Heat pump-boiler integration unit 106 series Hybrical® 01233/13 GB

ACCREDITED

ISO 9001

FM 21654

ISO 9001 No. 0003

Function The integration unit allows two heat generators to be connected to a single air conditioning system. The diverter valve diverts the fluid arriving from the heat pump or from the boiler towards the terminals of the system. The electronic regulator and the outside temperature probe manage the switching on of the appropriate generator.

Product range Code 106160 106 Series Code 106060

Heat pump-boiler integration unit with connection kit Heat pump-boiler integration unit Diverter kit

size DN 25 (1”) sizes DN 32 (1 1/4”), DN 50 (1 1/2” and 2”) size DN 25 (1”)

Technical specifications Diverter valve Materials: - Body: - Ball: - Ball seal - Control stem seal: - Union seal:

brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated PTFE with EPDM O-Ring double EPDM O-ring EPDM O-ring

Performance Medium: water, glycol solutions Max. percentage of glycol: 50% Maximum working pressure: (size 1”) 10 bar (size 1 1/4” –2”) 16 bar Maximum differential pressure: 10 bar Connections: 1” M - 1 1/4” M - 1 1/2” M - 2” M (ISO 228-1) Connection kit (only for size 1”) Materials: - Pipes: copper EN 12735-1 CW-DHP Insulation Material: closed cell expanded PE-X Thickness: 15 mm Density: - inner part 30 kg/m3 - outer part 80 kg/m3 Thermal conductivity (DIN 52612): - at 0°C 0,038 W/(mK) - at 40°C 0,045 W/(mK) Coefficient of resistance to diffusion of water vapour (DIN 52615): >1.300 Working temperature range: -10–110°C Reaction to fire (DIN 4102): class B2

Actuator Synchronous motor Electric supply: Power consumption: Auxiliary microswitch contact rating: Protection class: Operating time: Electric supply cable length: Dynamic torque: Electronic regulator Electric supply: Power consumption: Contact rating on switch-over: Protection class: Protection class: Selectable temperature range: Factory intervention hysteresys: Intervention hysteresis range: Outside probe Cable length: Temperature measurement range: Type of probe:

230 V (ac) 6 VA 6 (2) A (230 V) IP 65 50 s (90° rotation) 0,8 m 9 N·m

230 V (ac) 7 VA 2 A (230 V) IP 54 II -60–150°C 2K 0,1–20 K

1,5 m -20–45°C NTC

Ambient, transportation, storage conditions Operation: -10–55°C EN 60721-3-3 Cl. 3K3, max. humidity 85% Transportation: -30–70°C EN 60721-3-2 Cl. 2K3, max. humidity 95% Storage: -20–70°C EN 60721-3-1 Cl. 1K2, max. humidity 95%

50

7 VA IP 54

Serie 106 230 V(ac) ± 10%

7 VA Serie 106 IP V(ac) 54 ± 10% 230

52

52

130 50

7 VA IP 54

50

C

B

C

D

A

A

A

A

A B

D

D AA

D

F E

A A

A

A A

E

A

F

130 130

A

C

B

130

52

50

130 130

A

°C

SET

C

7 VA Serie 106 IP V(ac) 54 ± 10% 230

°C

SET

A

Serie 106 230 V(ac) ± 10%

SET

130

°C

SET

130

°C

52

Dimensions

A

H

G

H

G

Code CodeDN* DN* A** A** B BC CD DE EF FG G H Weight H Weight (kg) (kg) 106160 106160 25 25 1” 80 1” 211 80 211 60 60 80 148 80 148 42 42 93 93 4,5 4,5 * body * body valvevalve ** connections ** connections (mm (mm w.g.)w.g.)

Code Code DN* 2 106170 106170 32 106180 106180 50 106190 106190 50

4

A B

E

E

5

DN* A** A** B B C C D D E E Weight Weight (kg) (kg) 184 18454,5 54,5124 124 80 80 4,4 4,4 321 1/4” 1 1/4” 232 232 74 74 194 194105 105 5,3 5,3 501 1/2” 1 1/2” 50 2” 2” 240 240 74 74 194 194105 105 5,4 65,4

3

7

Kv=8,0 Kv=8,0Kv=13,0 Kv=13,0

Characteristic components

4

1 4

5 2

2

5 3

6

3 1 Electronic regulator 2 Outside probe 3 Diverter valve 4 Actuator 5 Anti-condensation extension 6 Insulation 1 7 Return connection kit

7

1 Electronic regulator 2 Outside probe 3 Diverter valve 4 Actuator 5 Anti-condensation extension 6 Insulation

4 Hydraulic characteristics

2

w.g. w.g.

1 1 3

1

2 2

5

w.g. w.g.

2

6

25 25

Connections Connections

1 18,0

8,0

Connections Connections

2 213,0 13,0

6

Construction details Diverter valve size 1”

Diverter valve sizes 1 1/4” - 1 1/2” - 2”

The diverter valve of the integration unit and of the diverter kit has a compact design that adapts easily to existing systems. More than one kit can be connected in series to meet the needs of more complex systems.

The valve has a union with a flat seat. Using the ball shut-off mechanism enables high differential operating pressures and, when fully open, low head losses. The low torque values when opening/closing, together with an adequate actuator dynamic torque, make for short operating times.

The ball inside the diverter valve has been designed to optimise and balance passages in the two configurations of use.

Thermal decoupler Between the valve body and the actuator there is a polymer thermal decoupler PIC, which contains two stainless steel stems and a central insulating ring. This prevents the transmission of heat from the electric actuator to the thermal medium. This prevents condensation build-up inside the actuator.

Return connection kit (only size 1”) The return connection kit, which allows direct coupling to the kit of the heat pump, boiler and system circuits, has been designed to facilitate the realisation of the system and to obtain compact and aesthetically valid solutions.

Directions of flow and position indicator

38429.02

Actuator Open/close The actuator is equipped with a control lever (2), for valve manual opening/closing, that can be operated by pressing the button (1). The lever also acts as a position indicator. The fixing of the actuator to the valve body, by means of a stainless steel clip, enables quick disassembly in order to check and operate the control stem of the ball with the aid of a screwdriver.

T max 100ϒC P max 10 bar

38429.02

T max 110ϒC Pmax 10 bar

T max 110ϒC Pmax 10 bar

Toutside < Tset

Toutside > Tset

size 1"

size 1"

HEAT PUMP

SYSTEM

HEAT PUMP

BOILER

BOILER

size 1 1/4” - 1 1/2” - 2”

HEAT PUMP

BOILER

SYSTEM

SYSTEM

size 1 1/4” - 1 1/2” - 2”

HEAT PUMP

BOILER

SYSTEM

CLOSING OPENING

Protection class The valve can be installed in a vertical, horizontal or upside-down position, as shown in the figure, as the actuator is certified with an IP 65 protection class.

Insulation The hot pre-formed shell insulation, supplied in the package, prevents condensation build-up on the valve body surface, so that the kit can also be used in cooling systems. This system, moreover, ensures not only perfect thermal insulation, but also the resistance to the diffusion of water vapour from the ambient toward inside.

T max 100ϒC P max 10 bar

INTEGRATION UNIT Operating principle The 106 series integration unit provides a simple means of connecting the hydraulic circuits of the heat pump and boiler to the heating system terminals, using the return connecting kit which allows the circuits to be joined together in a compact way. Function is controlled by the electronic regulator which automatically activates and manages the heat pump (A) or the boiler (B) depending on the temperature of the outside air measured by the probe. The regulator activates the heat pump (A) when requested by the room thermostat and the outside air temperature has risen above the switching temperature set on the regulator (setpoint temperature). It activates the boiler (B) when requested by the room thermostat and the outside air temperature is below the switching temperature. The switching over is made by means of a diverter switch that closes the contact of the thermostat towards the boiler (B) or the heat pump (A), through auxiliary relays if needed. Toutside > Tset

38429.02

38429.02

Toutside < Tset

T max 110ϒC Pmax 10 bar

T max 100ϒC P max 10 bar T max 110ϒC Pmax 10 bar

A

B

A

T max 100ϒC P max 10 bar

A

B

code 106160 - 1"

A

B

code 106160 - 1"

B

A

RISC.

PDC

RISC.

PDC

38429.02

38429.02

PDC

A

B

T max 110ϒC Pmax 10 bar

T max 100ϒC P max 10 bar T max 100ϒC P max 10 bar

38429.02

T max 110ϒC Pmax 10 bar

T max 100ϒC P max 10 bar

CALDAIA

TESTERNA

code 106170 - 1 1/4” code 106180 - 1 1/2” code 106190 - 2”

TSET

code 106170 - 1 1/4” CALDAIA code 106180 - 1 1/2” code 106190 - 2” TESTERNA T

CALDAIA

TESTERNA

TSET

Electronic regulator and electric connections The regulator manages the system operating controls. It has a terminal board with six connections for the electric supply, outside probe, diverter kit, heat pump, boiler and room thermostat. From the display, you can view and set the switching temperature and view the temperature read by the outside probe.

HEAT PUMP

R

Source A electronic control unit (Heat pump)

Electronic regulator 11

BOILER

°C

12

7HEAT 8

Serie 106 230 V(ac) ± 10%

7 VA IP 54

HEAT PUMP

3

BOILER

SYSTEM

Outside probe

Diverter kit

A 1B 1A

BOILER

2B 2A

3B 3A

4B 4A

5B 5A

6B 6A

7B 7A

B 8B 8A

9B 9A

10B 10A

10

System

Boiler

1

SYSTEM

NTC

SYSTEM

Heat pump Room thermostat

Term.

PUMP

SET

Source B electronic control unit (Boiler)

com.

Outside probe

Heat Pump

T max 110ϒC Pmax 10 bar

Electric supply

Boiler

RT

F N 230 V (ac) Diverter kit actuator

N.B. The contacts coming from the room thermostat and going to the generators are voltage-free. If the generators or the thermostat require live connections, a relay must be used.

Switching temperature This is the set-point temperature set on the regulator at which switching occurs between the two generators. • Outside temperature rising When the outside temperature rises and reaches the set-point value (switching temperature) the regulator (with the consent of the room thermostat) switches off the generator B (generally the boiler) and controls diversion of the diverter valve: when diversion reaches about 90% opening towards the source A, the auxiliary microswitch starts the generator A (generally the heat pump). • Outside temperature decreasing When the outside temperature decreases, the regulator switches off the source A (heat pump) below the set-point corrected with hysteresis and activates (with the consent of the room thermostat) the source B (boiler). Switching takes place with a delay (hysteresis) to avoid hunting in the operation of the two generators. Example: Temperature set-point = 6°C Source A switch-on temperature = T set-point = 6°C Source A switch-off temperature and source B switch-on temperature = T set-point - hysteresis = 6-2 = 4°C

After having calculated the coefficient R, the switching temperature is determined with the COP/temperature diagram supplied by the heat pump manufacturer (similar to the one shown below as an example): a minimum value of COP is assumed equal to the coefficient R obtained and, depending on the system operating temperature, the switching temperature is obtained.

COP 6,0 5,5

R=

4,5

35°

4,0

40°

3,5

45° 50° 55°

3,0 2,5

T system

2,0 1,5

Calculation of the switching temperature The switching temperature is the limit temperature below which it is not convenient to heat with a heat pump. Generally it is convenient to use a heat pump rather than a gas boiler only if the heat pump is able to work with an efficiency (COP) higher than the coefficient R (ratio between the cost of the electric kWh and the thermal kWh). COP > R Coefficient

30°

5,0

1,0 -10

-5

0

5

10

15

20

Outside temperature [ °C ] Outside temperature probe The probe must be located at a minimum height of 2,5 m on the coldest wall of the building, normally facing north. In any case it must never be exposed to the rays of the sun. In addition the probe must never be installed near doors, windows, air ejectors or other sources of heat, nor even under balconies. To avoid errors in measurement, the hole, through which the cable connecting to the control unit passes, must also be sealed. Lastly, the probe cannot be painted. The probe is supplied with a cable 1,5 m long which may be extended to a maximum length of 100 m.

C ( kWh.e) · PCI · h

Cgas C(kWh,e): cost of electric kWh Cgas: cost per Nm3 gas PCI: gas lower calorific value (kWh/Nm3) h: combustion efficiency Combustion efficiency generally varies within the range of the following values: h = 0,70–0,80 old boilers h = 0,90–0,95 new boilers without condensation h = 0,95–1,05 new boilers with condensation

11

12

2 7

3

4

8

5 1

6 3

B

7 Source 8 A 9

10

electronic control unit (heat pump)

Source B electronic control unit (boiler)

OPEN

1

CLOSE

A

Outside probe

com.

INTEGRATION UNIT AND DIVERTER KIT Operating principle The code 106060 diverter kit can be installed downstream of the integration unit in order to connect several circuits while maintaining a solution that is compact and easy to install. The actuator of the diverter kit cannot be managed by the electronic regulator of the integration unit but must be controlled by an external auxiliary contact. In this example the diverter kit is used to manage the priority ofSource domestic water Source B storage with respect to the heating A electronic control unit electronic control unit (boiler) (heat pump) 11 12 7 storage; 8 1 the 3 auxiliary system: the actuator is managed by the immersion thermostat located on the microcontact of the actuatorDiverter must be electrically kit actuator connected in parallel to the TA to control starting of the generator. When the storage temperature falls below the thermostat set-point the contact MICRO AUX M opens, causing the diverter kit to switch and activating one of the two generators. MC2 MC1 NTC

Diverter kit actuator

MICRO AUX

1

OUTSIDE PROBE

2

3

5

6

7

Integration unit actuator

°C

SET

Serie 106 230 V(ac)± 10%

4

8

9

10

TA

230 V (ac) N Max 6(2) A L

7 VA IP 54

RT OUTSIDE PROBE

BOILER

HEATING SYSTEM

°C

SET

Serie 106 230 V(ac)± 10%

SANITARY HOT WATER STORAGE

7 VA IP 54

RT HEATING SYSTEM

SANITARY HOT WATER STORAGE

HEAT PUMP

HEAT PUMP

Room thermostat

INTEGRATION UNIT

INTEGRATION UNIT

DIVERTER KIT

DIVERTER KIT

BOILER

M MC2

OPEN

230 V (ac) Outside N Max 6(2) A Lprobe

TA

B

com.

A

TS

Safety thermostat

MC1

CLOSE

Integration unit actuator

NTC

Room thermostat

TS

Safety thermostat

Application diagrams

RT

RT 1 2

1 2

3

CALEFFI

1 2

3

1 2

3

1 2

3

3

4

4

4

4

4

L/MIN

L/MIN

L/MIN

L/MIN

L/MIN

BAGNO

SOGGIORNO

HOBBY

CAMERA

CALEFF

CAMERA

HOBBY

BAGNO

WC

SOGGIORNO

CALEFFI

WC

CALEFFI

°C

SET

7 VA IP 54

DCW GAS DHW

Serie 106 230 V(ac)± 10%

T °C

SET

7 VA IP 54

38429.02

Serie 106 230 V(ac)± 10%

T max 110ϒC Pmax 10 bar

T max 100ϒC Pmax 10 bar

T

Product range

Code

Size

106160

1”

106

106

Heat pump-boiler integration unit, with connection kit

Heat pump-boiler integration unit

230 V

106

Code

Size

106170 106180 106190

1 1/4” 1 1/2” 2”

230 V 230 V 230 V

Diverter kit

Code

Size

106060

1”

230 V

SPECIFICATION SUMMARY 106 series Heat pump-boiler integration unit. Complete with: - Diverter valve. Brass body. Sizes from DN 20 to DN 50. Connections 1” (from 1” to 2”) M (ISO 228-1). Ball bore: full (size 1”), reduced (sizes from 1 1/4” to 2”). Brass body. Chrome plated brass ball. Control stem seal with double EPDM O-Ring. PTFE ball seal with EPDM O-Ring EPDM O-Ring union seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Maximum working pressure 10 bar (size 1”), 16 bar (sizes from 1 1/4” to 2”). Maximum differential pressure 10 bar. Actuator electric supply 230 V (ac); power consumption 6 VA; with auxiliary microswitch, auxiliary microswitch contact rating 6 (2) A (230 V); dynamic torque 9 N·m. Operating time 50 seconds (90° rotation) Protection class IP 65. Electric supply cable length 0,8 m. Ambient conditions for valve with actuator: medium working temperature range -10−110°C; ambient temperature: operation -10−55°C EN 60721-3-3 Cl. 3K3, maximum humidity 85%; transportation: -30–70°C EN 60721-3-2 Cl. 2K3, maximum humidity 95%; storage: -20–70°C EN 60721-3-1 Cl. 1K2, maximum humidity 95%. - Connection kit (only for code 106160). Copper pipe. Size 1” M (ISO 228-1). - Insulation in closed cell PE-X. - Electronic regulator. Selectable temperature range: -60–150°C. Intervention hysteresys: 2K. Intervention hysteresis range: 0,1–20 K. Electric supply 230 V (ac). Power consumption: 7 VA. Contact rating on switch-over 2A (230 V). Protection class: IP 54. Protection class: II. - Outside temperature probe. Measurable temperature range: -20–45°C. Cable length: 1,5 m.

Code 106060 Diverter kit for heat pump and boiler. Complete with: - Diverter valve. Brass body. Size DN 20. Connections 1” M (ISO 228-1). Ball bore: full. Brass body. Chrome plated brass ball. Control stem seal with double EPDM O-Ring. PTFE ball seal with EPDM O-Ring EPDM O-Ring union seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Maximum differential pressure 10 bar. Actuator electric supply 230 V (ac); power consumption 6 VA; with auxiliary microswitch, auxiliary microswitch contact rating 6 (2) A (230 V); dynamic torque 9 N·m. Operating time 50 seconds (90° rotation) Protection class IP 65. Electric supply cable length 0,8 m. Ambient conditions for valve with actuator: medium working temperature range -10−110°C; ambient temperature: operation -10−55°C EN 60721-3-3 Cl. 3K3, maximum humidity 85%; transportation: -30–70°C EN 60721-3-2 Cl. 2K3, maximum humidity 95%; storage: -20–70°C EN 60721-3-1 Cl. 1K2, maximum humidity 95%. - Connection kit. Copper pipe. Size 1” M (ISO 228-1). - Insulation in closed cell PE-X.

We reserve the right to make changes and improvements to the products and related data in this publication, at any time and without prior notice. Caleffi S.p.A. S.R. 229 n. 25 · 28010 Fontaneto d’Agogna (NO) · Italy Tel. +39 0322 8491 · Fax +39 0322 863723 [email protected] · www.caleffi.com © Copyright 2013 Caleffi