Installation and maintenance instructions

High-efficiency hot water storage tank

Installation and maintenance instructions English High-efficiency hot water storage tank

EKHWP300B EKHWP500B List of contents

1 Safety ...... 4 7 Technical data ...... 22 1.1 Observing instructions ...... 4 7.1 Basic data ...... 22 1.2 Warning signs and explanation of symbols . . . . 4 7.1.1 EKHWP ...... 22 1.3 Avoid danger ...... 4 7.2 Performance diagrams ...... 23 1.4 Proper use ...... 5 7.2.1 EKHWP ...... 23 1.5 Instructions for operating safety...... 5 7.3 Tightening torque ...... 23 1.5.1 Before working on the hot water storage tank and  the heating system ...... 5 8 List of keywords ...... 24 1.5.2 Electrical installation of optional accessories . . . . .5 1.5.3 Installation room ...... 5 1.5.4 Requirements of the heating and filling water . . . . .5 1.5.5 Heating and sanitary side connection ...... 5 1.5.6 Operation ...... 5 1.5.7 Instructing the user/owner...... 5 1.5.8 Documentation ...... 5

2 Product description...... 6 2.1 Design and components ...... 6 2.1.1 High-efficiency hot water storage tank  (Unpressurised system - drain-back) ...... 7 2.2 Brief description ...... 8 2.3 Accessories ...... 8 2.3.1 Electric immersion heaters ...... 8 2.3.2 Non return valves ...... 8 2.3.3 Dirt filter...... 8 2.3.4 Scalding protection ...... 9 2.3.5 Solar storage tank extension kit ...... 9

3 Set-up and installation ...... 10 3.1 Set-up ...... 10 3.1.1 Important information ...... 10 3.1.2 Scope of delivery...... 10 3.1.3 Installing the hot water storage tank ...... 11 3.2 Installation ...... 12 3.2.1 Important information ...... 12 3.2.2 Overview of connections...... 12 3.2.3 x Hydraulic connection ...... 13 3.2.4 Connecting together several hot water storage  tanks ...... 13 3.2.5 Connection booster heater (accessories) ...... 14 3.2.6 Filling the hot water heat exchanger ...... 15 3.2.7 Filling the storage tank ...... 15 3.2.8 Filling solar panel circuit ...... 15 3.2.9 Filling the heating system and the storage tank  charging circuit ...... 15

4 Commissioning, decommissioning . . . . . 16 4.1 Start-up ...... 16 4.2 Taking out of service ...... 17 4.2.1 Temporary shutdown ...... 17 4.2.2 Final shutdown ...... 18

5 Hydraulic connection ...... 19 5.1 Connection diagrams ...... 19 5.1.1 EKHWP...... 19

6 Operation and maintenance ...... 21 6.1 Operation ...... 21 6.1.1 Storage tank ...... 21 6.1.2 Booster heater EKBH3S (Accessories)...... 21 6.2 Service and maintenance ...... 21

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 2 008.1618744_00 – 02/2013

1 x Safety 1 Safety

1.1 Observing instructions Special warning signs Some types of danger are represented by special symbols: This instruction is the >> Original Version << in your language. Please read this manual carefully and thoroughly before Electric power proceeding with the installation or modification of the heating system. Risk of burning or scalding. These instructions are intended for authorised and trained heating and sanitation experts who have experience in the proper Validity installation and maintenance of heating systems and hot water Some information in this manual has limited validity. The validity storage tanks by virtue of their technical training and knowledge. is highlighted by a symbol. This manual provides all the necessary information for instal- Observe stipulated tightening torque. lation, start-up and maintenance, as well as basic information on operation and settings. Please go through the attached Only applicable for the unpressurised system (drain-back) documents for a detailed description of operation and control. Order number Relevant documents Notes related to order numbers are identified by the shopping – When connecting to an external heat generator; the associ- cart symbol . ated installation and operating instructions. – When connecting to a DAIKIN solar system; the associated Handling instructions installation and operating instructions. ● Instructions on actions are shown as a list. Actions of which The guides are included in the scope of supply for the individual the sequential order must be maintained are numbered. units.  Results of actions are identified with an arrow.

1.2 Warning signs and explanation of symbols 1.3 Avoid danger Meaning of the warnings The DAIKIN EKHWP 300/500B is state-of-the-art and is built to Warnings in this manual are classified according into their meet all recognised technical requirements. However, improper severity and probability of occurrence. use may result in serious physical injuries or death, as well as property damage. DANGER! To prevent such risks, install and operate DAIKIN EKHWP Draws attention to imminent danger. 300/500B only: – as stipulated and in perfect condition, Disregarding this warning can lead to serious injury or – with an awareness of the safety and hazards involved. death. This assumes knowledge and use of the contents of this manual, the relevant accident prevention regulations and the recognised WARNING! safety-related and occupational medical rules. Indicates a potentially dangerous situation. WARNING! Disregarding this warning can result in serious injury or death. This unit is not intended for use by persons (including children) with impaired physical, sensory or mental faculties or persons with insufficient experience and/or CAUTION! expertise unless supervised by a person responsible for ensuring their safety or are given instruction by this Indicates a situation which may cause possible person on how to use the unit. damage.

Disregarding this warning can lead to damage to ● Keep flammable materials away from the DAIKIN EKHWP property and the environment. 300/500B.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 4 008.1618744_00 – 02/2013 1 x Safety

1.4 Proper use 1.5.4 Requirements of the heating and filling water The DAIKIN EKHWP 300/500B may only be used as a hot water Avoid damages caused by deposits and corrosion: Observe storage tank. The DAIKIN EKHWP 300/500B must be installed, the current technological regulations to prevent corrosion connected and operated only according to the information in this products and deposits. manual. Measures for desalination, softening or hardness stabilization are When connecting to a DAIKIN heat pump you must use only the necessary, if the filling and top-up water have a high total storage tank connection kits (E-PAC) provided for the purpose. hardness (>3 mmol/l - sum of the calcium and magnesium concentrations, calculated as calcium carbonate. Only those electric immersion heaters supplied by DAIKIN may be used. 1.5.5 Heating and sanitary side connection Any other use outside the intended use is considered as improper. The operator alone shall bear responsibility for any ● Create a heating system according to the safety requirements resulting damage. of EN 12828. ● With sanitary connection, you must observe; Use as intended also involves compliance with maintenance and –EN 1717 - Protection of domestic water from contamina- inspection conditions. Spare parts must at least satisfy the tion in domestic water installations and general require- technical requirements defined by the manufacturer. This is the ments concerning safety equipment for the prevention of case, for example, with the use of original replacement parts. domestic water contamination by back-flow –EN 806 - Technical regulations for domestic water instal- 1.5 Instructions for operating safety lations (TRWI) – and, in addition, the country-specific legal regulations. 1.5.1 Before working on the hot water storage tank ● During operation of the DAIKIN EKHWP 300/500B in combi- and the heating system nation with the solar energy exploitation, the hot water temperature can exceed 60 °C. Scalding protection needs to ● Work on the hot water storage tank and heating system (e.g. be included when you install the system (domestic hot water installation, connection and initial start-up) should only be mixing device e.g. VTA32). carried out by authorised and trained heating experts. ● Use a pressure reducer if the cold water connection pressure ● Switch off the main switch before starting any work on the >6 bar. domestic hot water storage tank and heating system and secure it against unintentional switch-on. 1.5.6 Operation ● Seals must not be damaged or removed. ● Make sure that the safety valves comply with the require- ● Only operate the DAIKIN EKHWP 300/500B;. ments of EN 12828 when connecting on the heating side, and – After all installation and connection work has been com- with the requirements of EN 12897 when connecting on the pleted. domestic water side. – With fully installed equipment covers and service accesses. 1.5.2 Electrical installation of optional accessories – With sanitary side pressure reducers installed (max. 6 bar). ● Before beginning work on live parts, disconnect them from the – With heating side pressure reducers installed power supply (switch off main switch, remove fuse) and (max. 3 bar). secure against unintentional restart. – With completely filled storage containers (fill level dis- ● Electrical installations may only be carried out by qualified play). electrical technicians under observance of the relevant electrical guidelines and the regulations of the electric utilities The specified servicing intervals should be adhered to and company. inspection work must be carried out. ● For each hardwired power connection, install a separate disconnector system compliant with EN 60335-1 for all-pole 1.5.7 Instructing the user/owner disconnection from the power mains. ● Before you hand over the heating system and the hot water ● Compare the mains voltage indicated on the nameplate with storage tank, explain to the owner how he/she can operate the supply voltage before connecting to the mains. and check the heating system. ● Hand over the technical documentation (this document and 1.5.3 Installation room all supporting documents) to the user and advise him that For safe and fault-free operation, it is necessary that the instal- these documents must be made available at all times and be lation location of the DAIKIN EKHWP 300/500B fulfils certain stored in the immediate vicinity of the unit. criteria. Information about the installation location for the high- ● Document the hand-over by filling in and signing the checklist performance hot water storage tank can be found in High- in chapter 4.1 "Start-up", together with the operator. efficiency hot water storage tank chapter 3.2 "Installation". 1.5.8 Documentation Information on the installation site of other components can be found in the associated documentation supplied with them. The technical documentation included in the scope of supply is a constituent part of the equipment. It must be stored in such a way that it can be consulted at any time by the operator or the techni- cians.

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 5 2 x Product description 2 Product description

2.1 Design and components

Item Explanation Applicable to hot water storage tank 1 Cold water connection * All 2 Hot water * All 3 Storage tank charging flow (via 1st. heat source) * 3 B /D

4 Storage tank charging return flow (via 1st. heat source) * 4 B /D 7 Heating support flow* (connect to return flow heat generator!) B 8 Heating support return flow* (connect to return flow heating!) B

11 Drain-back solar - flow 500l 9 300l 7 B 12 Storage tank (polypropylene double walled jacket with PUR hard foam heat insulation) All 13 Mount for solar R3 controller / handle All 14 Safety overflow connection (1¼" male thread, 1" female thread) All 15 Drain-back solar - return flow B Filling and draining connection for storage tank water All 16 Fill level indicator All 17 Connection for booster heater (R 1½" female thread) All 18 Optional: Electric immersion heater (designated as a booster heater in heat pump systems.) All

19 Sensor pocket for tank temperature sensor 500l 10 300l 8 All 20 Corrugated pipe stainless steel heat exchanger for domestic hot water generation via 1st. heat source All 21 Stainless steel corrugated pipe heat exchanger for charging storage tank (SL-WT1) via 1st. heat source B /D 27 Solar inflow layering pipe B 28 Pressure-free storage tank water All 29 Solar zone All 30 Hot water zone All 31 Type plate All B Hot water storage tank EKHWP500B D Hot water storage tank EKHWP300B X Recommended wall distance 200 mm Outer Outer thread thread Internal Internal thread thread * Recommended accessories (Convection brake (2 Stk.)) Tab. 2 -1 Legend designation for images in section 2.1.1 and 2.2.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 6 008.1618744_00 – 02/2013 2 x Product description

2.1.1 High-efficiency hot water storage tank (Unpressurised system - drain-back)

Fig. 2-1 Connections and dimensions, High-efficiency hot water storage tank with solar support - Type EKHWP 300/500B-DB

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 7 2 x Product description

2.2 Brief description The DAIKIN High-efficiency hot water storage tank is a combi- Economical operation nation of heat storage tank and instantaneous water heater. The full area heat insulation of the storage tank ensures very low The pressureless storage water serves as heat storage medium. heat losses in use and means that the best use is made of the Useful heat is supplied and removed via the spiral corrosion- heat energy being applied. resistant heat exchanger, which is made from a corrugated Modular extension facility stainless steel pipe (1.4404), and is completely immersed in the If the heat output of a single DAIKIN High-efficiency hot water storage tank water. In the heat exchanger for domestic hot water storage tank is not adequate, you can interconnect several generation, domestic hot water is stored at the temperature level storage tanks in a modular manner. of the preparation zone. Electronic control The cold water which flows in when the hot water is drawn off is A control system integrated in the heat generator controls all first routed to the storage tank at the very bottom of the heat heating and hot water functions for the direct heating circuit, a exchanger, where it cools the lower zone of the storage tank mixed heating circuit which can be connected as an option and a down as much as possible. The readiness zone is heated by an storage tank charging circuit. external heat generator (condensing boiler, heat pump, solar system, electric immersion heater). Water flows through the heat When connecting to a DAIKIN heat pump system, the exchanger for storage charging (SL-WT) from top to bottom. setting and regulation of the solar heating, supple- On its way to the top, the domestic water continuously absorbs mentary to the regulation and pump station EKSRPS3, the heat of the storage tank water. The flow direction, operating is carried out via the regulator integrated in the heat on the principle of counter-flow, and the coil-shaped heat pump. exchanger create a pronounced temperature layering in the hot water storage tank. As high temperatures can be maintained for 2.3 Accessories a very long time in the upper section of the storage tank, a high hot water output is achieved even if water is drawn off over a long 2.3.1 Electric immersion heaters period of time. The DAIKIN High-efficiency hot water storage tank listed in In addition to the heating possibilities via the corrugated stainless section 2.1.1 can be heated by solar in addition to the external steel pipe heat exchanger from various different heat sources heat generator. Depending on the available heat from the sun, and energy carriers, the DAIKIN High-efficiency hot water the entire hot water storage tank can be heated up. The stored storage tank can also be charged using an electric immersion heat is now used both for hot water generation and for heating heater. support. The high total storage capacity also temporarily allows In DAIKIN heat pump systems, the electric immersion heater is time without sunshine to be bridged. designated a booster heater.

Optimum water hygiene Type EKBH3S Low flow or unheated zones on the domestic water side are completely excluded with the DAIKIN High-efficiency hot water Operating voltage 230 V / 50 Hz storage tank. It is impossible for sludge, rust or other sediments Heating output 3 kW to be deposited, as can be the case with other large volume Temperature range 35-65 °C tanks. The water which is fed into the system first is also discharged first (first in, first out principle). Cable length — Heating element length 0.9 m Low maintenance and corrosion The DAIKIN High-efficiency hot water storage tank The is made Screw-in thread R 1½" of plastic and is completely corrosion free. No sacrificial anode or Suitable for All EKHWP similar corrosion protection system is necessary. This means that associated maintenance work, e.g. changing the protective Tab. 2 -2 Booster Heater - Overview and technical data anodes or cleaning the storage tank, does not need to be carried out on the DAIKIN High-efficiency hot water storage tank. Only 2.3.2 Non return valves the fill level of the storage tank water needs to be checked. During periods without potable water discharge, and when the The corrugated stainless steel pipe heat exchangers on the circulation pump is switched off, to avoid heat losses through the heating and potable water side are made from high quality connection lines (gravity circulation), circulation brakes should be stainless steel (1.4404). installed in the connections of the DAIKIN High-efficiency hot water storage tank. Low scaling On the storage tank side only one deposition of scale is possible. 2.3.3 Dirt filter The immersion heater therefore remains clean, as do all the stainless steel heat exchanger pipes in the storage tank water. If the DAIKIN High-efficiency hot water storage tank is connected This means that no scale can build up which would continuously to a heating system with steel pipes, radiators or non-diffusion- reduce the efficiency of heat transfer in the course of operation proof floor heating pipes, slurry and swarf could enter the hot (as is the case with other storage tank designs). water storage tank and cause blockages, local overheating or The thermal and pressure expansion and high flow rates in the corrosion. This can be prevented by fitting a dirt filter or sludge domestic water heat exchanger release any possible scale trap (see DAIKIN price list). deposits, which are then flushed away.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 8 008.1618744_00 – 02/2013 2 x Product description

2.3.4 Scalding protection There is a danger of scalding at hot water temperatures over 60 °C. Fitting scalding protection enables the hot water temper- ature to be varied continuously and limited from 35 - 60 °C. – Scalding protection VTA32 – Screw connection kit 1"

2.3.5 Solar storage tank extension kit The following components are offered for the interconnection of several DAIKIN High-efficiency hot water storage tank to the solar system: – Solar storage tank extension kit CON SX – Solar storage tank extension kit CCON SXE – FlowGuard FLG

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 9 3 x Set-up and installation 3 Set-up and installation

3.1 Set-up

3.1.1 Important information 3.1.2 Scope of delivery – DAIKIN EKHWP 300/500B hot water storage tank WARNING! – Bag of accessories (see fig. 3-1) The storage tank plastic wall on the DAIKIN EKHWP 300/500B can melt under the effects of external heat (>80 °C) and, in the extreme case, can catch fire. ● Erect the DAIKIN EKHWP 300/500B only at a minimum distance of 1 m to other heat sources (>80 °C) (e.g. electric heater, gas heater, chimney) and flammable materials.

CAUTION! ● Only erect the DAIKIN EKHWP 300/500B if a ground load-bearing capacity of 1050 kg/m² plus safety factor is guaranteed. The ground must be flat and level. ● Erection outdoors is only possible to a limited A Handle (required only for D Clamping piece for safety extent. The storage tank must not be exposed to transport) overflow continuous direct sunlight, as the UV radiation B Cover screen E Installation spanner and the effects of the weather will damage the C Safety overflow connection plastic. Fig. 3-1 Contents of bag of accessories ● The DAIKIN EKHWP 300/500B must be protected from frost. ● Make sure that the supply company does not provide corrosive domestic water. – Suitable water treatment may be required.

CAUTION! If the hot water storage tank is not installed adequately lower than the flat solar panels (the top edge of the of the storage tank is higher than the bottom edge of the solar panel) the unpressurised solar system in the outdoor area will be unable to drain completely. ● Erect the DAIKIN EKHWP 300/500B low enough, with a solar connection, with regard to the flat solar panels (observe minimum gradient in the solar connecting lines).

EKHWP Observe the permitted lengths of pipes between the hot water storage tank and the hydraulic connections on the heat pump (see installation and operating instructions of the heat pump and the relevant storage tank connecting kit "E-PAC").

Requirement: The installation site meets the applicable country- specific requirements. Incorrect set-up and installation would render the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical Customer Service.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 10 008.1618744_00 – 02/2013 3 x Set-up and installation

3.1.3 Installing the hot water storage tank ● If you are using an electric immersion heater (booster heater) (see chapter 2.3.1 "Electric immersion heaters"), screw it ● Remove the packaging and dispose of it in an environmen- into the opening in the cover on the hot water storage tank tally sound manner. (example see fig. 3-3). ● Unscrew the threaded inserts (fig. 3-2, item G), onto which – Only tighten hand-tight ( see chapter 7.3 "Tightening the carrier loops are to be attached, from the hot water torque"). storage tank. – With restricted headroom tilt the hot water storage tank ● Thread the carrier loops (item A) through the threaded pieces until the electric immersion heater can be fitted without (item G) and mount onto the available connections on the damage. front and back of the hot water storage tank. Switch the power supply to the electric immersion heater (booster heater) on only after filling the hot water storage tank.

Fig. 3-2 Mount the handle

● Transport the domestic hot water storage tank carefully to the site of erection, using the handles provided. ● Install the domestic hot water storage tank at the installation site. – Recommended distances (fig. 3-3): From the wall (s1): ≥200 mm To the ceiling (X): ≥1200 mm. – Install the hot water storage tank close to the discharge point. Fig. 3-3 Erecting the hot water storage tank (shown on the EKHWP) When setting up the unit in a cabinet, behind panels or in other restricted conditions, sufficient ventilation (e.g., using ventilation gratings) must be ensured.

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 11 3 x Set-up and installation

3.2 Installation 3.2.2 Overview of connections EKHWP 3.2.1 Important information

WARNING! There is a danger of scalding at water temperatures >60 °C. This can arise with solar energy utilisation, if the Legionella protection is activated or if the target temperature is set to >60 °C. ● Fit scalding protection (see chapter 2.3.4 "Scalding protection").

CAUTION! If the hot water storage tank is connected to a heating system with steel pipes, radiators or non-diffusion- proof underfloor heating pipes, sludge and swarf could enter the hot water storage tank and cause blockages, local overheating or corrosion. ● Flush the feed pipes before filling the heat exchanger. ● Rinse out the heat distribution network (in the existing heating system). ● Fit a dirt filter or sludge catcher in the heating return pipe (see chapter 2.3.3).

● For potable water pipes observe the stipulations of EN 806 Fig. 3-4 External connections hot water storage tank and EN 1717. (shown on EKHWP500B ) ● The position and dimensions of the connections can be  fig. 3-4 taken from. 1 Cold water connection ● Check the cold water connection pressure (maximum 6 bar). 2 Hot water* – At higher pressure in the drinking water line, a pressure 3 Storage tank charging flow (via 1st. heat source)* reducer must be installed. 4 Storage tank charging return (via 1st. heat source)* ● Connect the pressure relief line to the safety pressure relief 7 Heating support flow* (connect to return flow heat generator!) valve and the membrane expansion tank as per EN 12828. 8 Heating support return flow* (connect to return flow heating!) ● Note tightening torque (see chapter 7.3 "Tightening 11 Drain-back solar - flow (1¼" male thread, 1" female thread) torque"). 12 Storage tank 13 Mount for solar R3 controller / handle CAUTION! 14 Safety overflow connection 15 Drain-back solar - return flow or If filling or topping up the storage tank is done by Filling and draining connection for storage tank water with valve in- means of the boiler filling and drain valve, a temporary sert UK only! filling loop must be used with the appropriate backflow 16 Filling level indicator prevention device in accordance with clause G24.2, 17 Connection for booster heater (R 1½" female thread) Guidance to the Water Supply (Water Fittings) 19 Sensor immersion sleeve for storage tank temperature sensor Regulations 1999. 31 Rating plate

Male thread Avoid damages caused by deposits and corrosion: Observe Female thread the relevant regulations of technology to prevent creation of * Recommended accessories: (circulation brakes) corrosion products and deposits. Tab. 3 -1 Legend for fig. 3-4 Measures for desalination, softening or hardness stabilization are necessary, if the filling and top-up water have a high total hardness (>3 mmol/l - sum of the calcium and magnesium concentrations, calculated as calcium carbonate.

To prevent heat loss from the connection pipes when the heating pump is switched off and during periods when no domestic water is drawn off (gravity circula- tion), you should fit circulation brakes (see chapter 2.3.2) in the connections to the DAIKIN hot water storage tank.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 12 008.1618744_00 – 02/2013 3 x Set-up and installation

3.2.3 Hydraulic connection 8. Establish connections to the heat generator. – EKHWP: In combination with a DAIKIN heat pump, the 1. Only with connection of a EKHWP hot water storage tank to heating side connection of the hot water storage tank a DAIKIN heat pump: must be carried out in accordance with the installation and ● Fit the storage tank connection kit "E-PAC", suitable for operating instructions of the individual storage tank con- the DAIKIN heat pump, EKHWP to the hot water storage nection kit (E-PAC). tank (see the individual installation and operation instruc- – Optional: Connect the connections to the solar system tions of the storage tank connection kit supplied). (see solar installation and maintenance manual). 2. When using circulation brakes, fit them into the pipe 9. Carefully lag the hot water pipes to prevent heat loss. Install connections on the DAIKIN EKHWP 300/500B. heat installation in accordance with country-specific 3. Connect the drain hose to the connector of the safety guidelines. DAIKIN recommends a lag thickness of at least overflow (fig. 3-4, item 14) on the hot water storage tank. 20 mm. – Use transparent drain hose (draining water must be visi- ble). 3.2.4 Connecting together several hot water storage – Connect the drain hose to an adequately dimensioned tanks waste water installation. If the heat output of a single DAIKIN hot water storage tank is not – Drain should not be lockable. adequate you can interconnect several EKHWP 300/500B modules. This means that both the stainless steel heat exchangers for post-heating and the hot water heat exchangers are intercon- nected in accordance with the Tichelmann principle (chapter 5 "Hydraulic connection"). With seasonal variations in demand these individual units can be added or taken out of service accordingly. In this way the total hot water output can be manually matched to the actual demand. In chapter 7.2 "Performance diagrams" you can see what efficiency characteristics can be achieved by interconnecting several DAIKIN EKHWP 300/500B units.

Fig. 3-5 Installation of drain hose at safety overflow

4. Check the water pressure at the cold water connection (<6 bar).  If the pressure in the domestic water supply is greater then fit a pressure reducer and limit the water pressure to <6 bar. 5. Create connection of the cold water inlet to the hot water storage tank (fig. 3-4, item 1). In order to be able to flush out the stainless steel corru- gated heat exchanger for domestic hot water heating in the event of bad water quality, install a removal facility to each of the cold water and hot water connections on the storage tank (T-piece with draw-off cock). Above a hardness level of >3 mmol/l we recommend also fitting a dirty water filter that can be back-flushed into the cold water connection.

6. Connect the connections to the hot water distribution network (fig. 3-4, item 2). 7. Establish connections to the heating circuit. – EKHWP: The heating side connection of the hot water storage tank must be carried out in accordance with the installation and operating instructions of the individual storage tank connection kit (E-PAC). You must always ensure proper de-aeration of the storage tank lines.

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 13 3 x Set-up and installation

WARNING! Touching live parts can result in an electric shock and lead to potentially fatal injuries and burns. ● Before beginning work on live parts, disconnect them from the power supply (switch off fuse, main switch) and secure against uninten- tional restart. ● The electrical connection and working on the electrical components should only be performed by electrical engineers in compliance with valid standards and guidelines as well as the specifica- tions of the energy supply company. ● For each rigidly fixed cable connection fit a separate isolator in accordance with EN 60335-1 for all-pole disconnection from the power mains and a residual current device RCD (FI) in accordance with the individual country-specific regulations. ● The equipment covers and maintenance opening covers must be re-fitted immediately after completion of the work.

Modifications on the electrical installation are dangerous and prohibited. The operator alone shall bear responsibility for any resulting damage. Requirements 1 Hot water storage tank – For electrical connections and consumable electrical materi- 2 Regulation and pump unit EKSRPS3 als (cable, insulation, etc.), follow all valid country-specific 3 Solar flow distribution pipe guidelines. 4 T-connector – Cabling may only be connected to the terminal block intended for this. No other terminal blocks may be used. CON SX B Storage tank extension kit – Be sure that there is sufficient tension relief on all electrical FLG FlowGuard lines ( see chapter 7.3). FLS FlowSensor – The distance between the cabling of temperature sensors Fig. 3-6 Schematic for storage tank extension and the power cable must always be at least 25 mm so that the cables to the temperature sensor are not exposed to elec- For the interconnection of several DAIKIN EKHWP 300/500B tromagnetic interference. units we have the additionally available storage tank extension kit CON SX and the FlowGuards. For purchasing information see EKBH3S chapter 2.3.5. Connection of the electric immersion heater (booster heater) is only possible in combination with a DAIKIN heat pump. The The installation and operation of this accessory component is installation is to be carried out in accordance with the associated described in detail in the individual operating and installation installation and operating instructions of the DAIKIN heat pump instructions provided. and the individual storage tank connection kit (E-PAC). 3.2.5 Connection booster heater (accessories)

WARNING! If non-flame-resistant power supply cables are fixed directly on the hot water storage tank they can catch fire if the electrical cable is overheated. ● Do not lay or fix the power supply cable directly on the hot water storage tank. or ● Use flame-resistant power supply cable (in accordance with IEC 60332.1).

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 14 008.1618744_00 – 02/2013 3 x Set-up and installation

3.2.6 Filling the hot water heat exchanger 1. Open the shutoff valve for the cold water supply pipe. 2. Open the hot water tap connections so that the draw-off volume can be set as high as possible. 3. Once water has been discharged from the tap connections, do not interrupt the cold water flow; this will ensure that the heat exchanger will be fully vented and that any impurities or residue will be discharged.

3.2.7 Filling the storage tank

CAUTION! If filling or topping up the storage tank is done by means of the boiler filling and drain valve, a temporary UK only! filling loop must be used with the appropriate backflow prevention device in accordance with clause G24.2, Guidance to the Water Supply (Water Fittings) Regulations 1999.

Without installed solar system 1. Connect the filling hose. a) Connect the filling hose with return flow preventer (1/2") to the connection "Drain-Back Solar - Flow" (see fig. 3-4, item 11). 2. Fill the storage tank on the DAIKIN EKHWP 300/500B until water comes out of the safety overflow connection  (see fig. 3-4, item 14). With installed solar system 1. Mount the KFE cock (customer provision) to the optional threaded connector (1" female thread, 1¼" male thread) of the solar regulation and pump unit (EKSRPS3). 2. Connect the filling hose with backflow preventer (1/2") to the previously installed KFE cock. 3. Fill the storage tank on the DAIKIN EKHWP 300/500B until water comes out of the safety overflow connection  (see fig. 3-4, item 14).

3.2.8 Filling solar panel circuit ● Fill the solar panel circuit and de-aerate in accordance with the regulation and pump unit instructions.

3.2.9 Filling the heating system and the storage tank charging circuit ● Fill the heating system and storage tank charging circuit in accordance with the installation instructions of the individual heat generator (max. 3 bar) and de-aerate. ● After de-aeration, check the installation pressure again and adjust if necessary (max. 3 bar).

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 15 4 x Commissioning, decommissioning 4 Commissioning, decommissioning

4.1 Start-up

WARNING! ● Units which have been set-up and installed incor- rectly may not operate properly and can be a health and safety risk endangering human life. ● Installation commissioning may only be carried out by authorized and trained heating technicians following the installation and maintenance manual included. ● Only original DAIKIN replacement parts may be used.

CAUTION! A hot water storage tank commissioned improperly can lead to property damage. ● Observe the regulations in VDI 2035 in order to avoid corrosion and deposits. ● If the filling and top-up water has a high degree of hardness, measures must be taken to stabilise this hardness or soften the water. ● Set the pressure reducer on the cold water connection to a maximum of 6 bar.

CAUTION! If the booster heater is started with the storage tank empty or not completely full, it can lead to a reduction in performance of the electric heating (tripping of the safety temperature limiter). ● Operate the booster heater only with the storage tank completely full.

Incorrect start-up makes the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical Customer Service. Requirements – The DAIKIN domestic hot water storage tank is installed and fully connected. –The heating and hot water system are filled and subjected to the correct pressure. – The DAIKIN hot water storage tank is filled to the overflow point. – Optional accessories have been mounted on and connected up. Checks before start-up ● Check all connections for leakage. Start the system ● Check all the points on the enclosed checklist. Make a record of the test results and sign it, together with the operator. ● If an electric immersion heater / booster heater is fitted, set the desired storage tank water temperature. ● Switch on the mains supply switch on the heat generator. Wait for the start phase. Only if all points on the checklist can be answered with Yes may the DAIKIN EKHWP 300/500B be started up.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 16 008.1618744_00 – 02/2013 4 x Commissioning, decommissioning

Check list for start-up 1. Is the hot water storage tank is correctly set up according to an admissible set up variant and without visible  Yes damages? 2. Minimum distance between the hot water storage tank and other heat sources (>80 °C) of 1 m?  Yes 3. If booster heater installed: – Does the mains connection comply with the regulations and is the mains voltage 230 volts, 50 Hz?  Yes – Has the residual current device been fitted in accordance with the individual country-specific regulations?  Yes – Only when using non-flammable power supply cable: Has the electric cable not been laid directly to the hot  Yes water storage tank? 4. The storage tank is filled with water to the overflow point?  Yes 5. On restoration: Has the heat distribution network been cleaned? Is a dirt filter installed in the heating return flow?  Yes 6. Is the safety overflow connection connected to an open drain?  Yes 7. Is the water pressure on the sanitary side < 6 bar?  Yes 8. Is the water pressure on the heating side < 3 bar?  Yes 9. Are the heat generator and heating system vented?  Yes 10. Are all hydraulic connections tight (leaks)?  Yes 11. Does the installation operate without faults?  Yes 12. In the case of new installations: Has the operating manual been handed over, and has the owner been  Yes instructed?

Location and Date: Signature of installer:

Signature of owner:

4.2 Taking out of service

4.2.1 Temporary shutdown CAUTION! CAUTION! If filling or topping up the storage tank is done by means of the boiler filling and drain valve, a temporary A heating system which is shut down can freeze in the UK only! filling loop must be used with the appropriate backflow event of frost and may suffer damage. prevention device in accordance with clause G24.2, ● In the event of a danger of frost, start the entire Guidance to the Water Supply (Water Fittings) DAIKIN heating system up again and activate the Regulations 1999. frost protection function or take the appropriate frost protection measures for the hot water storage a) Without installed solar system: tank (e.g. by draining). ● Remove the safety overflow from the overflow connection (fig. 3-4, pos. 14) on the hot water storage tank. ● If installed: Switch off the power supply to the DAIKIN booster ● Fit the safety overflow (fig. 3-1, pos. C) to the filling and heater. draining connection (fig. 3-4, pos. 15). ● Connect the drain hose to the refitted safety overflow. If the danger of freezing will only last for a few days, the ● Drain out water content from cylinder. very good heat insulation of the DAIKIN EKHWP 300/500B means that it need not be drained, as long as b) With installed solar system: the storage tank temperature is observed regularly and ● Connect the drain hose to the KFE cock on the solar not permitted to fall below +3 °C. This does not, how- regulating and pump unit fitted during filling (EKSRPS3). ever, provide any protection against frost for the con- ● Drain out water content from cylinder. nected heat distribution system! Draining the heating circuit and hot water circuit If a storage tank temperature of less than +3 °C is ● Connect the drain hose to the DAIKIN heat generator. reached, the STB of the booster heaters automatically ● Allow the heating and warm water circuit to run empty based triggers. This prevents consequential damage to the on the suction lifter method. electric immersion heater caused by frost when starting ● Disconnect the heating flow and return flow, as well as the up again. cold water inflow and the hot water outflow from the DAIKIN EKHWP 300/500B. Draining the storage tank ● Connect the discharge hose on the heating flow and return ● If installed: Switch off the power supply to the DAIKIN booster flow as well as the cold water inflow and hot water outflow so heater. that the hose opening is at ground level. ● Allow the individual heat exchangers to run empty one after the other based on the suction lifter method.

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 17 4 x Commissioning, decommissioning

4.2.2 Final shutdown ● DAIKIN EKHWP 300/500B disconnected from all electrical and water connections. ● Dismantle the DAIKIN EKHWP 300/500B in accordance with the instruction manual (chapter 3 "Set-up and installation") in reverse order. ● DAIKIN EKHWP 300/500B disposed off in a professional manner. Recommendations for disposal DAIKIN, thanks to the environmentally friendly design of the EKHWP 300/500B hot water storage tank, has established the preconditions to ensure environmen- tally friendly disposal. Proper disposal in compliance with the respective national regulations of the country of use is the responsibility of the user/owner.

The designation of the product means that electrical and electronic products may not be disposed of together with unsorted domestic waste. Proper disposal in compliance with the respective national regulations of the country of use is the respon- sibility of the user/owner. ● Only a qualified technician may disassemble the system. ● Disposal may only be carried out by a facility that specialises in reuse, recycling and recovery. Further information is available from the installation company or the responsible local authorities.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 18 008.1618744_00 – 02/2013 5 x Hydraulic connection 5 Hydraulic connection

5.1 Connection diagrams

5.1.1 EKHWP

Fig. 5-1 Standard connection layout with heat pump and drain-back solar1) (shown in the version with just room heating function) 1) (legend see tab. 5 -1)

Short name Meaning Short name Meaning 1 Cold water distribution network CW Cold water 2 Hot water distribution network DHW Domestic hot water 3 Heating inflow E Expansion valve 4 Heating return flow EP3 Hot water module E-PAC (heating/cooling) 5 Mixer circuit FlowGuard - solar regulating valve with flow indi- FLG 6 Circulation cator FlowSensor - solar flow and flow temperature 7 Check valve, return valve FLS measurement 7a Non return valves H H ... H Heating circuits 8 Solar circuit 1, 2 m HYW Low loss header 9 Gas pipe (refrigerant) MAG Diaphragm expansion vessel 10 Fluid pipe (refrigerant) MIX 3-way-mixer with drive motor 3UV1 3-way switch valve (DHW) MK1 Mixer group with high-efficiency pump 3UV2 3-way switch valve (cooling) Mixer group with high-efficiency pump 3UV3 3-way switch valve (heating support) MK2 (PWM controlled) Not available P1 Central heating pump Hot water storage tank EKHWP500B PHP Heating circulation pump P Mixing circuit pump BOH Booster heater Mi P Solar operating pump BSK Burner blocking contact in RPS3 S1 P Solar pressure increasing pump BV Overflow valve S2 P Circulation pump C Refrigerant compressor Z PWT Panel heat exchanger (condenser)

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 19 5 x Hydraulic connection

Short name Meaning RLB Return temperature limiter RoCon M1 Mixer circuit control RPS3 Solar regulating and pump unit RRLQ External unit for heat pump RKHBX Heat pump indoor unit RT Room thermostat SOL-M1 Solar printed circuit board heat pump SK Solar panel field SV Safety overpressure valve

tAU Outside temperature sensor Storage tank temperature sensor (heat genera- t DHW tor)

tMi Mixer circuit flow temperature sensor TK Solaris collector temperature sensor TR Solaris return flow temperature sensor TS Solaris storage cylinder temp. sensor TV Solaris inflow temperature sensor V Fan (vaporiser) VS Protection against scalding VTA32 Tab. 5 -1 Short names in hydraulic drawings

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 20 008.1618744_00 – 02/2013 6 x Operation and maintenance 6 Operation and maintenance

6.1 Operation ● Carry out a functional inspection of the booster heater by checking the temperature display and the switching states in 6.1.1 Storage tank the individual modes: – Without connection to a DAIKIN heat pump: see No separate controller is required to operate the domestic hot section 6.1.2 water storage tank. The regulation is effected in each case by the – With connection to a DAIKIN heat pump: see chapter control system of the connected heat generator and, in the case "Operation" in the associated installation and operating of solar installations, by the regulation and pump station. instruction. ● Check the level in the storage tank (see chapter 2 "Product ● If a solar system is connected and is in operation, switch it off description") on the level indicator at regular intervals and top and empty the solar panels. up with water if required. ● Visual inspection of the general condition of the domestic hot water storage tank. ● Visual check of the water storage tank level (filling level 6.1.2 Booster heater EKBH3S (Accessories) indicator)  If necessary, replenish water; determine the reason for CAUTION! the low water level and remedy it. If the booster heater is started with the storage tank ● Check the connection of the safety overflow and drain hose empty or not completely full, it can lead to a reduction for leaks, free drainage and gradient. in performance of the electric heating (tripping of the  If necessary, clean the safety overflow and drain hose and safety temperature limiter). relay it; replace damaged parts. ● Operate the booster heater only with the storage ● Visual check of connections and pipes. In the event of tank completely full. damage, determine the cause.  Replace defective parts. The booster heater should only be adjusted via the configuration ● Check all electrical components, connections, and cables. menu of the DAIKIN heat pump (see associated installation and  Repair damaged parts or replace them. operating instructions). ● Check the water pressure of the cold water supply (<6 bar)  and if necessary the fitting or adjustment of the pressure 6.2 Service and maintenance reducer. The DAIKIN EKHWP 300/500B The is practically maintenance Clean the storage tank (annually) free as a result of its design. No corrosion protection equipment ● The low-maintenance plastic must only be cleaned with a is required (such as sacrificial anodes). This means there is no soft cloth and a mild detergent. Do not use cleaning agents need for maintenance work such as changing the protective containing aggressive solvents, as this will damage the anodes or cleaning the inside of the storage tank. plastic surface. Regular inspection of the domestic hot water storage tank guarantees a long working life and fault-free operation. Tests performed during the annual service:

WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. ● If there is a booster heater or regulation and pump station installed in the hot water storage tank then these components must be isolated from the power supply before starting the inspection and maintenance work (e.g. fuse, main switch switched off and secured against inadvertent switching on again).

WARNING! All work performed on live components must be carried out in accordance with the proper procedures, otherwise there may be a danger to the life and health of individuals and the function may be impaired. ● Rectification of damage to live components may only be carried out by heating specialists authorised and recognised by the energy supply company.

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 21 7 x Technical data 7 Technical data

7.1 Basic data

7.1.1 EKHWP

Unit EKHWP300B EKHWP500B Basic data Total storage capacity litres 300 500 Empty weight kg 59 93 Total filled weight kg 359 593 Dimensions (L x W x H) without switching unit from E-PAC cm 59.5 x 61.5 x 164 79 x 79 x 164 Maximum permissible storage water temperature °C 85 Heat consumption at stand-by and at 60 °C kWh/24h 1.4 Drinking water heat exchanger (stainless steel 1.4404) Potable water capacity litres 27.9 29.0 Maximum operating pressure bar 6 Domestic water heat exchanger surface m2 5.8 6.0 Storage tank charging heat exchanger (stainless steel 1.4404) Water capacity heat exchanger litres 13.2 18.5 Heat exchanger surface area m2 2.7 3.8 Solar heating backup (stainless steel 1.4404) Water capacity heat exchanger litres — 2.3 Heat exchanger surface area m2 — 0.5 Thermal output data 364 3)7) / 318 4)7) Volume of hot water without reheating at draw-off rate  3) 4) 3) 4) litres 184 / 153 (8 l/min /12 l/min ) (TKW = 10 °C / TWW = 40 °C / TSP = 50 °C) 328 3)8) / 276 4)8)

Volume of hot water without reheating at draw-off rate  3) 4) 3) 4) 4) 4) litres 282 / 252 540 / 494 (8 l/min /12 l/min ) (TKW = 10 °C / TWW = 40 °C / TSP = 60 °C)

Volume of hot water without reheating at draw-off rate  3) 4) 3) 4) 4) 4) litres 352 / 321 612 / 564 (8 l/min /12 l/min ) (TKW = 10 °C / TWW = 40 °C / TSP = 65 °C) Reheating time (Wh) with a draw-off quantity  (bathtub: 140 l 5) / shower: 90 l 6))  min. 45 5)9) / 30 6)9) 25 5)10) / 17 6)10) (TKW = 10 °C / TWW = 40 °C / TSP = 50 °C) Pipe connections Cold and hot water inches 1" outer thread Heating flow / return flow inches 1" female thread / 1" male thread Solar connections inches 1" internal thread

Tab. 7 -1 Basic data EKHWP - Drain-Back

7) Charging by heat pump and electric booster heater. 9) With heat pump 8 kW. 8) Charging only by heat pump without electric booster heater. 10) With heat pump 16 kW.

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 22 008.1618744_00 – 02/2013 7 x Technical data

7.2 Performance diagrams

7.2.1 EKHWP 7.3 Tightening torque

Designation Thread size Tightening torque Hydraulic line connections (Water) 1" 25 to 30 Nm Booster heater max. 10 Nm 1.5" (hand-tight) Cabling on terminal rail K1 (EHS) All 0.5 - 1.5 Nm Tension release (EHS) M20 6 Nm Cover flap fixing screws (EHS) 4.2 x 19 1.5 Nm Tab. 7 -2 Tightening torque

B EKHWP500B Z/ L/min D EKHWP300B Draw-off rate in litres per minute VZmax/L Maximum draw-off rate in litres

Hot water volume without re-heating (TKW = 10 °C, TWW = 40 °C, TSP = 60 °C). Fig. 7-1 Hot water performance as a function of the draw-off rate

Draw-off rates >36 l/min can, in certain rare circum- stances, lead to noises in the domestic water heat exchanger of the hot water storage tank.

f

a Drinking water heat exchanger  (EKHWP500B) b Drinking water heat exchanger  (EKHWP300B) c Storage tank charging heat exchanger 1 (EKHWP500B) d Storage tank charging heat exchanger 1 (EKHWP300B) f Heating support heat exchanger (EKHWP500B)

p/mbar Pressure drop in millibar m/ L/h Flow rate in litres per hour m/ L/h Flow rate in litres per minute Fig. 7-2 Pressure drop characteristic for the heat exchanger

EKHWP 300/500B Installation and maintenance instructions High-efficiency hot water storage tank 008.1618744_00 – 02/2013 23 8 x List of keywords 8 List of keywords

A S Additional water ...... 5 Sacrificial anode ...... 8, 21 Safety overflow connection . . . . 13, 21 B Sanitary connection ...... 5 Booster heater ...... 11, 14, 21 Scalding protection ...... 9, 12 Scope of delivery ...... 10 Set-up ...... 10 C Shutdown ...... 17 Check list for start-up ...... 17 Solar Cleaning ...... 21 Storage tank extension equipment 9 Convection brake ...... 6, 8, 12 Start-up Corrosion protection ...... 5 Checklist ...... 17 Requirements ...... 16 D Storage tank  Dangers ...... 4 connection kit ...... 5, 10, 13, 14 Design and components ...... 6 Storage tank extension equipment . 14 Dirt filter ...... 8, 12 Disposal ...... 18 T Distance from ceiling ...... 11 Tapping rate ...... 23 Domestic water pipes ...... 12 Tightening torque ...... 23 Draw-off volume ...... 23 Type plate ...... 6, 12

E U Electric immersion heater 8, 11, 16, 21 Unit installation room Electrical installation ...... 5 Requirements ...... 5 Electronic control ...... 8 E-PAC ...... 5, 10, 13, 14, 22 W Explanation of symbols ...... 4 Wall distance ...... 11 Warning signs ...... 4 F Water hardness ...... 16 Filling ...... 15 Water pressure ...... 13 FlowGuard ...... 14 Frost protection ...... 17

I Installation ...... 12 Instructions for operating safety . . . . 5 Interconnection of several storage  tanks ...... 13

M Make-up water ...... 12

O Operating mode ...... 8 Operation ...... 21 Overview of connections ...... 12

P Performance diagrams ...... 23 Proper use ...... 5

R Regulation and Pump Station . . . . . 21 Relevant documents ...... 4

Installation and maintenance instructions EKHWP 300/500B High-efficiency hot water storage tank 24 008.1618744_00 – 02/2013 25 26 27 Copyright © Daikin

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