Kensol HYDROBOX KTH1 Manuel utilisateur

Installation and operating instructions for HYDROBOX KENSOL KTH1

INSTALLATION AND OPERATING

INSTRUCTIONS

HYDROBOX KENSOL KTH1

Installation and operating instructions for HYDROBOX KENSOL KTH1 2/11

Table of contents

1. INTRODUCTION.......................................................................................................................................................3

2. ILLUSTRATIVE INSTALLATION DIAGRAM.......................................................................................................3

3. PRECAUTIONS AND RECOMMENDATIONS......................................................................................................3

4. TECHNICAL DATA AND COMPONENTS.............................................................................................................4

5. TRANSPORTATION AND STORAGE...................................................................................................................5

6. WALL INSTALLATION AND SERVICE DISTANCES ........................................................................................5

7. HYDRAULIC CONNECTIONS................................................................................................................................6

8. ELECTRICAL CONNECTIONS ..............................................................................................................................7

9. MAGNETIC FILTER OPERATION .........................................................................................................................8

10. CIRCULATION PUMP OPERATION .....................................................................................................................9

11. LAUNCHING AND OPERATING THE SARG1 SYSTEM ................................................................................... 10

12. CLEANING AND MAINTENANCE........................................................................................................................11

13. DISPOSAL................................................................................................................................................................11

Installation and operating instructions for HYDROBOX KENSOL KTH1 3/11

1. Introduction

Hydrobox is a module designed for indoor installation, speeding up the installation of a system with a

monobloc air-to-water heat pump, a buffer tank and a hot water storage tank. The compact form and

thoughtful design makes the entire installation take up less space, while providing easy access for

maintenance activities.

Due to the company’s philosophy of continuous product improvement, we reserve the right to change

the manual and any specifications in this document without notice.

2. Installationsschema

FIG. 1. EXAMPLE INSTALLATION DIAGRAM USING HYDROBOX MODULE KTH1

Heating circuit Heat pump

DHW tankCH buffer

HYDROBOX

3. Precautions and recommendations

PRECAUTIONS:

• All installation work must be performed only by a qualified and trained installer. Improper in-

stallation carries the risk of fire, flooding, electrical shock or damage to the unit and heat pump.

• Please refer to the instructions of the individual main components, in particular the magnetic

filter, the anti-freeze system and the controller.

• The device is not intended to be operated by children.

• For the sake of safety of use, it is necessary to regularly check the technical condition of the

device.

• Lightning can damage the device, so it should be unplugged during a storm.

• The device must not be misused.

• Do not touch the device with wet hands - risk of shock!

Installation and operating instructions for HYDROBOX KENSOL KTH1 4/11

ELECTRICAL:

• Live electrical device. Before doing anything with the power supply (connecting cables, instal-

ling the device, etc.), make sure that the device is not connected to the grid.

• Connection of heating elements must be carried out taking into account the electrical para-

meters of the device and in accordance with applicable regulations. The electrical installation

components used such as electrical wiring and apparatus must be selected properly.

HYDRAULIC:

• The device can be filled with low-oxygen water, preferably using dedicated corrosion inhibitors

for heating systems.

• The device should be installed with a view to applying the necessary pressure and thermal pro-

tection in accordance with PN-EN 12828+A1:2014-05.

• Dry operation of the heater and circulation pump is not allowed.

• Do not block the trigger of the safety valve. ON THE SECTION FROM THE SAFETY VALVE TO THE

HEAT PUMP, DO NOT INSTALL BALL VALVES, CHECK VALVES, FILTERS OR OTHER SHUT-OFF

DEVICES!

• When using the device for installations operating in cooling mode, vapor-proof hydraulic compo-

nents should be additionally insulated to reduce the effect of condensation.

4. Technical data and components

Diverter valve DN25

Electric heater 3 x 2 kW (level adjustable)

Circulation pump IBO AMG 25-60

Anti-freeze kit SARG1

Magnetic filter 11000G magnet, 500μm mesh

Safety valve 3 bar

Size of hydraulic connections GW 1”

Dimensions H x W x D. 530 mm x 650 mm x 295 mm

Mass 35 kg

Noise < 35 dB

Recommended electrical supply min. 3 x 10A, 230V AC, 50Hz

Recommended power cord 5 x 2,5 mm²

Recommended cable for sensor with SARG1 2 x 1 mm² shielded

Installation and operating instructions for HYDROBOX KENSOL KTH1 5/11

FIG. 2. COMPONENTS AND DESCRIPTION OF HYDRAULIC CONNECTIONS

ELECTRIC SOCKETS SAFETY VALVE CH/DHW VALVE FLOW THROUGH HEATER

PC CONTROLLER

JUNCTION BOX ELECTRICAL MODULE

DHW TANK

CH BUFFER

HEAT PUMP INLET

HEAT PUMP OUTLET

DHW/CH RETURN

PRESSURE GAUGE

AIR VENT

CIRCULATION PUMP

HYDRO MODULE SARG1

MAGNETIC FILTER

5. Transportation and storage

• Store the device in a dry and dust-free place.

• Do not store the device below 0°C and above 40°C.

• It is not recommended to transport the device unpacked from the supplied packaging. Moving the

device requires at least two people or the use of a transport cart.

• When lifting the device, be careful against accidentally opening the door. Do not lift by grasping

the connector pipes.

6. Wall installation and service distances

Installation of the device should be carried out on the wall or a structure that allows vertical hanging.

Observe the minimum distances from obstacles according to Figure 3. Suspend the device by first

fastening the two top M8 screws according to Figure 4. For installation, you can use the supplied set

of screws and screw anchors or use others adapted to the condition of the wall/ or structure. The

installer selects the appropriate anchoring elements. Then further fix the device using the lower

installation holes.

Installation and operating instructions for HYDROBOX KENSOL KTH1 6/11

FIG. 3. MINIMUM DISTANCES FROM OBSTACLES

FIG. 4. INSTALLATION HOLES

7. Hydraulic connections

All hydraulic connections should be made using piping and fittings of the correct diameters. Examples

of recommended diameters for the most popular systems are shown in Table 2.

Installation and operating instructions for HYDROBOX KENSOL KTH1 7/11

Pump model Required flow

[M3/H] Pp-R-Gf Press Steel Copper Multilayer Pipe

KTM 6 1,4 Ø40x6,4 Ø 28x1,5 Ø 28x1 Ø32x3

KTM 10 2,2 Ø50x8,3 Ø 35x1,5 Ø 35x1 Ø40x3,5

KTM 14 3,1 Ø50x8,3 Ø 35x1,5 Ø 35x1 Ø40x3,5

The device should be connected to the installation according to the purpose of the connector pipes as

described in Figure 5.

FIG. 5. HYDRAULIC CONNECTIONS

DHW TANK

CH BUFFER

DHW/CH RETURN

HEAT PUMP INLET

HEAT PUMP OUTLET

REMEMBER TO INSTALL A SAFETY VALVE, AN EXPANSION VESSEL AND A PROPER SELECTION IN

ACCORDANCE WITH PN-EN 12828:2014 OR LATER.

8. Electrical connections

The basic electrical connections for the HYDROBOX installation include:

• Power supply to the heater (Figure 6) - plug the power wires into the ZUG rail bonds and into the

• N and PE rails.

• Installation of temperature sensors of the SARG1 system (Figure 7) - extend the wires of sensors

T1 (outdoor temperature IN1) and T2 (water circulation temperature IN2),

• THE POWER SUPPLY OF THE OUTDOOR UNIT MUST BE DONE SEPARATELY ACCORDING TO THE

INSTALLATION INSTRUCTIONS OF THE HEAT PUMP!

• REFER TO THE CONTROLLER/HEAT PUMP MANUAL FOR HOW TO CONNECT THE OTHER SENSORS

AND OTHER DEVICES!

Cable list:

Recommended power cord 5 x 2,5 mm²

Recommended cable for sensor with SARG1 2 x 1 mm² vvvv

Installation and operating instructions for HYDROBOX KENSOL KTH1 8/11

FIG. 6. CONNECTIONS IN THE ELECTRICAL BOX

NPE

POWER L1

POWER L2

POWER L3

FIG. 7. SARG1 SYSTEM SENSOR SOCKET LOCATION

9. Magnetic filter operation

The circulation is protected by a magnetic filter. It is recommended to clean it for the first time after

about a month of operation of the installation, and then a minimum of once a year.

STEP-BY-STEP ACTIVITIES:

1. Close the shut-off valve (1),

2. Empty the filter chamber with the drain valve (4),

3. Unscrew the filter chamber (3),

4. Remove and clean cartridge and magnetic element under running water the mesh (2),

5. Remove and clean cartridge and magnetic element under running water the mesh (2),

6. Carefully screw the filter chamber, paying attention to the correct position of the gasket,

7. Unscrew the ball valve (1).

Installation and operating instructions for HYDROBOX KENSOL KTH1 9/11

FIG. 8. MAGNETIC FILTER

10. Operation of the circulating pump

If a pump malfunction occurs, verify the malfunction and remove the cause according to Figure 9.

FIG. 9. CIRCULATION PUMP ERROR CODES

ERROR CODE

Shaft blockage

Voltage too high or too low

No phase

Engine overload

The pump shaft is blocked

Mains voltage is too low

or too high

No phase

Engine overload

DISPLAY CAUSE LÖSUNG

Dismantle the motor ho-

using and then check

whether the pump impeller

rotates without resistance,

if there is resistance, the

pump shaft should be di-

smantled and then cleaned

from the accumulated de-

posits.

Check the line voltage, if

there are deviations, con-

tact an electrician.

Check the electrical

network

Replace the pump

11. Launching and operating of the SARG1

Place the probe of the outdoor temperature sensor T1 outside, away from heat sources and in the

shade. Place the probe of the heating water temperature sensor T2 as close as possible to the heat

pump on the outlet pipeline, directly on the pipe, under the insulation layer or in a suitable capillary.

In the case of pipes made of poorly conductive material, such as PP-R, it is advisable to find another

location for the sensor, such as on a metal made fitting, and insulate effectively. If necessary, the

probe cable can be extended.

Installation and operating instructions for HYDROBOX KENSOL KTH1 10/11

FIG. 10. INSTALLATION OF CIRCULATION SENSOR

Installation of a circulating water temperature sensor:

1 - pipe, 2 - clamp, 3 - thermal insulation (insulation

lagging), 4 - temperature sensor

It is imperative to make sure that the T1 and T2 sensors are correctly identified. Incorrect connection

of sensors may result in malfunction of the system and lack of antifreeze protection of the heat pump!

If there are cyclic beeps, first verify the correct plugging in of the sensor wires and the circulating

pump, as well as the connections when extending the wires if necessary. After repair, the error si-

gnaling subsides with a time delay (except for an error related to battery damage - in which case the

error must be reset).

If you need to mute the acoustic signal (e.g., until the arrival of a technician), it is possible to disable

the buzzer by removing jumper #3 on connector SW1.

Error reset is possible by removing jumper #2 on SW1 connector for 30 seconds.

FIG. 11. INTERIOR OF SARG1 MODULE

12. Cleaning and maintenance

Basic maintenance activities include:

• Washing the housing with a damp cloth with a possible mild detergent,

• Vacuuming the inside of the case,

• Cleaning the magnetic filter (see „Magnetic filter operation”), Checking the condition of the

electrical cables,

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