show the model of the unit and the options installed.

CERTIFICATION

All the electrical components in the heat pump have certification for electrical safety. All the
exposed components are rated to IP66 against weather ingress.

All  Thermex  products  are  manufactured  by  Aqua  Cooler  in
Australia.  Aqua  Cooler  is  an  accredited  participant  in  the
WaterMark QA scheme and is audited annually by SAI Global
The Watermark scheme cover all products that are connected
to the town water supply.

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Summary of Contents for THW100

Page 1: ...Heat Pump Manual Thermex Solutions PRODUCT MANUAL HEAT PUMPS Document 001 D135 11 May 2015 Models THW20 THW40 THW60 THW80 THW100 THW150 THWW20 THWW40 THWW50 THWW60 THWW80 THWW100 THWP20 THWP40 THWP60 ...

Page 2: ... of the specified charge in the units It is not Thermex Solutions s responsibility to connect the heat pump to the BMS unless agreed to before delivery of the heat pump The heat pump must not be installed too close to walls and other heat pumps with clearances to be at least what is specified in the manual The heat pump must be installed with proper neat access to facilitate servicing in a manner ...

Page 3: ...oad Chester Hill NSW 2162 Australia Toll Free 1800649233 or 612 9721 9300 Fax 612 9721 9344 www thermex com au CONTENTS Safety 4 Marking 6 Certification 6 Warranty 7 General Information 7 Intended Use 7 Water Circuit 7 Technical Data 8 Heating System Schematic 16 Dimensions 17 Transport and Storage 19 Installation electrical water connection water treatment control circuit and final checks 19 Oper...

Page 4: ...ed after carrying out any maintenance work The unit is not to be used by the infirmed or children unless they are supervised by responsible persons qualified to carry out the supervision The unit should be secured to prevent it from toppling over WARNING All wiring must be performed by qualified electricians Improperly installed wiring and grounding may result in electrocution and fire hazards To ...

Page 5: ...water for 15 minutes DO NOT apply any form if direct heat Seek medical attention Ingestion For advice contact the poisons centre on 131126 in Australia If swallowed do not induce vomiting Ingestion is considered unlikely due to product form Advice to Doctor Use of adrenaline and other catacholamines may be contraindicted due to possible cardiac sensation Treatment for asphyxia R134a HazChem code 2...

Page 6: ...umber Thermex can trace the date of manufacture of the product and details on the unit The wiring diagram will show the model of the unit and the options installed CERTIFICATION All the electrical components in the heat pump have certification for electrical safety All the exposed components are rated to IP66 against weather ingress All Thermex products are manufactured by Aqua Cooler in Australia...

Page 7: ... are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure Attached to this document is a comprehensive commissioning procedure This must be carried out in accordance with the procedure and returned to Thermex or Thermex can do the commissioning otherwise the warranty will be voided GENERAL INFORMATION ...

Page 8: ...hat any water treatment is passive to the wetted parts of the system which include Stainless Steel Copper High Density Polyethylene Brass ABS Plastic Nitrile Rubber The water to water models have a water sourced evaporator that is connected to typically the return condenser water from the installed chillers This evaporator can have either a plate heat exchanger or a coaxial heat exchanger These he...

Page 9: ...45 C Water supply 60 RH Water Supply Temperature 45 C 50 C 55 C 60 C 65 C 70 C Heating Capacity kW 10 C Ambient 8 11 7 94 7 79 7 65 7 59 7 55 Power Input kW 2 19 2 43 2 69 2 97 3 08 3 17 COP 3 70 3 27 2 90 2 58 2 46 2 38 Heating capacity kW 20 C Ambient 9 51 9 27 9 05 8 83 8 74 8 67 Power Input kW 2 21 2 45 2 72 3 01 3 13 3 22 COP 4 30 3 78 3 33 2 93 2 80 2 69 Heating Capacity kW 30 C Ambient 11 1...

Page 10: ...ating Capacity kW 10 C Ambient 25 50 24 85 24 10 23 45 23 19 22 98 Power Input 6 30 7 05 7 80 8 55 8 85 9 09 COP 4 05 3 52 3 09 2 74 2 62 2 53 Heating capacity kW 20 C Ambient 29 30 28 45 27 50 26 45 26 03 25 69 Power Input 6 30 7 05 7 80 8 55 8 85 9 09 COP 4 65 4 04 3 53 3 09 2 94 2 83 Heating Capacity kW 30 C Ambient 33 40 32 30 31 15 29 80 29 26 28 83 Power Input 6 30 7 00 7 75 8 50 8 80 9 04 C...

Page 11: ... C 55 C 60 C 65 C 70 C Heating Capacity kW 10 C Ambient 52 65 52 05 51 40 50 70 50 42 50 20 Power Input 13 75 15 35 17 10 19 00 19 76 20 37 COP 3 83 3 39 3 01 2 67 2 55 2 46 Heating capacity kW 20 C Ambient 61 90 60 80 59 85 59 10 58 80 58 56 Power Input 13 90 15 45 17 20 19 15 19 93 20 55 COP 4 45 3 94 3 48 3 09 2 95 2 85 Heating Capacity kW 30 C Ambient 72 35 70 80 69 45 68 20 67 70 67 30 Power ...

Page 12: ...28 Model THW150 and THWDW150 Nominal heating capacity kW 150 Water Supply Temperature 45 C 50 C 55 C 60 C 65 C 70 C Heating Capacity kW 10 C Ambient 131 2 127 8 123 6 118 8 113 4 107 4 Power Input 33 2 37 41 2 45 8 50 8 56 4 COP 3 69 3 45 3 00 2 59 2 23 1 90 Heating capacity kW 20 C Ambient 152 2 148 4 144 0 138 8 133 0 126 6 Power Input 35 8 37 2 41 2 46 0 51 6 58 0 COP 4 25 3 99 3 50 3 02 2 58 2...

Page 13: ...tor water water to water units 20kW 1 1 30kW 1 1 40kW 1 1 50kW 1 1 60kW 2 2 80kW 2 2 100kW 2 2 130kW 2 2 150kW 2 2 200kW 2 2 Swimming pool heat pumps 2 PVC screwed connection WATER TO WATER HEAT PUMPS PERFORMANCE DATA Performance Chart at 40 45 C Water Return Supply 50 C Condensing temperature 20 C 15 C evaporator water Model THWW20 THWW40 THWW50 THWW60 THWW80 Nominal heating capacity kW 20 40 50 ...

Page 14: ...7 152 2 118 8 198 4 154 247 6 192 Power Input 24 4 24 4 35 8 35 8 49 2 49 2 60 4 60 4 COP 4 1 3 2 3 9 3 3 4 0 3 1 4 1 3 2 Total Unit COP 7 3 7 2 7 1 7 3 GENERAL INFORMATION Model THWW20 THWW40 THWW50 THWW60 THWW80 Pressure drop across condenser kPa 50 50 50 50 50 Pressure drop across evaporator cold side kPa075 50 50 50 50 50 Noise rating at 3m dB at 3m 60 60 60 61 62 GENERAL INFORMATION Model THW...

Page 15: ... Cooled Evaporator Pressure transducer Pump One way valve Ball valve Compressor TX valve Flow meter Sight glass Drier Pressure gauge Low pressure switch Drain Thermowell Motorised ball valve Expansion tank Water regulating valve Pressure relief valve Strainer High pressure switch Hot gas bypass valve Isolation valve Plate heat exchanger ...

Page 16: ...Heat Pump Manual 16 DIMENSIONS dxf and dwg files are available for all models please contact Thermex for details THW07 THW20 ...

Page 17: ...Heat Pump Manual 17 DIMENSIONS THW30 and THW40 THW50 and THW60 ...

Page 18: ...Heat Pump Manual 18 DIMENSIONS THW80 THW100 AND THW130 ...

Page 19: ...Heat Pump Manual 19 DIMENSIONS THWW20 to THWW40 Water to Water THWW50 THWW60 and THWW80 Water to Water ...

Page 20: ...let jack The unit is supplied with wooden supports under the compressor to protect the pipe work in transport They have to be removed before starting the unit it up Failure to do so will stop the compressor moving on its rubber mounts and may cause stress on the pipe work INSTALLATION A comprehensive commissioning program carried out by qualified refrigeration mechanics is available through Aqua C...

Page 21: ... environment Should you have concerns over the installation site then please contact Thermex for advice Note Under no circumstances is ducting to be attached to the evaporator fan outlet This heat pump has been designed to draw air from each side and to exhaust vertically through the top of the unit Preferably there should be no obstructions above the heat pump with a minimum of one metre clearanc...

Page 22: ...re displayed on the red screen display on the exterior of the unit is the return water temperature from the storage tank The swimming pool heat pumps are not supplied with the same heat sensor the swimming pool heat pumps main temperature sensor is installed in the return water line so unlike the normal units the unit does not need the sensor installed remotely The normal 20m temperature probe wil...

Page 23: ...ere there is a two refrigeration circuits be sure and check both circuits Underneath the evaporators will be two fitting for the process water one will have a flow switch attached to it These are the water fittings for the connection to the installation and will be marked supply and return The supply is the hot water to the storage The pipe sizes are listed in the Technical Data above All pipe wor...

Page 24: ... heat pump under all load conditions Three phase power must be symmetrical ensuring equal effective voltage and equal phase angle between consecutive phases The pump and the compressor rely on correct phase rotation The power supply cable can be fed through the marked access hole at the rear of the heat pump or through the marked access hole in the base of the heat pump under the electrical box an...

Page 25: ... are now logged in as Administrator The webpage should appear showing the status of the heat pump To change the heat pumps IP address go to the Advanced tab on the home page and then Network tab on the left hand side Put aquaipconfig into the password page and un tick the DHCP enable tab This will allow the loading of the site specific IP address To load in email addresses go to the Email tab on t...

Page 26: ... Holding Register cross connection Using the SNMP OIDs as a basis this cross connection is programmed into the Pump and Transfer controller via the uploading of a text based xml file derived from the mapping file Without a valid xml mapping file uploaded into the controller only the SNMP Agent will be operational All SNMP OIDs have remained unchanged from previous Pump and Transfer firmware releas...

Page 27: ...roperty error message and unimplemented services will respond with a BACnet Service Unavailable error message All data points can also be accessed via Modbus Holding Registers Register numbers for Analog objects can be calculated by multiplying the hundreds tens and units portion of the localreg number by two subtracting one then adding 40 000 and the thousands portion of the localreg numbers on t...

Page 28: ... be designated the master and the other heat pumps will need to be designated the slaves This can be done in the programming On the controller use the up and down keys to scroll to the PARAMETERS MENU and press OK scroll to the SYSTEM sub menu and scroll to MASTER SLAVE option The heat pump will be supplied as MASTER being the default so any other heat pumps will need to be programmed to be the sl...

Page 29: ...mark the terminals 91 and 92 and it is designed to switch the active signal or the active for a pump up 10A It is important that this pump is installed and wired correctly before starting the heat pump as the heat pump has a flow switch and if this does not enable then the heat pump will not run OPERATION Again before starting the heat pump ensure that the pressure in the suction side of the syste...

Page 30: ...nitored CCT2 DISCHARGE TEMP circuit 2 discharge temperature VIEW PRESSURES CCT 1 SUCTION PRESSURE circuit 1 suction pressure CCT2 SUCTION PRESSURE circuit 2 suction pressure on a heat pump with 1 compressor the discharge pressure will show here also VIEW ON TIMES This will give the run times on the compressor VIEW HT LOAD If the unit is supplied with a flow meter typically on units designed to ope...

Page 31: ...l compressor units the controller will cut the second compressor off 0 5C before set point to stop both compressor from crashing off when set point is reached Temperature Control Set Point Compressors will turn compressors off when the set point is breached Compressors will be turned on again at temperature minus hysteresis Default temperature setting is 60 degrees and the hysteresis is 2 degrees ...

Page 32: ...ks If however the water temperature drops below set point minus hysteresis it will start the second heat pump and then monitor the change in temperature in the tank If the tank temperature is rising slower than the rate of change in the settings it will start another unit If it is still dropping it will start another unit If it is rising quickly it will take no action If the temperature is rising ...

Page 33: ...plied with a flow meter The flow meter is installed to ensure that adequate flow is supplied to the unit across the condenser With heat pumps running at higher temperatures discharge gas temperature and pressure need to be kept within the performance envelope of the compressor Therefore to remove the heat and keep these temperatures down the unit needs higher than normal water flow through the con...

Page 34: ...e energised the power contactors are live even if the components are not operating All maintenance must be carried out by qualified refrigeration mechanics These units have been designed for the minimum of maintenance However to ensure optimum performance qualified personnel should carry out regular maintenance A comprehensive preventative maintenance program is available through Thermex carried o...

Page 35: ...stly by placing a USB key into the USB slot on the rear of the controller Then on the keypad go to the parameters menu and press OK scroll to the Data Logs menu and scroll to the choice that suits an option for example is Time Log to USB press OK and the data will start downloading the screen will flash USB download and then download complete The USB key will now have an Excel file on it which can...

Page 36: ... calibrate the sensor to the thermostat and press OK again 6 Exit the program Updating Software Always remember that when working in the electrical box that care is taken to ensure that none of the live parts are touched From time to time requirements may require a software upgrade of the system and with the right programmer this can be done from a laptop on site If the heat pump is connected to t...

Page 37: ... can be used to program the heat pump otherwise remove the front panel of the heat pump to access the electrical box Take precautions to ensure that none of the electronics or the switching gear can get wet By opening the electrical box the programmable circuit board controller can be seen mounted on the door The four small red buttons next to the display are the buttons used for changing the para...

Page 38: ... ALM ACK DELAY Press OK and change to setting Select choice and press OK and the screen will confirm choice Press the escape key to revert to home page It is recommended that the setting is not greater than 1 or 2 minutes Assigning the heat pump as either a master or slave In multiple machine set ups the heat pump can be assigned either as the master or one of the slaves up to eight machines can b...

Page 39: ... Keypad time lock ON Air to Water or W2W Selected as part of unit construction EMAIL LOG MENU EMAIL ALARM ON OFF OFF MANAGE DATA LOG OFF DATA LOG PERIOD 30 seconds SET TIME MENU TIME ZONE Set after install SET DAY OF MONTH Set after install SUMMERTIME ON OFF Set after install SET WEEKDAY Set after install SET YEAR Set after install SET TIME Set after install SET MONTH Set after install DELAY HOLD ...

Page 40: ...ross the bottom of the board IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 0 10V Input 0 10V NC Input 0 10V NC Input 0 10V NTC thermistor 0 10V NTC thermistor 0 10V NTC thermistor 0 10V NTC thermistor 0 10V NC input 0 10V Input 0 10V input Flow rate and flow switch Compressor 1 fault Compressor 2 fault Return temp or evaporator temp Process temperature storage tanks Supply temperature Discharge tempera...

Page 41: ...WIRING DIAGRAM This diagram shows the basic wiring between the master and slave units If any of the slaves has a fault then it will report back to the master that is has a fault but the master will not shut the system down ...

Page 42: ...r circuit breaker CMCB Compressor motor circuit breaker PF Phase failure relay LP Low pressure switch HP High pressure switch ER Enable relay PMCB Pump motor circuit breaker PVSD Pump variable speed drive CRITICAL SPARE PARTS Thermex maintains a full stock holding of all critical spare parts please contact the service department on 61297219315 to arrange parts Compressors Heat Pump Supplier Part T...

Page 43: ...mp Manual 43 TROUBLE SHOOTING In the event the heat pump develops a fault then the fault is displayed on the screen readout on the control board The faults displayed are comprehensive but not fully descriptive ...

Page 44: ...oid not working Fan not moving enough air faulty fans or fans that may be tightening and thermal overload may be open Unit may have loss refrigerant or have small leak Check pressures and sight glass for evidence of refrigerant charge Unit may be starved of air it may be installed too close to another unit or a wall CTOL Compressor thermal over load compressor is drawing too many amps Compressor m...

Page 45: ...ave dropped out check the phase rotation relay Low voltage check power is between 380 and 415V Faulty controller check that the screen is active or the lights are on at the rear of the controller if the screen develops a fault then the controller may still operate Switching gear may be faulty check contactors are energising Check for loose wiring the units vibrate during operation and can cause wi...

Page 46: ...t poin 23 02 15 F U302_64_EB4_214 Added to Ethernet P334 Networked System Updated state machine to use common functions Cycle on and off timers now pre emptive were post emptive 01 04 15 G U302_64_EB4_215 Fixed 1st compressor on cycle bug Test for RS485 Network up and Master on line before changing slave HTEMP and HYST A2W and W2W hot gas defrost now both suction pressure driven Added Evaporator u...

Page 47: ...f 100Kw and 150Kw units finalised 01 01 15 D o All swimming pool models re designed with wider and angles drip trays o Drip tray for 100kW and 150kW unit re designed to be wider and angled o All models manufactured with copper bender being used to eliminate as many elbows as possible o Water to water units fitted with flow meter flow switch wired into the meter evaporator water sensor also added 2...

Page 48: ...ion section Check that the isolation switch has been installed close to the heat pump in line of sight On standard heat pumps and remote condenser models ensure that the power connection to the heat pumps and between the modules is protected Note down the pipe run from the heat pump to the process Note down the water pipe sizes to and from the heat pump Has the water pipe work been fitted with ins...

Page 49: ...r temperature setting and all other alarms to customer or site needs After heat pump has started check and note down the current draw for the compressors pump and fans Pump 6 amps Compressors 28 amps Fans 8 amps Note down the water flow reading Should be 2 l s Note down pump pressure Does pump performance fall on the respective pump curve Check the sight glass for evidence of bubbles or moisture C...

Page 50: ...ault the running heat pump and check the other heat pump starts and vis a versa Finishing Off Is the electrical box closed and door secure Are all panels secure If the mesh was removed from the side of the heat pump has it been replaced Are all tools and debris clear of the site Are there any site specific feature that may hinder the operation of the heat pump in the future Notes ...

Page 51: ...Site Street Address Installation Site Phone Number Installation Site Facsimile Number Installation Site Contact Name Installation Site Contact Position Access Limitations Any issues relating to service access including after hours access induction course requirements hot works permits confined spaces safety harness requirements Equipment Serviced By Heat pump ...

Page 52: ...ctual Foot print Space Required around heat pump R Series I 975L x 590W x 1060H 600 E x 2000 H R Series II 975L x 590W x 1060H 1495L x 790W x 1340H 800 E x 2000 H 800 E x 2000 H R Series III T Series 2015L x 860W x 1545H 800 E x 2000 H R3000 2585 L x 1400 W x 1830 H 1000 E x 2000 H R3000 Condensing Unit 2135 L x 1400 W x 1680 H 1000 E x 2000 H R3000 Refrigeration Unit 1200 L x 970 W x 1510 H 600 E...

Page 53: ...tion Length Height Difference Balancing Valve YES NO Isolation Valves YES NO Water Treatment YES NO Make Up Water YES NO Treatment Used Supply Pressure Flow Rate Pressure Tap Points YES NO In Line Filtration YES NO Remote Condenser Requirements Notes Pipe Size Pipe Insulation Length Height Difference ...

Page 54: ...process then Thermex will take steps to address them with the customer ensuring that the heat pump operates reliably and without compromise to the long service life we expect of our products We appreciate any feedback given as all data is used to influence our continual product development program Signature Of Service Agent Print Name Date Signature Of Customer Representative Print Name Date Filin...

Page 55: ...d electrician and the phases must be wired correctly to ensure correct rotation and balance between the phases o There are small bleed points that can be accessed through holes in the metal work on the underside of the unit They should be opened to ensure that all the air is bled from the system The fan coil unit has water fittings for hot water from the heat pump and cold water from the heat pump...

Page 56: ...ame time Control The fans have been designed to run all the time whenever the system is enabled that is when the RS relay has power The control of the motroised ball valve and therefore the water flow is not automatic is it designed to be controlled by a remote management system When the system has power then the fans will start If there is a call for heat recovery presumably during summer then th...

Page 57: ... with motorized ball isolation Pressure drop across the coil Pascals 90 Rated air flow M3 h 10000 Sound at 5m dB 66 Heat absorption 8 12 C cross the coil kW 17 Heat rejection 50 45 C across the coil kW 20 Coil construction Copper tube with aluminum fins Nano coated Nano Coating on the coil fins is a glass silicon based coating which is super hydrophobic that repels water and keeps coil dry Unit I ...

Page 58: ...Heat Pump Manual 58 WIRING DIAGRAM 20kW HEAT RECOVERY COIL ...

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