62 105 30-4 2014-11-19 Providing sustainable energy solutions worldwide Installation and Maintenance Manual CTC EcoHeat 400 400V 3N~ / 230V 1N~
Removing the cooling module 1. Disconnect the cooling module’s power cable connector and hoses. 2. Attach the two carrying handles to the bottom of the cooling module. 3. Unscrew the cooling module’s screws. 4. Pull the cooling module by first lifting the front edge slightly with the carrying handles. 5. Lift the cooling module using the carrying handles and shoulder straps. 6. Lift the cooling module into the product using the carrying handles and shoulder straps.
Installation and maintenance manual CTC EcoHeat 400 400 V 3N~ / 230 V 1N~ 162 105 30-4 2014-11-19
General Information General Information Table of Contents GENERAL INFORMATION Check list______________________________________ 6 Important to remember!__________________________ 7 Safety Instructions______________________________ 7 Your home’s heating installation__________________ 8 1. Technical Data______________________________________________________ 11 2. 3. 4. 5. 6. 7. Operation and Maintenance_______________________________ 38 Fault Tracing/Appropriate Measures_________________ 39 7.
General Information Congratulations on buying your new product You have just bought a CTC EcoHeat 400, which we hope you will be very pleased with. In the following pages you can read about how to operate and maintain your heat pump. One chapter is written for the property owner and one chapter for the installer. Keep this handbook containing the installation and maintenance instructions. If it is looked after properly, you will be able to enjoy the use of your CTC EcoHeat 400 for many years.
General Information Check list The check list must be completed by the installer. • In the event of a service, this information may be called for. • Installation shall always be done according to the installation and maintenance instructions. • Installation shall always be carried out in a professional manner. • Following installation, the unit shall be inspected and checked for functionality. The points below shall be checked off.
General Information Important to remember! Check the following points in particular at the time of delivery and installation: • The product must be transported and stored in a standing position. When moving the product, it can be placed temporarily on its back. • Remove the packaging and check before installation that the product has not been damaged in transit. Report any transport damage to the carrier. • Place the product on a solid foundation, preferably made of concrete.
General Information Your home's heating installation The House Heating Curve The heating curve is the central part of the product’s control system. It is the heating curve which determines the compensated flow temperature requirements for your property dependent upon the outdoor temperatures. It is important that the heating curve is correctly adjusted, so that you achieve the best operation and economy possible.
General Information Adjusting the heating curve The method described below can be used to adjust the heating curve correctly. Adjustment if it is too cold indoors • If the outdoor temperature is lower than 0 degrees: Increase the Inclination value by a couple of degrees. Wait 24 hours to see if any further adjustment is required. • If the outdoor temperature is higher than 0 degrees: Increase the Adjustment value by a couple of degrees. Wait 24 hours to see if any further adjustment is required.
General Information Examples of Heating Curves You can see in the diagram below how the heating curve changes with different Inclination settings. The gradient of the curve shows the temperatures that the radiators require at different outdoor temperatures. Primary Flow Temperature Curve Inclination The inclination value which is set is the primary flow temperature when the outside temperature is –15 °C.
General Information 1. 1.1 Technical Data Three-phase 400V 3N~ Electrical Data EcoHeat 406 EcoHeat 408 EcoHeat 410 EcoHeat 412 Electrical data 400V 3N~ Rated power Max starting current kW 11.7 12.6 13.4 14.1 A 16.6 17.7 19.8 23.5 2.1 / 7.2 / 9 2.1 / 6.9 / 9 Immersion heater (steps of 0,3 kW) kW Max immersion heater output @ fuse size 16 / 20 / 25 A kW 0 - 9.0 6.9 / 7.8 / 9 2.1 / 7.
General Information 1.2 Single phase 230V 1N~ Electrical Data EcoHeat 406 EcoHeat 408 EcoHeat 410 EcoHeat 412 Electrical data 230V 1N~ Rated power kW Immersion heater (steps of 0,3 kW) kW Min. main fuse @ 3.5 / 5.5 / 9.0 kW Immersion heater A 11.7 12.6 30 / 38 / 54 34 / 43 / 58 IP class 37 / 46 / 61 41 / 49 / 65 EcoHeat 406 EcoHeat 408 EcoHeat 410 EcoHeat 412 @ -5/45 kW 4.68 6.84 8.33 @ -5/45 - 3.09 3.34 3.30 3.30 kW 5.90 | 5.48 5.17 8.19 | 7.87 7.55 9.97 | 9.55 9.28 11.
General Information 192 618 8 595 83 192 Nr 83 7, 8 672 595 114 9 5 344 3 6 423 344 2 4 10 426 1 423 194 190 114 Datum 672 347 595 114 Ändr. meddel. 618 7 1748 1904 1748 1904 1.3 Measurements and connections 1. Bleeding connection 22 compression 2. Connection waste pipe 3/4" BSP 3. Cold water connection Ø22 4. Hot water Ø22 5. Radiator primary flow 22 compression 6. Radiator return/expansion Ø22 7. From ground loop Ø28 (right, left and back) 8.
General Information 2. CTC EcoHeat 400 design The picture below shows the fundamental construction of the heat pump. The energy in the lake or ground is drawn up by the cooling system. The compressor then increases the temperature to a usable level. Afterwards it releases the energy for the heating system and hot water. Mains Water Connections Here you connect the property's mains water connections. The cold water is directed down to the lower part of the coil.
General Information 3. Parameter list The product is delivered with set factory values which are suitable for a standard house with a standard radiator system. These values can be easily changed as required. You should check in particular your “home parameters”. Ask your installer to help you determine the correct values. The following default values are set by the factory: Heating circuit 1 Factory value Max.
General Information 4. Menu overview Start menu CTC EcoHeat 1 Night reduction heat circ. Monday 09:35 Room temp. DHW Operation Installer 1 1 2 1 Weekly program Monday Tuesday Wednesday Thursday Friday Saturday Sunday 2 Day by day 06 - 09 07 - 09 06 - 09 06 - -06 - -10 - 12 10 - 12 NR 18 - 21 20 - 23 10 - 21 -- - 21 -- - 21 20 - 23 20 - 23 2 22,2 ºC 1 2 21,2 ºC 58 ºC Night reduction heat circ.
General Information Stored oper data Total operation time h: Max primary flow °C: Consumtion kWh 14196 51 20 Compressor: Operation time /24 h:m 00:00 Compressor Compressor Charge pump Brine pump HP in/out °C On On 47% On 35.5 / 42.3 Current L1 4.
General Information 5. Detail Description Menus All the settings can be configured directly on screen using the well-structured control panel. The large icons operate as buttons on the touch display. Operational and temperature information is also displayed here. You can easily enter the different menus to find operational information or to change any settings. Start menu CTC EcoHeat 5.1 Start menu 1 1 Room temp.
General Information 1 2 5.2 Room temp. Room temp. You set the room temperature you want to achieve via this menu. Use the plus and minus buttons to set the temperature you want, which gives you the “setpoint” temperature, in brackets. You can see the current value next to the brackets. If two radiator systems are installed, the values for both are displayed. 11 If you want to schedule a temperature reduction, you can continue to the Night reduction or Holiday submenus.
General Information 1 5.2.3 Night reduction temperature enu coHeat Night reduction heat circ. Monday 09:35 Weekly program Monday Tuesday Wednesday Thursday Friday Saturday Sunday You use this menu to activate and set a reduction in the temperature at night. A night reduction means that you reduce the temperature indoors during scheduled periods, at night orInstaller when you are working. DHW for example, Operation m temp. 1 2 1 The value by which the temperature is reduced - Room temp.
CTC EcoHeat Heating circuit 2 Monday 09:35 (50) 2 General Information 1 Night reduction Room temp. 1 5.3 DHW enu coHeat You use this to setMonday the DHW 09:35 comfort level you want and extra DHW. Temperature You set the values for this option which apply to the heat pump's normal operation. There are three modes: 2 DHW 1 Operation 22,2 ºC Installer Economic - If you have a small DHW requirement.
Temperature Normal General Information Weekly schedule 5.4 Operation Heating system data Operation data system 12 ºC 21,5 ºC This menu displays current temperatures and the operational data for your heating system. 2 ºC The screen shows the incoming and outgoing temperatures from the heat pump. Brine in At the top left of the heat pump (2 °C) the brine's current temperature is shown from the collector to the heat pump.
Weekly program Monday Tuesday Wednesday Thursday Friday Saturday Sunday ature l Day by day 06-09 18-21 07-09 00-00 06-09General 00-00 06-09 00-00 06-09 00-00 10-12 00-00 10-12 00-00 Information Weekly schedule 5.4.1 Operation data CTC EcoHeat system data peration data system This menu displays current temperatures and the operational data for your EcoHeat system. The first figure is the actual operational value, with the value in brackets 12 ºC ºC pump is trying to achieve.
ature al General Information Weekly program Monday Tuesday Wednesday Thursday Friday Saturday Sunday Day by day 06-09 07-09 06-09 06-09 06-09 10-12 10-12 18-21 00-00 00-00 00-00 00-00 00-00 00-00 Weekly schedule Delay mixing valve A microswitch in the mixing valve’s motor ensures that system data auxiliary heating is not used unnecessarily, for example, when ventilating a room or if the temperature (outdoors) peration data system occasionally drops during the night.
General Information 5.4.2 Stored operation data Stored oper data t reduction heat circ. gram y Day by day 06 - 09 07 - 09 06 - 09 06 - -06 - -10 - 12 10 - 12 NR Heat 18 - 21pump 20 - menu 23 This shows the operational values for the heat pump 10 - 21 over a long period. -- - 21 -- - 21 Total Operating Time h 20 - 23 Shows 20 - 23the total time during which the product has been Total operation time h: Max primary flow °C: Consumtion kWh 14196 51 20 Compressor: Operation time /24 h:m 00:00 on.
ogram g circuit 1 y g circuit 2 1 Day by day 06 - 09 07 - 09 06 - 09 (50) 06 - -06 - -10 - 122 10 - 12 NR 1 18 - 21 General 20 - 23 10 - 21 -- - 21 -- - 21 20 - 23 20 - 23 Information Night reduction 2Total operation time h: Max primary flow °C: Consumtion kWh 14196 51 20 Holiday Compressor: Operation time /24 h:m 00:00 Holiday 5.4.3 Operation data compressor Compressor ht reduction heat circ.
22,3 ºC 42 ºC General Information 34 ºC 2 ºC -1 ºC reduction heat circ. 5.5 Installer gram Day by day 06 - 09 07 - 09 06 - 09 06 - -06 - -10 - 12 10 - 12 NR 18 - 21 20 - 23 This contains four submenus: Time/Language, 10 - menu 21 -- - 21 Define system and Service. Settings, -- - 21 Time/Language includes time and language settings for 20 - 23 20 - CTC 23 EcoHeat 400. your Settings are used both by the installer and users for installing the system. reduction heat circ.
gram Installer Day by day 06-09 18-21 General 07-09 00-00 06-09 21:34 00-00 06-09 00-00 2012-02-05 06-09 00-00 10-12 00-00 10-12 00-00 me y e Information 5.5.2 Settings ation data EcoHeat Installer HP upper tank °C 49 (60) This menu is used to set the parameters for your home's °C 42 (45) It is important that this default Stored oper data w °C 42 (43) heating requirements. setting is adjusted for your property.
General Information Room temp reduced/Primary flow reduced Room temp reduced indicates whether a room sensor is installed. Otherwise, Primary flow reduced is displayed. Room temp reduced -2 (0...-40) You define here how many degrees the room temperature will be reduced by during the various scheduled reduction periods, e.g. Night reduction, Holiday etc. 1 Room temp.
General Information Heat pump Compressor Brine pump on 10 days Tariff HP Electric heater Boiler upper ºC 40 (30...60) Temperature when the electric heater is activated and assists the heat pump in reaching the correct primary flow temperature. A low setting is recommended. The electric heater is also responsible for providing the house with additional heating. If the house requires a higher temperature than that selected, the control system compensates by automatically raising the temperature.
Boiler upper add °C 70 Boiler upper extra DHW °C 60 Boiler upper max kW 5.8 Delay mixing valve 180 General Main fuse A 25 Input voltage 3x400 V Tariff EL Off Upper tank Stop temp HP °C 58 (40...60) At this temperature the heat pump starts charging towards the upper tank. The heat pump will charge the upper tank at temperatures above 60 °C. Start/stop diff upper ºC 5 (3...10) Hysteresis before the heat pump starts or stops the charging of the upper tank.
Tariff HP Electric heat Off General Information Electric heater 5.5.3 Solar panels (accessories) Boiler upper °C 40 Input voltage Tariff EL 3x400 V Off Boilersettings upper addare °C for70accessory solar panels and these These Boiler upper extra DHW °C 60 areBoiler described in the Settings menus for solar upper max kW chapter 4.
Heating circuit 2 Heat pump Electric heater General Upper tank Remote control NR Communication Diff thermostat function Save settings Load settings Load factory settings Installer HP upper tank °C °C w 1 °C °C mp e g valve venska wer kW L2/L3 ump/Temp, 49 (60) 42 (45) 42 (43) 34 On Open 180 Nederlands 0.0 0.0 0.0 0.0 0.0 0.0 Suomi Française Stored oper data Compressor English Deutsch circuit 2 5.5.
Electricvalve heater L2 DownLow 3-way Electric heater L3 High Dansk Type Action Status Level of signal Eesti Battery General Information Version 8.8.3 Def. SMS Alarm log HP This is for defining whether SMS control is installed, Test Elec.heater Latest alarm: I(A) Electric heater L1 Low brine flow L2 Electric heater 3.9 Electric heater L3 (accessory). Time HP (b) LP (b) Off 07:20 6/3 8.8 3.3 Activate Yes (Yes/No). Low SH (K) 15.9 High the menus below will be displayed.
Heating circuit 1 Heating circuit 2 Heat pump ation data heating Suomi Française Dansk Norsk Settings 1 Heating circuit 2 ating circuit 1 ating circuit 2 at pump 20 0 4 8 12 Room temp. 5.5.6 Service ctricRoom1 heater Prim1 Return Room2 Prim2 per tank mote control NR Heating circuit 1 mmunication ve settings ad settings ad factory settings Define system ! Note! This menu is only for the installer to use.
General Information Test Heat pump Test Heat pump Communication Function test Heat pump. MB address 1 Baud rate HP Compr. 9600 Parity evenis where the function test is Compressor On/Off. This Stop bit carried out on the compressor. 1 The brine and charge HP Compr. HP Brine p HP Charge p pump Communication Communication are also operating so that the compressor is not going to trigger its pressure switches. MB address 1 MB address 1 Baud rate 9600 Baud rate HP Brine p.
General Information Alarm log HP Test Heating circuit Mixing valve1 Rad pump1 Mixing valve2 Factory Rad pump2 LED room sensor ! Open On Off settings coded Off On Latest alarm: Low brine flow Time 07:20 6/3 HP (b) LP (b) SH (K) 8.8 3.3 15.9 I(A) 3.9 Stored alarms: Wrong phase order 10:30 1/3 27.9 8.6 -227 50.0 Comm. error 1/3 27.9 3.6 42.2 allowed tomotor logprotect in to the09:01 Factory settings 0.0 Note! Only an authorised service engineer is coded option.
General Information 6. Operation and Maintenance When the installer has installed your new heat pump, you should check along with the installer that the system is in perfect operating condition. Let the installer show you where the switches, controls and fuses are so that you know how the system works and how it should be maintained. Bleed the radiators after around three days of operation and top up with water if required.
General Information 7. Fault Tracing/ Appropriate Measures EcoHeat is designed to provide reliable operation and high levels of comfort, as well as have a long service life. Various tips are given below which may be helpful and guide you in the event of an operational malfunction. If a fault occurs, you should always contact the installer who installed your unit. If the installer believes the malfunction is due to a materials or design fault, then they will contact us to check and rectify the issue.
General Information Current Monitor EcoHeat has an integrated current monitor. If the system is fitted with a current sensor (accessory for 230V 1N~), the property’s main fuses are continuously monitored to ensure they are not overloaded. If the fuses are overloaded, the heat pump will automatically reduce its power output to prevent overloading the property's supply.
General Information Motor protection EcoHeat constantly monitors the compressor's operating current and an alarm is triggered if the compressor is using an unusually high current. When a fault occurs the message “Motor protect high current” is displayed. The cause of the fault may be as follows: • Phase failure or mains interruption. Check the fuses, which are the most common cause. • Compressor overload. Call out a service engineer. • Faulty compressor. Call out a service engineer.
General Information 7.2 Alarm messages Alarm: Wrong phase order compressor Reset alarm If a fault occurs with a sensor, for instance, an alarm is triggered. A message appears on the display informing about the fault. You reset the alarm by pressing the Reset alarm button on the display. If several alarms are triggered, they are displayed one after the other. An outstanding fault cannot be reset without being rectified first. Some alarms are reset automatically if the fault disappears.
General Information Alarm Text Description Max thermostat If the heat pump has been stored in an extremely cold place, the max thermostat may have been triggered. You reset it by pressing in the button on the electrical switchboard behind the front panel. Always check that the max thermostat may have been triggered. Communication error PCB, Communication error HP, Communication error motor protect This message appears when the display card cannot communicate with the PCB.
Installation Installation 8. Installation This chapter is aimed at anyone responsible for one or more of the installations required to ensure that the product works the way the property owner wants. Take your time going through functions and settings with the property owner and answer any questions. Both you and the heat pump benefit from a user who has completely understood how the system operates and should be maintained. ! The product must be transported and stored in a standing position. 8.
Installation 9. Pipe installation The installation must be carried out in accordance with current standards and regulations, see BS EN6700 and building regulations. The product must be connected to an expansion vessel in an open or closed system in accordance with vented and unvented regulations (G3 or G4 in 2011 amendments). Do not forget to flush the radiator system clean before connection. Apply all the installation settings based on the description in the chapter on First start.
Installation 9.2 Schematic diagram This shows the main connection between the heat pump and the property's radiator and hot water system. Different installations and systems may look different, such as a one- or two-pipe system, which means that the finished installation may be different. To find out about connecting the cold side, see the chapter on Connecting the brine system.
Installation Circulation pump for radiator system (36) (37) The circulation pump is fitted on the heat pump's primary flow and must be connected electrically from the boiler, see chapter on Electrical installation. Mixing valve DHW (65) Install a mixing valve for the hot tap water in order to avoid the risk of scalding. valve DHW (93) Fit the enclosed valve to the incoming cold water connection. Connect the waste pipe to the waste system through the waste funnel.
Installation Operation without a brine system EcoHeat can be used without the brine system's cold side being connected. The heat pump then operates like a normal electric boiler with its control system providing full functionality. However, the DHW capacity is slightly lower as only the upper part of the tank is heated. Make sure that the compressor is blocked.
Installation Pressure drop Pressure drop in mixing valve The diagram below shows a drop in pressure in the mixing valve. Start with the heat requirement in kW (e.g. 15 kW), then move vertically to the selected ∆t (e.g. 10 °C). Then move horizontally to the line for the EcoHeat mixing valve = line 6.3 DN20. The reading for the pressure drop is taken from the scale directly below (4 kPa). For EcoHeat, see valve DN20.
Installation 10. Connecting the brine system The brine system, i.e. the ground collector loop, must be assembled and connected by a qualified tradesman in accordance with current regulations and design guidelines. Extreme care must be taken to ensure that no dirt gets on the collector hoses, which must be washed clean before being connected. The protective caps must remain in place at all times while work is in progress. The temperature in the brine system can go below 0 °C.
Installation Valves You fit the valves as shown in the schematic diagram on the next page. To facilitate servicing of the cooling unit, shut-off valves should be fitted to both the incoming and outgoing connections. Fit bifurcated valves so that you can fill and bleed the collector circuit later on. Bleeding The collector circuit must not contain any air. Even the smallest amount of air can jeopardise the heat pump's operation. See the section Refilling and venting below.
Installation 10.1 Brine system schematic diagram 96 Level/expansion vessel 97 Brine filling kit 98 Shut-off valve 99 Filter 100 3-way valve 101 External filling pump 102 Mixing vessel 103 Brine pump 104 Evaporator 105 Safety valve 3 bar cTc 96 99 100 98a 105 98c 98b 98d 101 97 104 103 102 The diagram shows the main connection for the brine system. The filling equipment is represented by the parts displayed with dashes.
Installation Brine filling kit with dirt filter A filling kit for topping up, adding and filtering brine. Arrows on the valve housing indicate the flow direction. Close valves (98c and 100) when cleaning the filter. Unscrew the filter cap and flush the filter clean. When refitting, the pin under the filter holder should be fed into the designated hole in the filter housing. Top up with a little brine, if necessary, before fitting the cap.
Installation 10.2 External systems (solar heating, pool heating) The product is adapted for the connection of external systems for energy supply or heat extraction. In order to avoid damage to the product, it is important that any external system is hydraulically separated through a plate heat exchanger. The connection is made to the front of the unit behind the front panel.
Installation 11. Electrical installation The installation and heat pump connection shall be done by an authorised electrician. All wiring shall be installed according to valid requirements. The immersion heater is internally connected by the factory and set for a 5.5 kW power output. It has equal phase loading at all power steps. Electrical connections are made behind the product's front panel.
Installation Connecting the primary flow/return sensor Fit the primary flow sensor to the primary flow pipe, ideally after the circulation pump. Fit the return sensor to the return pipe. The sensor component is at the front of the sensor unit, see diagram. Sensor Contact past applied Connection cables Pipe • Attach the sensor using the tie strap provided. • Ensure that the sensor has good contact with the pipe.
Installation Terminal board There is a terminal board for sensors etc. behind the panel.
Installation 11.1 Settings made by the installation electrician. The following settings shall be made by the installation electrician after installation: • Select main fuse size • Select the power limitation for the immersion heater. • Check room sensor connection • Check that the sensors connected indicate reasonable values. Carry out the following checks: Main fuse and effect limitation settings See the chapter on First start.
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12. First start When CTC EcoHeat is delivered, the compressor is blocked to avoid it being unintentionally started. The heat pump can be installed and started before the brine circuit is put into operation. CTC EcoHeat can also be started without a room sensor being fitted as the curve which has been set then regulates the heating. Deselect the room sensor in the Settings menu. The sensor can however always be fitted for the alarm LED function. Before first start 1.
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161 421 50 10-01 Enertech AB. P.O Box 309 SE-341 26 Ljungby Sweden. www.ctc.se, www.ctc-heating.
