Bosch GREENSTAR PLUS Technical data

INSTALLATION AND MAINTENANCE INSTRUCTIONS
HYBRID SYSTEM WITH AIR TO WATER HEAT PUMP
GREENSTAR PLUS HYBRID
FOR COMBINATION WITH WORCESTER APPLIANCES THAT HAVE A CENTRAL HEATING OUTPUT UP TO 28kW
6720803687-00.1Wo
6 720 803 687 (2012/11)
UK/IE
TABLE OF CONTENTS
TABLE OF CONTENTS
1
Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 4
1.1
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2
About the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 5
2.3
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4
Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6
Tools, materials and miscellaneous parts . . . . . . . . . . . . 6
2.7
General information on energy use and heat production 6
2.8
Function description of the hybrid manager . . . . . . . . . . 7
2.9
Handling circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.10 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Combi boiler with serial buffer tank, bypass valve and
unmixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 System boiler with serial buffer tank, bypass valve and
unmixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.13 Combi boiler with serial buffer tank, bypass valve,
unmixed heating circuit and independently controlled
mixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.14 System boiler with serial buffer tank, bypass valve,
unmixed heating circuit and independently controlled
mixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.15 Overview of components . . . . . . . . . . . . . . . . . . . . . . . 13
2.15.1 Greenstar Plus hybrid manager (internal unit) . . . . . . 13
2.15.2 Greenstar Plus hybrid external unit . . . . . . . . . . . . . . . 14
2.16 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.16.1 hybrid manager (internal unit) . . . . . . . . . . . . . . . . . . . 16
2.16.2 external unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.17 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.1 Hybrid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.2 Hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.3 External unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1
Standards, regulations and guidelines . . . . . . . . . . . . . 19
3.1.1 General regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Lifting and carrying the external unit . . . . . . . . . . . . . .
4.2
Unpacking the external unit . . . . . . . . . . . . . . . . . . . . .
4.3
Unpacking the hybrid manager . . . . . . . . . . . . . . . . . .
4.4
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
19
20
20
5
Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . .
5.2
System component configuration . . . . . . . . . . . . . . . .
5.2.1 General requirements . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Buffer tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Thermostatic radiator valves . . . . . . . . . . . . . . . . . . . .
20
20
20
21
21
21
21
21
21
2
5.2.6
5.2.7
5.3
5.3.1
5.3.2
5.3.3
5.4
5.5
5.5.1
5.5.2
5.5.3
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
5.7
5.7.1
5.7.2
5.7.3
5.8
5.8.1
5.8.2
5.9
6
Hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
External unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pre-installing pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Preparing the hybrid manager connection . . . . . . . . . . 24
Fitting the bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting the FW200 programming unit . . . . . . . . . . . . 24
Mounting the hybrid manager . . . . . . . . . . . . . . . . . . . . 24
Installing the external unit . . . . . . . . . . . . . . . . . . . . . . . 25
Preparing the condensate drain for the external unit . . 26
Mounting on foundations . . . . . . . . . . . . . . . . . . . . . . . . 26
Making a condensate drain for the external unit . . . . . . 26
Installing the refrigerant circuit . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . 27
Routing refrigerant lines . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting the hybrid manager . . . . . . . . . . . . . . . . . . . 27
Connecting the external unit . . . . . . . . . . . . . . . . . . . . . 28
Checking the refrigerant circuit for tightness . . . . . . . . 28
Insulating the refrigerant shut-off valve . . . . . . . . . . . . . 29
Evacuating and drying the refrigerant circuit . . . . . . . . 29
Making the electrical connection . . . . . . . . . . . . . . . . . . 30
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connecting the external unit . . . . . . . . . . . . . . . . . . . . . 30
Installing the outside temperature sensor . . . . . . . . . . . 31
Select the installation location . . . . . . . . . . . . . . . . . . . . 31
Connecting the outside temperature sensor . . . . . . . . . 32
Setting the DIP switches of the external unit . . . . . . . . . 32
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1
Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.2 Commissioning requirements . . . . . . . . . . . . . . . . . . . . 32
6.2
Commissioning the system for the first time . . . . . . . . . 33
6.2.1 Providing the external unit with a power supply ahead of
commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.2 providing the external unit with a power supply during
commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.3 Connecting the CANBUS cable to the hybrid manager unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.4 Making the power supply connection . . . . . . . . . . . . . . 33
6.2.5 Switching on the hybrid system . . . . . . . . . . . . . . . . . . . 33
6.2.6 Connecting the programming unit to the hybrid control
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2.7 Connecting the heat source to the hybrid manager . . . 34
6.2.8 Communication error from External unit on initial power
ON of External Unit and Hybrid Manager . . . . . . . . . . . 34
6.2.9 Adjusting the Hybrid manager circulating pump in the
hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.10 System with series buffer tank . . . . . . . . . . . . . . . . . . . . 35
6.2.11 Venting the hybrid manager . . . . . . . . . . . . . . . . . . . . . . 38
6.2.12 Setting the bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.13 Setting parameters for optimising energy use and costs of
the hybrid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.14 Explanation of the parameters for energy and cost
optimization of the hybrid system (control strategy) . 39
6.2.15 Control Strategy: Option CO2 Optimised and
co2 :cost mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6 720 803 687 (2012/11)
TABLE OF CONTENTS
6.2.16 Control Strategy: Co2 optimised (environmental factors)
41
6.2.17 Control Strategy: CO2: Cost mix . . . . . . . . . . . . . . . . . 42
6.2.18 Control Strategy: Option changeover temperature . . . 42
6.2.19 Control Strategy: Cost optimised . . . . . . . . . . . . . . . . . 42
6.2.20 Control strategy: hydraulic connection . . . . . . . . . . . . 42
6.2.21 Control strategy: Delay time for boiler heating . . . . . . 43
6.2.22 Control strategy: Temperature diff for boiler switch ON . .
43
6.2.23 Setting parameters at the hybrid control module . . . . 44
6.2.24 Commissioning of the air to water heat pump at outside
temperatures outside the standard operating range . .46
6.2.25 Informing the customer and handing over the technical
documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
7
8
9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.1
Automatic defrost function . . . . . . . . . . . . . . . . . . . . . . 46
7.2
System shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.1 Regular system shutdown . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.2 System emergency shutdown . . . . . . . . . . . . . . . . . . . . 46
7.3
Restarting the hybrid system after an interruption in
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Environmental protection/disposal . . . . . . . . . . . . . . . . . . . . 47
8.1
Disposing of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2
Appliance disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
Preparing for inspection and maintenance . . . . . . . . .
9.2
Enter into an inspection and maintenance contract . .
9.3
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4
Maintaining the hybrid manager . . . . . . . . . . . . . . . . . .
9.4.1 Visual inspection of the hybrid manager . . . . . . . . . . .
9.4.2 Draining the heating water from the hybrid manager .
9.4.3 Cleaning the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.4 Checking the temperature sensor . . . . . . . . . . . . . . . .
9.4.5 Completing inspection and maintenance . . . . . . . . . . .
9.5
Servicing the external unit . . . . . . . . . . . . . . . . . . . . . .
9.5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Visual inspection of external unit . . . . . . . . . . . . . . . . .
9.5.3 Cleaning the external unit air intake . . . . . . . . . . . . . . .
9.5.4 Completing inspection and maintenance . . . . . . . . . . .
9.5.5 Overview of DIP switches in the external unit . . . . . . .
9.6
Inspection and maintenance reports . . . . . . . . . . . . . .
47
47
48
48
49
49
49
49
50
50
51
51
51
51
51
52
53
10.2.8 DC fan motors/check PCB . . . . . . . . . . . . . . . . . . . . . . 71
10.2.9 Check external unit temperature sensor . . . . . . . . . . . 72
10.2.10Check linear expansion valves (LEV) . . . . . . . . . . . . . . 74
11 Replace components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.1 Pumping refrigerant back into the external unit . . . . . 76
11.2 Removing the casing from the external unit . . . . . . . . 77
11.3 Replacing the fan motor . . . . . . . . . . . . . . . . . . . . . . . . 78
11.4 Replacing the PCB housing . . . . . . . . . . . . . . . . . . . . . . 79
11.5 Replacing PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.5.1 Noise circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.5.2 Power circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.5.3 Controller circuit board . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.6 Replacing faulty temperature sensors TH3, TH6 or TH33
79
11.7 Replacing outside temperature sensor TH7 . . . . . . . . 79
11.8 Replacing temperature sensors TH4 and TH32 . . . . . 79
11.9 Fitting and removing the linear expansion valve . . . . . 80
11.10 Removing the transformer (ACL) . . . . . . . . . . . . . . . . . 80
12 Filling the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 Evacuating and drying the refrigerant circuit . . . . . . .
12.2 Vacuum drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Opening the shut-off valves of the external unit . . . . .
80
81
81
81
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
13.1 Cost weighting electricity price — gas price . . . . . . . . . 82
13.2 System wiring (heatronic III boiler connections) with a
bypass valve and one unmixed heating circuit . . . . . . . 83
13.3 System wiring (CUS boiler connections) with a bypass
valve and one unmixed heating circuit . . . . . . . . . . . . . 84
13.4 Wiring to PCB in the external unit (heat pump) . . . . . . 85
13.5 Controller circuit board in external unit . . . . . . . . . . . . 87
13.6 Alternative pipe work lengths and DT . . . . . . . . . . . . . 89
14 General details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
15 Assembly and installation report for the installer . . . . . . . . 92
16 Commissioning report for the commissioning engineer . . . 94
10 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.1 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . . 54
10.1.1 General faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.1.2 External unit faults — frequently asked questions . . . . 54
10.2 Displayed faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.2.1 Fault displays on the hybrid control module . . . . . . . . 55
10.2.2 Check temperature sensor of hybrid manager . . . . . . 56
10.2.3 Faults of the FW200 programming unit . . . . . . . . . . . . 57
10.2.4 Fault display on the FW 200 weather-compensated
controller at user level . . . . . . . . . . . . . . . . . . . . . . . . . .57
10.2.5 Fault display on the rear of the hybrid manager . . . . . 59
10.2.6 External unit faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.2.7 Check components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 720 803 687 (2012/11)
3
KEY TO SYMBOLS AND SAFETY INSTRUCTIONS
1
KEY TO SYMBOLS AND SAFETY
INSTRUCTIONS
1.1
EXPLANATION OF SYMBOLS
WARNING SYMBOLS
Safety instructions in this document are framed and
identified by a warning triangle which is printed on a
grey background.
DANGER POSED BY EXPLOSIVE AND EASILY FLAMMABLE
MATERIALS
▶ Never use, store or place highly flammable materials (paper, clothing,
thinners, paints etc.) near the external unit.
SITING AND INSTALLATION
Correct siting, assembly and installation of the individual components
are the fundamental requirements for safe and economical operation of
the hybrid system.
▶ Installation of this heat pump should be done in accordance with
MCS/MIS 3005.
COMMISSIONING
Electrical hazards are identified by a lightning symbol
surrounded by a warning triangle.
▶ The hybrid system and the components may only be commissioned by
a competent person.
INSTRUCTING THE CUSTOMER
Signal words indicate the seriousness of the hazard in terms of the
consequences of not following the safety instructions.
• NOTICE indicates possible damage to property or equipment, but
where there is no risk of injury.
• CAUTION indicates possible injury.
• WARNING indicates possible severe injury.
• DANGER indicates possible risk to life.
▶ Explain to customers how the hybrid system and its individual
components work, and instruct them how to operate them.
▶ Inform customers that they must not carry out any modifications or
repairs.
▶ Hand customers the installation and operating instructions for
safekeeping.
IMPORTANT INFORMATION
Operator errors can result in injury and damage to property.
Notes contain important information in cases where
there is no risk of personal injury or material losses and
are identified by the symbol shown on the left. They are
bordered by horizontal lines above and below the text.
ADDITIONAL SYMBOLS
Symbol
▶

•
–
Meaning
a step in an action sequence
a reference to a related part in the document or to other
related documents
a list entry
a list entry (second level)
▶ Ensure that children never operate this appliance unsupervised or
play with it.
▶ Ensure that only personnel who can operate this appliance correctly
have access to it.
INSPECTION, MAINTENANCE AND REPAIRS
▶ Inspection, maintenance and repairs must only be carried out by
competent persons.
▶ Use only original Worcester spare parts. Losses caused by the use of
parts not supplied by Worcester are excluded from the Worcester
warranty.
▶ Only use accessories intended for this application.
▶ Customer recommendation: Arrange an annual service with a
competent person.
ENVIRONMENTAL PROTECTION
Table 1
1.2
RISK OF DAMAGE DUE TO OPERATOR ERROR
SAFETY INSTRUCTIONS
HANDLING REFRIGERANT
The air to water heat pump is filled with R410A refrigerant.
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant circuit.
▶ For all work with refrigerant, wear suitable safety gloves and goggles.
WHAT TO DO IF REFRIGERANT LEAKS
If refrigerant leaks and touches the skin, it can cause frostbite.
▶ In case of a refrigerant leak, never touch any part of the air to water
heat pump.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your skin or in your
eyes.
▶ At the end of the appliances life time span please ensure that the
effected appliance is disposed of according to the current
regulations.
▶ Dispose of the packaging materials in an environmentally responsible
manner.
HEAT EMITTERS
▶ It is important a hybrid system is installed on a system with the
appropriate heat emitters for the combination of a heat pump and
boiler.
▶ It is recommended a pre-design assessment is carried out to
determine the suitability of the system and heat loss calculations for
the property are carried out to determine the system design
requirements.
▶ If under floor heating is installed the system should be correctly sized
to work at lower temperatures.
DANGER THROUGH ELECTRICAL CURRENTS
▶ Electrical work must only be carried out by competent person. Work
on the electrical system that has not been carried out properly can
result in short circuit, overheating or fire.
4
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.1
ABOUT THE APPLIANCE
A
DESIGNATED USE
The appliance may only be installed in sealed unvented hot water central
heating systems to EN 12828. Any other use is considered improper.
Any damage that may result is excluded from liability. The commercial
and industrial use of the appliance for generating process heat is not
permitted.
• Use the appliance exclusively for the stated purpose whilst adhering
to the specification and environmental conditions ( chapter 2.17).
• The following gas condensing boilers can be used in the hybrid
system:
– Greenstar 29, 34, 38 & 42 CDi Classic Combi
– Greenstar 25 & 30Si
– Greenstar Highflow 440CDi & 550CDi
– Greenstar 28, 32 & 36CDi Compact
– Greenstar 30CDi System Classic
– Greenstar 12, 15, 18 &24i System
• Operate the appliance exclusively with R410A refrigerant.
• Take into account the data on the system component data plates.
• Maximum output of the system is 25kW at delta T of 20K. For higher
out put appliances see table 51 page 89.
Correct use includes adherence to maintenance and inspection
intervals.
B
0.43 A
50W
R410A 2.50 kg (30m)
4.15 MPa
2.30 MPa
IPX4D
230V 50Hz
3A
(A2W35) = 3.852kW
(A7W35) = 4.704kW
(A2W35) = 3.14
(A7W35) = 4.42
2
Serial No: 5570 - XXX - XXXXX - 7716160030
0.43 A
2.5 bar
R410A 2.50 kg (30m)
1
4.15 MPa
2.30 MPa
(A2W35) = 3.852kW
(A7W35) = 4.704kW
(A2W35) = 3.14
(A7W35) = 4.42
220 V - 240 V 50 Hz / 50 W IPX4D
5570 - XXX - XXXXX - 7716160030
2
1
6720803687-25.1Wo
2
Fig. 1
[A]
[B]
[1]
[2]
Data plates on the hybrid manager (internal unit)
Cover data plate
Superstructure data plate
Unit data
Serial number
C
The hybrid system must not be used for purposes other than those
specified. The manufacturer accepts no liability for losses arising from
improper, incorrect or unreasonable use.
HYBRID ODU
D
<G>
7716160021
2.5kg
R410A
~ /N
Observe requirements when using the air to water heat
pump (external unit) near buildings with sensitive or
interference-prone electronics.
2.2
LP Ps
IP24
4.15 MPa
2.30 MPa
COP
(A2W35) : 3.14,
(A7W35) : 4.42
(A2W35) : 3.852kW, (A7W35) : 4.704kW
1
EU DECLARATION OF CONFORMITY
The design and operation of this product conforms to the European
Directives and the supplementary national requirements. Its conformity
is demonstrated by the CE designation.
2.3
(30m)
Max. 13A
230V 50Hz
42kg
HP Ps
MADE IN JAPAN
Bosch Thermotechnik GmbH
D - 35576 Wetzlar/Germany
BH**A***H01
DATA PLATE
6720803687-26.1Wo
The data plate includes details of the serial number, appliance
performance and approval data.
The hybrid manager Fig. 1 has two data plates, one on the lower right
hand side panel of the outer casing [A], and one permanently affixed to
the main body of the appliance, on the arms of the control module
retainer [B].
Fig. 2
[C]
[D]
[1]
Data plate on the external unit
EPHA conformity label (European heat pump association)
External unit data plate
Unit data
The external unit Fig. 2 includes a data plate [D] and an EPHA conformity
label [C], these are located, on the lower right front of the external unit.
6 720 803 687 (2012/11)
5
ABOUT THE APPLIANCE
2.4
STANDARD DELIVERY
•
•
•
•
System components are supplied ready assembled.
Drain plug kit (including pre cut insulation for service connections)
Condensation catch pan
Trace heating element to prevent freezing of water in the catch pan
Refrigerant pipe ¼ " and ½ " OD
2.6
TOOLS, MATERIALS AND MISCELLANEOUS PARTS
Servicing the Hybrid Manager module requires standard tools as used by
heating system installers and those for gas and water installations.
2.7
1
GENERAL INFORMATION ON ENERGY USE AND HEAT
PRODUCTION
Buildings can be heated efficiently with condensing boilers and air to
water heat pumps. However, these two technologies have different
performance characteristics.
Condensing boilers as well as air to water heat pumps use energy gained
from fossil fuels. In condensing boilers, gas is burnt directly inside the
appliance.
2
Air to water heat pumps use electrical energy which has been obtained
from a number of different sources. This includes fossil fuel burning
power stations. These are typically around 40 % efficient in converting
fuel to useful electricity. Although an air to water heat pump is far more
efficient than a condensing boiler at converting its input energy
(electricity) into heat, the electricity used has a larger amount of fossil
fuel consumption attached. This consumption of fossil fuels is referred
to as the primary energy factor (PEF).
The PEF of electricity is generally 2.3, the PEF of oil and gas is 1.1, the
PEF of mixed electric power 2.6. The coefficient of performance (COP)
of an air to water heat pump is, subject to outside air temperature and
water flow temperature, between 2 and 5.5.
3
Depending on the current situation and heat demand, either the
condensing boiler or the air to water heat pump may offer a more
favourable energy-to-cost ratio.
The hybrid package integrates both technologies in one system and
thereby offers the opportunity to use either heat source optimally at any
time. Users can decide for themselves whether the emphasis should be
on primary energy consumption and/or whether costs take priority,
alternatively, a combination of primary energy and costs can be used.
4
6720803687-05.1Wo
Fig. 3
[1]
[2]
[3]
[4]
2.5
Standard delivery Greenstar Plus Hybrid
Hybrid manager (internal unit)
Mounting plate
Greenstar Plus external unit
Bag containing the manuals, drawings and small parts
ACCESSORIES
Here you will find a list of typical accessories. Our
general catalogue provides a comprehensive overview of
all available accessories.
REQUIRED ACCESSORIES
The system operation requires the following accessories:
• FW200 programming unit with outdoor sensor unit.
• Buffer tank
• Bypass valve.
OPTIONAL ACCESSORIES
• Wall mounting bracket for wall mounting the external unit including
anti-vibration mounts
• Floor bracket with anti-vibration mounts for raised siting of the
external unit
6
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.8
FUNCTION DESCRIPTION OF THE HYBRID MANAGER
The hybrid control module monitors the external unit, the condensing
boiler and the FW200 programming unit. Subject to outside
temperature, heating water flow and return temperature and the
primary flow temperature, the hybrid control module determines what
proportion of the total energy to be expended should be covered by the
condensing boiler and the external unit respectively. This process
optimises the efficiency of the heating system.
The hybrid control module delivers the control signal at the interface to
the air to water heat pump. This modulates the output of the external unit
subject to the current heat demand.
A hydraulic separator is integrated into the hybrid manager and
separates the condensing boiler and heating circuits. Thus, the heating
water, after flowing through the hybrid manager, can be either routed
through the condensing boiler or returned into the heating system.
A high efficiency (HE) pump integrated in the hybrid manager provides
the heating water circulation through the hybrid manager. The hydraulic
separator integrated into the hybrid manager also enables the HE pump
operation in the hybrid manager when the pump inside the condensing
boiler is not running.
6 720 614 366-24.1I
Fig. 4
Earthed wristband
Damage is usually undetected, and a circuit board can operate normally
during commissioning but may show signs of problems later.
A wristband connected to earth offers good ESD protection when
working with electronics. Wear this wristband before opening any
screened metallic packaging or exposing any fitted PCB's. Wear the
wristband until the PCB has been placed inside its screened packaging
or has been connected inside the closed external unit. Replaced PCBs
that must be returned must also be treated this way.
The pump inside the condensing boiler and the HE pump in the hybrid
manager run simultaneously if the condensing boiler operates on its own
or at the same time as the air to water heat pump.
If only the air to water heat pump is in operation, then only the HE pump
in the hybrid manager runs.
The filter protects the plate heat exchanger (condenser) inside the
hybrid manager and the heating system from contamination through
small particles with a diameter larger than 1 mm.
A flow switch with magnetic reed switch ensures that the external unit
operates only if the water flow rate is adequate for the plate heat
exchanger (condenser).
The heat exchange between the refrigerant (R410A) and the heating
water takes place inside the copper-brazed stainless steel plate heat
exchanger (condenser).
One temperature sensor each is located at the plate heat exchanger inlet
and outlet to protect the heating water from excessively high
temperatures during heating operation by the external unit and against
freezing when the external unit is being defrosted. The heat transfer
between the refrigerant(R410A) and the outside air takes place inside
the heat exchanger of the external unit (evaporator).
6 720 614 366-25.1I
Fig. 5
Handling electronic components
The buffer tank provides two functions: Firstly, the buffer tank ensures
that there is always sufficient heat energy within the heating system in
order to support the Heat Pump Defrost operation. Secondly, the buffer
volume prevents excessive heat pump cycling during low heat load
conditions. This optimises system efficiency and reduces excessive
wear on heat pump components.
BYPASS VALVE (OVERFLOW VALVE)
This function is particularly important during automatic defrosting.
The bypass valve begins to open when the heat demand has been
reached and the thermostatic valves reach their closed position. The
heating water flows through the bypass valve and so safeguards the
required minimum heating water flow rate through the hybrid manager.
2.9
HANDLING CIRCUIT BOARDS
Circuit boards with control electronics are sensitive to discharges of
static electricity (ESD – ElectroStatic Discharge) when handled. To
prevent damaging the components, special care is therefore required
when handled.
CAUTION: Equipment damage through electrostatic
discharge!
▶ Never touch a PCB without an earthed wristband.
6 720 803 687 (2012/11)
7
ABOUT THE APPLIANCE
2.10 REFRIGERANT CIRCUIT
14
7
15
1
16
2
3
13
4
5
17
18
A
B
18
19
6
20
21
12
11
7
10
9
8
7
6 720 646 970-04.3ITL
Fig. 6
[A]
[B]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
8
Refrigerant circuit
Refrigerant flow during defrosting
Refrigerant flow during heating
Heat exchanger / evaporator
Temperature sensor TH6 on the pipe to the evaporator
TH7 outside temperature sensor
Temperature sensor TH3 on pipe work for liquid refrigerant
Distributor
Temperature sensor TH33 on pipe work for liquid refrigerant
Dirt trap
Linear expansion valve LEV-A
Liquid receiver
Linear expansion valve LEV-B
Shut-off valve
Connection for liquid refrigerant
Connection for gaseous refrigerant
Shut-off valve with Schraeder valve
4-way valve
Charging connection
High pressure switch 63H
Silencer
Temperature sensor TH4 for hot gas
Temperature sensor TH32 on compressor casing
Compressor
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.11 COMBI BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE AND UNMIXED HEATING CIRCUIT
1
2
3
5
4
5
F
R
6
F
9
7
6720803687-01.1Wo
10
8
Fig. 7
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
System scheme with serial buffer tank, bypass valve and one unmixed heating circuit
Outside temperature sensor
Condensing boiler
Double pole fuse spur
FW200 programming unit
Radiator
Bypass valve for heating system with indicated flow direction
Expansion vessel
Serial buffer tank
Hybrid manager (internal unit) with hybrid control module
External unit
6 720 803 687 (2012/11)
9
ABOUT THE APPLIANCE
2.12 SYSTEM BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE AND UNMIXED HEATING CIRCUIT
1
12
2
4
5
3
5
F
R
6
F
9
7
6720803687-02.1Wo
10
8
Fig. 8
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[12]
10
System scheme with serial buffer tank, bypass valve and one unmixed heating circuit
Outside temperature sensor
Condensing boiler
Double pole fuse spur
FW200 programming unit
Radiator
Bypass valve for heating system with indicated flow direction
Serial buffer tank
Expansion vessel
Hybrid manager (internal unit) with hybrid control module
External unit
DHW cylinder
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.13 COMBI BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE, UNMIXED HEATING CIRCUIT AND INDEPENDENTLY
CONTROLLED MIXED HEATING CIRCUIT
1
2
3
5
4
11
F
R
A
A
A
A
№4
10
20
15
25
10
30
№4
20
15
25
10
30
№1
№3
№3
6
F
20
15
25
10
30
№2
№2
20
15
25
10
30
№1
9
7
6720803687-03.1Wo
8
Fig. 9
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
System scheme with serial buffer tank, bypass valve, one unmixed heating circuit and one mixed heating circuit
Outside temperature sensor
Condensing boiler
Double pole fuse spur
FW200 programming unit
Radiator
Bypass valve for heating system with indicated flow direction
Serial buffer tank
Expansion vessel
Hybrid manager (internal unit) with hybrid control module
External unit
Underfloor heating (independently controlled)
6 720 803 687 (2012/11)
11
ABOUT THE APPLIANCE
2.14 SYSTEM BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE, UNMIXED HEATING CIRCUIT AND INDEPENDENTLY
CONTROLLED MIXED HEATING CIRCUIT
1
12
2
5
4
3
11
F
R
A
A
A
A
№4
10
20
15
25
10
30
№4
20
15
25
10
30
№1
№3
№3
6
F
20
15
25
10
30
№2
№2
20
15
25
10
30
№1
9
7
6720803687-04.1Wo
8
Fig. 10 System scheme with serial buffer tank and one unmixed heating circuit
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
12
Outside temperature sensor
Condensing boiler
Double pole fuse spur
FW200 programming unit
Radiator
Bypass valve for heating system with indicated flow direction
Serial buffer tank
Expansion vessel
Hybrid manager (internal unit) with control module
External unit
Underfloor heating (independently controlled)
DHW cylinder
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.15 OVERVIEW OF COMPONENTS
2.15.1 GREENSTAR PLUS HYBRID MANAGER (INTERNAL UNIT)
18
17
16
15
14
13
1
2
3
4
5
6
12
7
10
8
9
6720646970-05.4Wo
11
Fig. 11 Main components of the hybrid manager
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
Connection, heating system return
(22 mm compression fitting)
Connection, pipe to the heat source
(22 mm compression fitting)
Isolation valves (water)
Hydraulic separator
Grundfos Alpha 2L HE pump, category A
Filter
Drain valve
Interface to the external unit
Hybrid control module
Heating water temperature sensor (at the condenser inlet)
Refrigerant temperature sensor (for liquid refrigerant)
Flow switch
Condenser
(copper-brazed stainless steel plate heat exchanger)
Heating water temperature sensor (at the condenser outlet)
Pipework for gaseous refrigerant, Ø ½ "
Pipework for liquid refrigerant, Ø ¼ "
Connection, heating system flow
(22 mm compression fitting)
Connection, pipe from the heat source
(22 mm compression fitting)
6 720 803 687 (2012/11)
13
ABOUT THE APPLIANCE
2.15.2 GREENSTAR PLUS HYBRID EXTERNAL UNIT
1
2
3
4
6
7
5
10
9
8
6 720 646 970-49.3ITL
Fig. 12 Main components and casing of external unit
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
14
Air grille
Top casing panel
Front casing panel
Evaporator
Fan
4-way valve
Cover for fill connection
Service cover
Connection for gaseous refrigerant with service connection
Connection for liquid refrigerant
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
1
2
3
4
5
6
7
8
9
11
10
12
13
14
15
16
17
18
29
19
20
21
22
28
27
26
25 24
23
6 720 646 970-58.6ITL
Fig. 13 Main components of the external unit
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
[23]
[24]
[25]
[26]
[27]
[28]
[29]
Fan motor
Evaporator
Enclosure for electric components
Temperature sensor TH8
Power circuit board
Controller circuit board
Noise circuit board
Terminal strip
Temperature sensor TH7
Transformer
Temperature sensor TH6
Temperature sensor TH4
Temperature sensor TH32
Linear expansion valve LEV-B
High pressure switch
4-way valve
Linear expansion valve LEV-A
Solenoid coil
Temperature sensor TH33
Temperature sensor TH3
Shut-off valve (pipe for liquid refrigerant)
Shut-off valve (pipe for gaseous refrigerant)
Service connection
Dirt trap
Refrigerant collector
Compressor
Silencer
Nut
Impeller
6 720 803 687 (2012/11)
15
ABOUT THE APPLIANCE
2.16 DIMENSIONS
2.16.1 HYBRID MANAGER (INTERNAL UNIT)
360
32
95
30
500
448
85
53
22
363
390
6720803687-23.1Wo
Fig. 14 Hybrid manager dimensions
16
6 720 803 687 (2012/11)
ABOUT THE APPLIANCE
2.16.2 EXTERNAL UNIT
365
300
330
152
155
43.6
400
347.5
40
23
10
155
90
300
600
18
32.5
45.4
150
69
183
287.5
500
800
6720803687-29.1Wo
Fig. 15 Dimensions of external unit
6 720 803 687 (2012/11)
17
ABOUT THE APPLIANCE
2.17 TECHNICAL DATA
2.17.1 HYBRID SYSTEM
Description
Max. heating output 1)
Power supply
Refrigerant R410A
Pipe for liquid refrigerant, external diameter
Pipe for gaseous refrigerant, external diameter
Minimum water flow rate in the air to water heat pump circuit
Unit
kW
V/Hz/PH
kg
inch
inch
l/min
Value
25.14
230/50/1~
2.5
¼
½
6.0
Table 2 Specification for hybrid system
1) At 20 K (T) between the heating system flow and return relative to a pressure drop of 200 mbar. For further information in the case of alternative pipe lengths and T see
appendix in chapter 13.6, page 89.
2.17.2 HYBRID MANAGER
Description
Max power consumption
Power supply, current rating
IP rating
Water content
Water flowrate range
Dimensions, internal unit (height x width x depth)
Weight
Unit
W
A
l
l / min
mm
kg
Value
50
3
IPX4D
1.4
6 to 20
500 x 390 x 360
21
Table 3 Specification for hybrid manager
2.17.3 EXTERNAL UNIT
Description
Power supply
Rated heating output (A2W35) 1)
Max. heating output (A2W35)1)
Rated heating output (A7W35)1)
Max. heating output (A7W35)1)
Rated heating output (A-7W35) 1)
Max. current
Recommended MCB/fuse rating
IP rating
Refrigerant – filling
Air flow rate
Sound level to EN 12102 2)
Dimensions (W x D x H)
Control outside air temperature operating range
Storage temperature
Water flow temperature operating range
Weight
Max. line length/height difference
Pipe work for liquid refrigerant external diameter
Pipe work for gaseous refrigerant external diameter
Unit
V / Hz / ph
kW / COP
kW / COP
kW / COP
kW / COP
kW / COP
A
A
kg
m3/min
dB(A)
mm
°C
°C
°C
kg
m
inch
inch
Value
230 / 50 / 1~
3.852 kW / 3.14
4.613 kW / 2.78
4.704 kW / 4.42
6.084 kW / 4.11
2.985 kW / 2.31
13
16 MCB type D
IP24
2.5
35
46
800 x 300 x 600
-9 to +21
-25 to +60
+20 to +50
42
30/30
¼
½
Table 4 Specification for external unit
1) Reference conditions: to EN 14511-2:2007
2) Measured at a horizontal distance of 1 m and a height of 1.5 m taken from the appliance bottom
18
6 720 803 687 (2012/11)
REGULATIONS
– The Building Regulations (Northern Ireland) 2000.
3
REGULATIONS
3.1
STANDARDS, REGULATIONS AND GUIDELINES
The product is in compliance with the following EC directives:
• Low Voltage Directive 2006/95/ EC
• Electromagnetic Compatibility Directive 2004/108/EC.
3.1.1 GENERAL REGULATIONS
Concerning the installation and operation of the hybrid
system, observe the country-specific standards and
directives.
Observe the details on the data plate of the components
of the hybrid system.
Observe the following guidelines and regulations:
• Local regulations and requirements by the relevant power supply
utility and the associated special connection requirements
• BS EN 378 Safety and environmental requirements for heat pumps
• BS EN 14511 Requirements heat pumps for space heating and
cooling
• BS EN 14276-2:2007 Pressure equipment for refrigerating systems
and heat pumps. Piping. General requirements
• BS EN 14324:2004 Brazing. Guidance on the application of brazed
joints
• BS EN 12735-1:2010 Copper and copper alloys. Seamless, round
copper tubes for air conditioning and refrigeration. Tubes for piping
system
• European Parliament Regulation (EC) 842/2006 on Certain
Fluorinated Greenhouse Gases
• Gas Safety Regulations 1998 (Installation and use)
• Building Regulations
• Building Regulations Northern Ireland)
• Building Regulations (Scotland) (Consolidation)
• IGE Gas Installation in Timber Frame Buildings
• Law no. 46 of 5/3/1990 - Regulations for the safety of installation
• Standard UNI-CIG 7129 - gas installations for domestic use supplied
from the mains network
• Standard UNI 11071 - Gas installation for domestic use controlled be
condensing and similar appliances
• Any other local requirement
– The Health and Safety at Work Act 1974
– The Management of Health and Safety at Work Regulations 1999
– The Construction (Health, Safety and Welfare) Regulations 1996
– The Construction (Design and Management) Regulations 1994
– The Lifting Operations and Lifting Equipment Regulations 1998
Where no specific instruction is given, reference should be made to the
relevant codes of Practice.
Potable water: All seals, joints, compounds (including flux and solder)
and components used as part of the secondary domestic water system
must be approved for use with potable water supplies.
This is to certify that the above ranges of products manufactured by
Bosch Thermotechnology have been tested and found to comply with:
• The requirements of the (Water Fittings) Regulations 1999 for
England and Wales, the Water Byelaws 2000, Scotland and the Water
Regulations Northern Ireland.
• The requirements of the UK Building Regulations:
– The Building Regulations 1991 (England & Wales) Requirements
G3, L1 and Regulation 7.
– The Building Standards (Scotland) Regulations 1990. Regulation
10 (B2), 22 (J3.3a and J3.4), 27 and 28 (P2.6 and P3).
6 720 803 687 (2012/11)
The relevant Standards to be followed include:
• BS 1306 Specification for copper and copper alloy pressure piping
systems
• BS 5440:1 Flues and ventilation for gas appliances of rated heating
not exceeding 70kW (net): Flues
• BS 5440:2 Flues and ventilation for gas appliances of rated heating
not exceeding 70kW (net): Air Supply
• BS 6798 Installation of gas fired boilers of rated input up to 70kW
(net)
• BS 7074:1 Code of practice for domestic and hot water supply
• BS 6891 Installation of low pressure gas pipe work up to 28 mm (R1)
• BS 5546 Installation of gas hot water supplies for domestic purposes
• EN:12828 Central heating for domestic premises 3 Product
Description
• BS 7593 Treatment of water in domestic hot water central heating
system
4
TRANSPORT
WARNING: Risk of injury through improper handling.
▶ Use a means of transport suitable for handling
appliances (e.g. sack truck with strap, stair climbing
or step trolley).
▶ When handling appliances, secure them against a fall.
▶ Let only trained personnel undertake the handling.
During handling, also observe the following:
▶ Never lift packages by the shipping straps.
▶ Wear safety gloves as sharp edges can result in cuts.
4.1
LIFTING AND CARRYING THE EXTERNAL UNIT
WARNING: Risk of injury through incorrect lifting and
carrying!
The external unit weighs in excess of 20 kg.
▶ Never lift or carry the external unit on your own.
Handling by trained personnel:
▶ Only remove packaging at the time of the final installation.
▶ At least two people should lift and carry the external unit.
▶ Only move the external unit upright.
▶ Never carry the external unit by the packing straps.
▶ During handling and unpacking, wear safety gloves to prevent injuries
on your hands through sharp-edged appliance components.
▶ Dispose of packaging materials appropriately.
4.2
UNPACKING THE EXTERNAL UNIT
WARNING: Risk of injury through sharp-edged tools.
▶ Handle tools carefully.
▶ Ensure that the outer carton is not damaged when
removing the straps.
▶ Undo straps carefully.
▶ Remove the outer carton by pulling it vertically upwards.
▶ Remove the padding from the front and sides.
▶ Remove the plastic cover and protective cover from the top of the
external unit and keep safe.
▶ Provide at least two people for lifting the external unit from the bottom
plate.
▶ Ensure that this does not damage the external unit.
▶ Dispose of packaging in an environmentally responsible manner.
19
MOUNTING AND INSTALLATION
4.3
UNPACKING THE HYBRID MANAGER
Worcester Bosch recommends the fitting of an in-line
system filter to the primary circuit which will assist with
maintaining system performance.
NOTICE: Damage to the hybrid manager and refrigerant
pipes may occur through incorrect handling.
▶ Treat refrigerant pipes and the hybrid manager with
care.
▶ Upon receipt, check that all packaging is in perfect condition.
▶ Remove packing straps and open the packaging at the top.
▶ Remove mounting plate and printed documents; keep safe for later
use.
▶ Remove outer packaging.
▶ Remove protective packaging.
▶ Dispose of packaging in an environmentally responsible manner.
▶ Carefully place the appliance on its back.
▶ Undo screws at the top and bottom of the appliance.
▶ Remove casing.
▶ Remove the screws on the transport bracket.
▶ Remove the transport bracket.
▶ Refit casing and screws.
4.4
CHECKING THE DELIVERY
▶ Check the delivery for completeness.
NOTICE:
Debris from the system can damage the hybrid manager
and reduce efficiency.
Failure to comply with the guidelines for the use of water
treatment with the appliance will invalidate the
appliance warranty.
BEFORE CLEANING THE SYSTEM:
NOTICE: Damage through high water flow:
The flow switch is damaged if the water flow is
excessively high.
▶ Flush the heating system with a water flow of  50l/
min.
▶ Ensure that the system and pipe work is in good working order.
▶ Where possible keep the existing boiler/circulating pump in place
when flushing the system.
FOLLOW THE GUIDANCE OF BS7593:
5
MOUNTING AND INSTALLATION
5.1
PREPARING FOR INSTALLATION
DANGER: Danger to life through electric shock!
▶ Before carrying out work on electrical components,
isolate them from the power supply (230 V AC) (fuse,
circuit breaker) and secure against unintentional
reconnection.
WARNING: Risk of injury and damage to appliance
through incorrect mounting and installation.
▶ The hybrid system and the components may only be
sited and installed by a competent person.
For commissioning:
The Power supply to the external unit must be “On”for at
least 12 hours before starting operation. This is to
ensure that the compressor is warmed up sufficiently to
avoid any liquid refrigerant from entering the
compressor. This is particularly important during colder
periods.The 12 hour period also compensates for any
unsettling of the lubricating oil within the compressor
which may have occurred during transportation.If this
12 hour time period cannot be met damage to the
outdoor unit may result.
Therefore, make the electrical connection as early as
needed ( chapter 5.7).
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
NOTICE: ARTIFICIALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.
FLUSHING THE SYSTEM
▶ Fill the system with cold water and check for leaks.
▶ Open all drain cocks and drain the system.
▶ Close drain cocks and add a suitable flushing agent compatible with
aluminium at the correct strength for the system conditions in
accordance with the manufacturer‘s instructions.
The pH value of the system water must be less than 8 or the
appliance guarantee will be invalidated.
▶ Circulate the flushing agent before the boiler is fired up.
▶ Run the boiler/system at normal operating temperature as directed by
the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
▶ It may be necessary to use a power flushing machine to aid the
cleansing procedure in some circumstances.
▶ Close the drain cocks and refill with fresh water and a suitable
inhibitor.
▶ Vent any air from the boiler and system.
INHIBITOR
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system
is exposed to freezing conditions, to the heating system in accordance
with the DWTA code of practice and manufacturer‘s guidelines.
5.1.1 CLEANING PRIMARY SYSTEMS
CAUTION:
ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
20
WARNING: Sealing agents
▶ Normally the addition of sealing agents to the system
water is not permitted as this can cause problems
with deposits left in the heat exchanger.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
WATER TREATMENT PRODUCTS
Suitable water treatment products can be obtained from the following
manufacturers:
FERNOX
SENTNEL
0870 601 5000 or www.fernox.com
0800 389 4670 or www.sentinel-solutions.net
Table 5
• Fit the bypass valve as near as possible to the heating system and as
far away as possible from the buffer vessel.
5.2.4 EXPANSION VESSEL
Install an additional expansion vessel on the heating system return
between the bypass valve and the hybrid manager. Size the expansion
vessel according to EN128-28.
ARTIFICIALLY SOFTENED WATER
5.2.5 THERMOSTATIC RADIATOR VALVES
It is possible to have an ion exchange water softener fitted to the cold
water system of the property. However, the boiler requires an untreated
cold water connection taken from the mains supply, before the water
softener, to the primary water filling point of the heating system.
For optimum comfort and system efficiency a thermostatic radiator
valve should be fitted to each radiator within the circuit, except for the
radiator in the same room as the room controller.
5.2.6 HYBRID MANAGER
Alternatively there are water softening/treatment devices that do not
adjust or alter the pH levels of the water. With these devices it may not
be necessary to provide an untreated water by-pass to the primary water
filling point of the heat system.
SYSTEM COMPONENT CONFIGURATION
5.2.1 GENERAL REQUIREMENTS
The following requirements must be met. The following
sections detail additional requirements for the
installation of the individual system components.
It is important the pump speed is set correctly, please set
the HE pump inside the hybrid manager
( chapter 6.2.9, page 35).
• The permissible maximum length of the refrigerant lines between the
external unit and the hybrid manager is 30 m with up to 15 bends
(single direction).
• The permissible minimum length of the refrigerant lines between the
external unit and the hybrid manager is 1 m in a single direction.
• A height differential between the installation site and the hybrid
manager is permissible. However, take the maximum pipe length of
30 m into account.
• If the hybrid manager is mounted above the heat source, fit an
automatic air vent valve at the highest point of the heating system.
• The maximum equivalent length of pipe work with which the hybrid
manager is connected to the existing heating system flow and return
should be determined from tables 50 and 51. One metre must be
subtracted for each 90° bend.
• Rooms where the hybrid manager or the refrigerant lines are installed
must have a volume of at least 5.7 m³, if the room can be occupied.
Information on the installation site:
• Ensure minimum clearances are maintained.
• Mount the hybrid manager on to a fixed rigid wall capable of
supporting the weight of the unit.
• To reduce the installation effort we recommend the installation of the
hybrid manager below the heat source ( Fig. 7, page 9).
• Flow and return pipes can be routed vertically from the top or bottom
into the hybrid manager.
• Refrigerant lines can be routed vertically from the top into the hybrid
manager.
• If refrigerant lines are to be routed downwards, allow for adequate
space to route the pipes downwards alongside the unit, preferably on
the left hand side.
MINIMUM CLEARANCES
Dimensions given are minimum clearances around the
Hybrid manager for the purposes of installation and
service.
The minimum volumetric requirements of the room size
must also be adhered to according to EN: 14511.
a
d
5.2.2 BUFFER TANK
d
c
b
NOTICE:
▶ Please refer to the Buffer tank installation instructions
for correct hydraulic connection.
6720803687-28.1Wo
5.2
WARNING: Rooms where the hybrid manager or the
refrigerant lines are installed must have an internal
volume of at least 5.7 m3, if the room can be occupied.
Fig. 16 Minimum clearances, hybrid manager
The buffer tank must be installed in series in the flow between the hybrid
manager and the system by-pass.
5.2.3 BYPASS VALVE
[a]
[b]
[c]
[d]
The bypass valve is connected between the flow out from the buffer
vessel and the first radiator on the heating system.
5.2.7 EXTERNAL UNIT
Further requirements of the installation site:
• The bypass valve must be fitted into a straight pipe section and not
immediately near a bend.
• For commissioning and maintenance the bypass valve must be easily
accessible.
6 720 803 687 (2012/11)
Top clearance: 250 mm
Bottom clearance: 200 mm
Front clearance: 800 mm for maintenance
Side clearance: 5 mm
DANGER:
▶ Never site the external unit in locations where
flammable gases could be released, accumulate or
flow past.
21
MOUNTING AND INSTALLATION
AMBIENT CONDITIONS AND SITE LOCATION.
The ambient conditions and site location significantly influence the
external unit's output and service life. Unfavourable ambient conditions
or site location can result in a significant reduction in output and even
possible appliance damage.
• Never site the external unit where it is exposed to vapour, volatile oils
(incl. machine oil) or sulphurous gas.
• In areas with a high salt content (e.g. on the coast), advice should be
taken on the protection of the unit's evaporator.
• If snow is expected, take appropriate measures to ensure that the
external unit cannot be covered by snow.
• In cold or frosty areas ensure that the condensate can drain off freely
(e.g. by means of a condensate drain or pan).
• Preferably avoid installing the external unit in locations where it would
be exposed to direct or to other heat sources.
6720803687-24.1Wo
a
FOUNDATION
Fig. 17 Orientation towards a wall (windy location)
• The installation surface must be level, firm and of appropriate loadbearing capacity. It must be able to bear the weight and absorb the
vibrations of the external unit.
• Wooden bases are unsuitable installation areas.
• Requirements for concrete foundations:
– Thickness of concrete: ≥120mm
– Load-bearing capacity: ≥320 kg
• Length of fixing screws: ≥70 mm (subject to foundation).
[a]
Minimum wall clearance 1000mm
If the air discharge is oriented directly against a wall this
may discolour over time.
▶ Direct the air discharge at an angle of 90° to the main wind direction
[1].
INSTALLATION SITE IN GENERAL
• Select an installation site (floor standing or wall mounting (available as
an accessory) installation) where the external unit creates no noise
nuisance for other occupants or the neighbourhood.
• Select an installation site where wiring and pipe work to power source
and hybrid manager can be easily accomplished.
• The external unit produces condensation during the heating
operation. Ensure suitable drainage is provided around the external
unit if such condensation is likely to cause risk of injury or damage.
• It is important that flue products or condensate do not drip onto or
enter the air intake of the external unit. Therefore, never locate the
external unit in immediate proximity or directly below the boiler flue
outlet.
• Recirculation of the discharge air can severely affect the output.
• We recommend a floor standing installation where possible.
Fig. 18 Air discharge alignment
WINDY LOCATION
[1]
1
6 720 646 970-08.2ITL
Main wind direction
If the external unit is sited on a roof or another site exposed to the wind,
ensure that the air discharge is not directly exposed to strong wind.
Possible preventive measures to safeguard against strong wind:
▶ Direct the air discharge towards the nearest wall. The minimum
clearance must be 1000mm.
22
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
MINIMUM CLEARANCES
e
f
1
d
a1
a
2
a1
e
4
f
d1
a
c
b
3
a2
c
b
5
6
6 720 646 970-12.2ITL
Fig. 19 Minimum clearances for specific installation situations
Pos.
1
2
Obstacle
• Rear
• Rear
• Above
3
• Rear
• Sides
• Connection side
Clearance [mm]
• a  150
• a1  300
• e  1000
• f  500
• a1  300
• b  200
• d  200
Pos.
4
5
Obstacle
• Front
• Front
• Rear
Clearance [mm]
• c  1000
• a  150
• c  1000
6
•
•
•
•
•
•
•
•
•
Rear
Sides
Above
Connection side
a2  500
b  200
d1  250
e  1500
f  500
Table 6 Key to Fig. 19
6 720 803 687 (2012/11)
23
MOUNTING AND INSTALLATION
5.3
PRE-INSTALLING PIPES
5.3.2 FITTING THE BYPASS VALVE
Regarding the arrangement and position of the bypass
valve, observe the information in section 5.2.3.
Contamination in the system can result in damage to the
air to water heat pump and reduce the output.
5.3.1 PREPARING THE HYBRID MANAGER CONNECTION
▶ Installing on-site pipe work. For this, observe the information on
system component configuration ( chapter 5.2).
Pipe work may be routed vertically or behind the
appliance.
▶ Connect the bypass valve between the heating system flow and
return.
▶ Install the bypass valve in the flow direction from the flow to the
return. The flow direction is identified on the bypass valve by an
arrow.
▶ Drill six holes into the wall using the drilling template provided [1].
▶ Insert suitable wall plugs.
▶ Fit the mounting plate of the hybrid manager to the wall using the top
drilled holes [2].
2
1.
2.
1
6 720 646 970-14.2ITL
Fig. 22 Mounting the bypass valve in flow direction
[1]
[2]
From the heating system flow
To the heating system return
5.3.3 MOUNTING THE FW200 PROGRAMMING UNIT
The FW200 must never be fitted in the front of the gas
appliance, and must not be placed in direct sun light.
The programming unit is mounted on the wall and it is
electrically linked via the hybrid control module via
CANBUS cable.
6720803687-27.1Wo
Fig. 20 Fitting the mounting plate
▶ Connect the heat source pipe work and that of the heating system to
the mounting plate. Ensure your connections are correct ( Fig. 21).
– Fit the pipe fully into the pipe connection.
– Tighten the compression fitting.
All installation information for the FW200 can be found in the separate
FW200 installation manual.
5.4
MOUNTING THE HYBRID MANAGER
PREREQUISITES
1
2
3
4
Prior to starting the mounting of the hybrid manager, ensure that the onsite conditions have been met ( chapter 5.2, from page 21).
• Where the unit is being fitted to an existing heating system ensure the
system has been flushed and cleaned prior to fitting of the Hybrid
manager unit ( chapter 5.1.1).
• The required minimum clearances are ensured ( chapter 5.2.6).
• The mounting plate has been secured to the wall and is correctly
connected ( chapter 5.3.1).
• The bypass valve has been fitted correctly ( chapter 5.3.2).
5
6 720 646 970-13.2ITL
Fig. 21 Hybrid manager mounting plate
[1]
[2]
[3]
[4]
[5]
Mounting plate
Heating system return (22 mm compression fitting)
Pipe work to the heat source (22 mm compression fitting)
Pipe work from the heat source (22 mm compression fitting)
Heating system flow (22 mm compression fitting)
NOTICE: Buffer tank installation:
▶ refer to the instructions provided with the buffer tank.
24
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
▶ Reposition the hybrid control module.
CASING REMOVAL
1. Undo the outer case screws [1].
2. Lift off the case.
1
1.
1.
1
6720803687-33.1Wo
2.
6 720 646 970-17.3ITL
Fig. 26 Reposition the hybrid control module
1. Screw both top screws for the hybrid manager almost all the way into
the wall, but do not tighten them fully.
Fig. 23 Casing removal
▶ Raise the hybrid manager and hook it onto both screws.
[1]
2. Connect pipe work. For this, on every connection:
– Insert fibre gasket
– Tighten the union nuts of all connections.
Fixing screws
WALL MOUNTING
▶ Undo the fixing screws of the casing at the top and bottom of the
hybrid manager.
▶ Remove the casing.
▶ Undo fixing screw on the left [1] of the hybrid control module.
▶ Push out the spring plate [2] and tilt the hybrid control module
forward.
2
▶ Tighten both top fixing screws of the hybrid manager wall mounting
plate.
3. Fit and tighten the lower fixing screws on the wall mounting plate.
▶ Lower the control module.
▶ Insert the side and front insulation piece.
▶ Reposition the hybrid control module until the spring plate clicks into
place.
▶ Push casing onto appliance
4. Tighten the fixing screws of the casing at the top and bottom of the
hybrid manager.
4.
2.
1.
1
6 720 646 970-15.3ITL
Fig. 24 Tilting the hybrid control module forward
[1]
[2]
Fixing screw
Spring plate
3.
▶ Remove the front and side insulation panels of the hybrid manager
and keep safely for later reassembly.
6 720 646 970-99.2ITL
Fig. 27 Mounting the hybrid manager on the wall
5.5
INSTALLING THE EXTERNAL UNIT
PREREQUISITES
Prior to siting and installing of the external unit, ensure that the on-site
conditions have been met ( chapter 5.2, from page 21).
• Required on-site steps have been taken correctly and have been
completed.
• The required minimum clearances are ensured ( chapter 5.2.7).
• The condensate drain has been prepared ( chapter 5.5.1).
6720803687-37.1Wo
Fig. 25 Remove insulation from the hybrid manager
6 720 803 687 (2012/11)
25
MOUNTING AND INSTALLATION
5.5.1 PREPARING THE CONDENSATE DRAIN FOR THE EXTERNAL
UNIT
5.5.3 MAKING A CONDENSATE DRAIN FOR THE EXTERNAL UNIT
NOTICE: Frost damage!
Frost damage on the external unit will result if the
condensate fails to drain off.
NOTICE: Damage from moisture!
Spilled condensate can be a nuisance as well as a hazard
if it leaks onto a walkway and freezes.
▶ Never permit condensate to drain across walkways;
instead, route them to a suitable drainage point.
▶ Either install a condensate drain or an optional
condensate pan fitted with a drain for the external
unit.
In addition to the condensate lines for the heat source, make provisions
for the condensate generated in the external unit.
Unlike boiler condensate, the condensate produced by the external unit
is not acidic and can soak away in chippings or be routed to a drain. The
diameter, slope and routing of the condensate pipe work must be
selected in such a way as to prevent blockage or freezing.
Preparing the condensate drain:
▶ Use a PVC rigid vinyl pipe (VP-32) or a vinyl hose with a minimum
internal diameter of 32 mm as condensate drain.
▶ Select the shortest possible pipe length.
▶ Keep condensate lines as vertical as possible with a minimum slope of
45 mm per metre to its outlet.
The condensate generated in the external unit must be drained off free
from the risk of frost.
▶ Ensure that the on-site requirements for reliable condensate drainage
are met ( chapter 5.5.1).
The bottom of the external unit has 3 holes suitable for draining off
condensate.
We recommend providing the pipe work with weatherresistant insulation.
5.5.2 MOUNTING ON FOUNDATIONS
WARNING: Personal injury from unsuitable surfaces!
An external unit that has not been properly sited may fall
over and cause personal injury and property damage.
3
2
1
6 720 646 970-21.2ITL
▶ Site the external unit on a stable, level substrate with
sufficient load-bearing capacity.
▶ Never site the external unit on wooden floors.
Fig. 29 Fitting the condensate drain
▶ Ensure that the foundations and installation surface meets
requirements ( chapter 5.2.7).
▶ Position and level the external unit.
▶ Mark out the holes to be drilled for the 4 anchor bolts.
▶ Move the external unit slightly to the side.
▶ Drill the holes for the 4 anchor bolts.
– Bolt size: M 10
– Select a hole depth that allows the anchor bolts to be screwed into
the foundations to a depth of at least 70 mm.
▶ Level the external unit.
▶ Secure the feet of the external unit with four M 10 anchor bolts.
[1]
[2]
[3]
Condensate pipe
Drain tap
Blanking caps (accessory)
▶ Glue the drain tap [2] into a suitable hole.
▶ Glue blanking caps [3] onto the other holes that are not used. Apply
adhesive properly as it also acts as a sealant.
▶ Connect the condensate hose [1] to the drain tap.
▶ Apply weather-resistant insulation to the drain pipe.
▶ Route the condensate drain into a suitable drain pipe or a dry well.
▶ Protect against the risk of frost:
We recommend the use of the “electric trace heating for the
condensate drain of the external unit” (available as an accessory).
Accessory pack for outdoor unit contains:
• Blanking caps
• Pre-cut insulation (for lagging the service/installer connections)
• Cable ties (for securing lagging of service/installer connections)
1
4x
b
a
6 720 646 970-19.2ITL
Fig. 28 Foundations for the external unit (2 plinth example shown)
[a]
[b]
[1]
26
As long as possible, minimum 365 mm
Minimum depth120 mm
M 10 anchor bolt ( 70 mm)
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
5.6
INSTALLING THE REFRIGERANT CIRCUIT
5.6.1 SAFETY
R410A is used exclusively as the refrigerant in the air to water heat
pump.
Compared to previously used refrigerants, the R410A
refrigerant operates at a pressure that is approx. 1.6times higher.
– Apply the utmost care when routing refrigerant lines.
Dust, foreign bodies and moisture inside the refrigerant lines can be
detrimental to oil quality or result in compressor failure.
▶ Use C1220 phosphorous copper for refrigerant pipe connections to
create seamless pipes from copper and copper alloys.
▶ Braze joints in refrigerant lines. Use phosphor bronze brazing rods
suitable for flux-free brazing.
Ensure that the lines are constantly shielded with
oxygen-free nitrogen (a little above atmospheric
pressure) whilst joints are being brazed to prevent
scaling and damage to the compressor.
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant system.
▶ For the installation work, use tools and pipe components specifically
made for use with R410A refrigerant.
▶ Check for leaks in the refrigerant system. Escaping refrigerant coming
into contact with a naked flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
▶ Apply small amounts of ester oil, ether oil or alkylbenzene as
refrigerant oil onto the flared sections of the refrigerant lines. Never
mix refrigerant oil with mineral oil.
▶ After cutting, immediately seal reusable lengths of refrigerant lines.
If refrigerant leaks and touches the skin, it can cause frostbite.
5.6.3 ROUTING REFRIGERANT LINES
▶ In case of a refrigerant leak, never touch any part of the air to water
heat pump.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your skin or in your
eyes.
5.6.2 PREPARING FOR INSTALLATION
CAUTION: Property damage from incorrect installation!
▶ Use only those tools that are specifically intended for
handling R410A refrigerant.
The room volume must be at least 5.7 m³ if refrigerant
lines are routed through occupied rooms.
▶ Ensure requirements have been met:
– A height differential between the installation site and the hybrid
manager is permissible. However, take the maximum pipe length of
30 m into account.
– The refrigerant line may have a maximum of 15 bends and a
maximum length of 30 metres one way.
▶ Start by connecting the refrigerant lines to the hybrid manager
(mounting plate).
▶ Bend pipes carefully to prevent breaking them. Bending radii between
100 mm and 150 mm are adequate.
Tools required to handle R410A refrigerant:
• Pressure gauge kit
• Charge hose
• Gas leak detector
• Torque wrench
• Flaring tool
• Flaring gauge
• Vacuum pump adapter
• Electronic refrigerant charging scale
• Pipe press tool
When brazing joints, ensure that the lines are constantly
shielded with oxygen-free nitrogen (a little above
atmospheric pressure). After brazing has been
completed, continue shielding the brazed area with
nitrogen until the temperature of the pipe work has
cooled down to below 200 °C.
PIPES AND PIPE JOINTS
WARNING: Risk of injury through escaping refrigerant!
Pipes that are not permissible or that are incorrectly
sized can burst.
▶ Use exclusively pipes with the specified wall
thickness.
▶ Generally braze refrigerant line joints.
▶ Wrap pipe work for liquid and gaseous refrigerant with commercially
available insulation (diffusion-proof, up to at least 100 °C, thickness
at least 20 mm).
▶ Use sealant to seal the ends of the thermal insulation around the pipe
connection sections to prevent water from entering the thermal
insulation.
5.6.4 CONNECTING THE HYBRID MANAGER
Pipe
Liquid refrigerant
Gaseous refrigerant
External diameter
[inch]
¼
½
Wall thickness
[mm]
0.8
0.8
Table 7 Refrigerant pipe dimensions
▶ Ensure the insides of the pipes are clean and do not contain any
harmful contaminants such as sulphuric compounds, oxidants,
debris, or dust.
– Never store the refrigerant pipes to be used outdoors.
– Do not unseal the pipe ends until immediately before they are
brazed.
6 720 803 687 (2012/11)
When brazing joints, ensure that the lines are constantly
shielded with oxygen-free nitrogen (a little above
atmospheric pressure). After brazing has been
completed, continue shielding the brazed area with
nitrogen until the temperature of the pipe work has
cooled down to below 200 °C.
▶ Remove plug and braze the ¼ " diameter to the pipe work for liquid
refrigerant and the ½ " diameter to the pipe work for gaseous
refrigerant at the hybrid manager.
27
MOUNTING AND INSTALLATION
5.6.5 CONNECTING THE EXTERNAL UNIT
Never connect the refrigerant lines to the external unit until
• the refrigerant lines have been completely arranged
• the refrigerant lines have been connected to the hybrid manager.
At the factory, the external unit has been filled with
sufficient R410A refrigerant for a line length (single
direction) of between 1 m and 30 m.
▶ Connect the external unit to the refrigerant line after completing the
installation work, including the connection to the hybrid manager
(internal unit).
▶ Remove the service cover (1 screw).
▶ Close the external unit’s shut-off valve completely.
▶ Fit the flare nut (17 mm external diameter) to the liquid refrigerant
pipe.
▶ Fit the flare nut (26 mm external diameter) to the gaseous refrigerant
pipe.
▶ Flare the pipes for liquid and gaseous refrigerant ( Fig. 30 and
table 8).
2°
8
0.
R
4~
0.
R
90° 0.5°
øA
45°
6 720 646 970-24.2ITL
Fig. 30 Flaring refrigerant pipes
Pipe
Liquid refrigerant
Gaseous refrigerant
External diameter
[inch]
¼
½
Faring dimension
Ø A [mm]
8.9 – 9.1
16.2 – 16.6
Table 8 Swaging dimensions for refrigerant pipes
▶ Apply a thin layer of refrigeration oil to pipe and joint seating surface
before tightening flare nut.
1
2
External
diameter
Pipe work
[inch]
Liquid refrigerant ¼
Gaseous refrigerant ½
OD conical nut
[mm]
Torque [Nm]
17
14 – 18
26
49 – 61
Table 9 Starting torque, external unit
▶ There should be no contact with the outer case of the ODU.
▶ There should be no contact between the liquid and gas refrigerant
pipes.
5.6.6 CHECKING THE REFRIGERANT CIRCUIT FOR TIGHTNESS
The addition “(g)” identifies the stated value as pressure
differential relative to atmospheric pressure.
After connecting the refrigerant pipes, check the connected pipes and
the hybrid manager for tightness.
▶ Connect the testing tools.
▶ Ensure that the shut-off valves on the pipe work for liquid [1]
( Fig. 32 and page 29). and gaseous refrigerant [2] ( Fig. 32
and page 29) are closed and do not open them.
▶ Feed nitrogen into the refrigerant lines via the shut-off valve's
Schrader valve on the gaseous refrigerant pipe work [2] and slowly
increase the pressure in the refrigerant circuit.
▶ Increase the pressure in stages:
– Step 1: build pressure to 0.5 MPa (5 bar(g)).
Wait 5 minutes.
Check pressure. A pressure drop indicates that there is a leak.
Identify the source, repair and check for tightness again.
– Step 2: build pressure to 1.5 MPa (15 bar(g)).
Wait 5 minutes.
Check pressure. A pressure drop indicates that there is a leak.
Identify the source, repair and check for tightness again.
– Step 3: Pressurise to 4.15 MPa (41.5 bar(g)).
Measure the ambient temperature and the pressure.
▶ After 24 hours, check ambient temperature and pressure again.
The refrigerant circuit has passed the tightness test if no pressure
drop can be identified.
A minor change in pressure can be caused by the change
in temperature (approx. 0.01 MPa (0.1 bar(g)) per
1 °C). Take this into account in the evaluation.
3
▶ A pressure drop indicates that there is a leak. Identify the source,
repair and check for tightness again.
Use a gas leak detector or a soapy solution to check for gas leaks.
6 720 646 970-48.2ITL
Fig. 31 Fitting refrigerant pipes
[1]
[2]
[3]
Connection to the external unit
Flared refrigerant pipe
Conical nut
▶ Tighten conical nut [3] with a torque wrench. Observe the allowable
starting torque when doing so ( Table 9).
28
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
▶ Trim off the excess “tails” of the cable ties [2].
9
1
4
2
2
10
6
7
3
5
Fig. 34 Insulation with cable ties
6 720 646 970-27.3Wo
[1]
[2]
Fig. 32 Shut-off valves, refrigerant circuit
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
6720803687-32.1Wo
1
8
Shut-off valve on the liquid refrigerant pipe work
Shut-off valve on the gas pipe work
Schrader valve (under the service port)
Section opening / closing
Service port
Do not use a spanner here
Use two spanners here
Insulation
¼ inch pipe
½ inch pipe
Insulating material (accessory drain kit EHP)
Cable tie (accessory drain kit EHP)
▶ Trim and fix the insulating material [1] for the gaseous refrigerant
pipe work.
▶ Fix the insulation material [1] using cable ties [2].
▶ Trim off the excess “tails” of the cable ties [2].
5.6.8 EVACUATING AND DRYING THE REFRIGERANT CIRCUIT
WARNING: Personal injury from rupturing refrigerant
pipes!
Air bubbles trapped in lines can result in pressure peaks
which can result in pipes bursting.
5.6.7 INSULATING THE REFRIGERANT SHUT-OFF VALVE
Insulate the refrigerant pipes, including the shut-off valve, following
connection to the external unit.
▶ Never allow air to remain in the lines.
▶ Trim insulation material [3] so that it fits snug around the refrigerant
valves.
▶ Install the insulation [3] for the liquid refrigerant pipes (small,
2 holes) on the liquid side so that the holes fit the valve caps [1] and
cover the shut-off valve [2] entirely.
▶ Trim the insulating material for the liquid refrigerant pipe work and
make 2 holes for the locking caps.
▶ Fix to the pipe so that the holes surround the locking caps [1] and the
shut-off valve [2] is completely covered.
The refrigerant circuit is pre-charged with 2.5 kg of
R410A refrigerant. Commissioning does not require
topping up with refrigerant.
Remove air from the refrigerant circuit by following recommended
procedure for vacuum drying. In the case of inadequate vacuum drying
air and water vapours remain in the refrigerant circuit. These may result
in an abnormal rise in positive pressure or in a drop in negative pressure
as well as to a loss of quality in the refrigerant oil through moisture. This
may have a negative effect on the compressor service life.
VACUUM DRYING
Never use the refrigerant from the external unit to purge
air from the refrigerant lines.
2
3
Fig. 33 Insulating material, shut-off valve and valve caps
[1]
[2]
[3]
Locking caps
Lock nut
Insulating material (accessory drain kit EHP)
▶ Secure insulating material [1] with cable ties.
6 720 803 687 (2012/11)
6720803687-31.1Wo
1
▶ Connect a high performance vacuum pump to the Schrader valve
( Fig. 32, [3]).
▶ With the vacuum pump build a pressure of 101 kPa(g) (5 Torr).
▶ Maintain this pressure for at least 1 hour.
– During this time check the vacuum pressure constantly at the
pressure gauge.
– If there is any moisture left in the pipe, complete evacuation is
sometimes not reached if the vacuum pump is applied for only a
short period.
▶ Close the distributor valve and then switch off the vacuum pump.
▶ Observe the pressure for one minute.
Should the pressure rise during that time (vacuum reduces), evacuate
and repeat the final test.
▶ Separate the vacuum pump from the refrigerant circuit.
29
MOUNTING AND INSTALLATION
OPENING THE SHUT-OFF VALVES
NOTICE: Material loss from closed shut-off valves.
Compressor and control valves will suffer damage if the
shut-off valves remain shut during the operation of the
external unit.
▶ Open shut-off valves for liquid and gaseous
refrigerant.
Opening the shut-off valves on the liquid and gaseous refrigerant pipe
work ( Fig. 35):
▶ Remove valve cap [2].
▶ With an Allen key (4 mm) turn the valve spindle [3] anti-clockwise as
far as it will go (approx. 10 turns).
Stop turning once the end-stop has been reached.
▶ Turn valve rod [3] ½ one turn back (clockwise).
▶ Attach valve cap [2]. When doing this ensure that the inside remains
undamaged as this serves as a sealing face.
▶ Tighten valve cap [2] with a torque of between 20 and 25 Nm.
Failure to replace and tighten the caps may result in refrigerant
leakage.
▶ Prior to making the electrical connection, isolate the heat source and
all other BUS subscribers from the power supply.
▶ Before opening the external unit or the hybrid manager:
Isolate all MCBs from the mains supply and secure against
unintentional reconnection. Switching off the programming unit is not
enough.
▶ Only use cables and leads for connecting the external unit to the
power supply that are rated for outdoor use.
▶ To protect against dripping water, route the electric cables through
ferrules and connect them without strain to the designated terminals.
▶ Ensure correct earthing of the external unit. Never connect the earth
lead to gas or water pipes, lightning conductors or telephone earth
cables.
▶ Use circuit breakers (RCD, disconnector with B fuse and MCB) with
the specified rating.
▶ Observe all relevant local and national regulations for electrical
installation.
5.7.2 GENERAL REQUIREMENTS
Prior to connecting the hybrid manager, ensure that the on-site
conditions have been met.
• One 10 A MCB with B characteristics each is provided for the heat
source and the hybrid manager.
1
To prevent inductive influences:
2
• Route 230 V or 400 V cables separately from LV cables/leads.
• Maintain a minimum clearance of 100 mm.
• Use screened cables where external inductive influences cannot be
avoided.
5
3
This screens the cables/leads from external influences,
such as HV cables, moving cables, transformer stations,
radio and TV appliances, amateur radio stations and
microwaves.
To safeguard the splashproof rating (IP):
4
6 720 646 970-28.2ITL
Fig. 35 Shut-off valve on the gaseous refrigerant pipe work
[1]
[2]
[3]
[4]
[5]
5.7
Schrader valve (under service cap)
Isolation valve cap
Isolation valve spindle
Pipe work to building
Pipe work to the external unit
MAKING THE ELECTRICAL CONNECTION
5.7.1 SAFETY
DANGER: Risk to life through electric shock!
Incorrectly executed work on electrical components can
result in life-threatening electric shocks.
▶ Only qualified electricians must carry out work on
electrical components. If you do not possess an
appropriate qualification, ask a qualified electrician
to make the electrical connection.
WARNING: Do not connect the trace heating cable to
the electrical connection of the outdoor unit. If this is
done severe damage to the outdoor unit will result.
• Route cables so that the cable sheath protrudes at least 20 mm into
the cable entry.
5.7.3 CONNECTING THE EXTERNAL UNIT
WARNING:
Do not connect the trace heating cable to the
electrical connection of the outdoor unit.
If this is done severe damage to the outdoor unit will
result
NOTICE: Damage from wet conditions!
Ingress of rain, humidity or dust can damage the PCB
inside the external unit.
▶ Never work on the external unit when it is raining.
▶ Following work on the terminal strip check that the
service cover sits firmly.
For the power supply and the electrical connection
between the external unit and the hybrid manager,
select only cables with flexible Neoprene® sheathing to
60245 IEC 57.
▶ Route cables through a conduit.
Always pay close attention to safety during all work on the electrical
system and components. This includes the following:
30
6 720 803 687 (2012/11)
MOUNTING AND INSTALLATION
PREREQUISITES
Prior to connecting the external unit, ensure that the on-site conditions
have been met.
• A 16A circuit breaker with type D characteristic and 300mA fault
current circuit breaker for AC and DC current at the main distribution
board.
• An external isolator switch with at least 3.0 mm contact separation
across all poles has been installed near the external unit.
MAKING THE POWER SUPPLY CONNECTION
To prevent electrical interference, route all LV cables/
BUS cables separate from 230 V or 400 V cables
(minimum clearance 100 mm).
▶ Remove the service cover from the external unit.
– Undo the screw.
– Remove service cover [3].
1
For outdoor use, the three-core power cable for the
external unit must have a flexible Neoprene® sheath and
a cross-section of at least 1.5 mm2. We recommend the
use of screened cables, run inside conduits, e.g.
LIY CY (TP).
▶ Connect the earth cable to the external unit ( Fig. 38, [1]).
Use an earth cable which is longer than the other cables so that it will
not become disconnected when strain is applied.
CONNECTING THE CANBUS CABLE ON THE OUTDOOR UNIT
For outdoor use, the two-core power cable for the
external unit must have a flexible Neoprene® sheath and
a cross-section of at least 0.75 mm2 (at least 0.3 mm2).
▶ Connect the CANBUS cables from the air to water heat pump control
unit to terminals S2 to S3 ( Fig. 38, [1]).
– The two wires are not polarity sensitive.
2
3
3
L
N
S1 S2 S3
1
2
6 720 646 970-32.3ITL
Fig. 36 Removing the service cover from the external unit
[1]
[2]
[3]
Terminal strip
Earth terminal
Service cover
6 720 646 970-109.1ITL
Fig. 38 External unit terminal
[1]
[2]
[3]
▶ Connect the power cable to terminal strip [1].
3
2
Hybrid manager LV terminals (S2/S3)
External unit earth cable connection
Not assigned (S1)
▶ Refit the service cover after connection.
L
N
If CANBUS cable has been used with earth shielding,
connect shielding to point 2
S1 S2 S3
1
5.8
INSTALLING THE OUTSIDE TEMPERATURE SENSOR
5.8.1 SELECT THE INSTALLATION LOCATION
The installation location of the outside temperature sensor significantly
influences the captured outside temperature and consequently the
control of the entire system.
6 720 646 970-108.1ITL
Fig. 37 Power supply to the external unit
[1]
[2]
[3]
Electrical supply – earth
Electrical supply – Live
Electrical supply – neutral
6 720 803 687 (2012/11)
▶ Fit the outside temperature sensor at least 4 metres away from any
flue terminal or exhaust air vent and the external unit.
▶ Mount the outside temperature sensor north facing wall.
▶ Select approximately the centre of the height of the building to be
heated (generally 2. to 2.5 metres above ground level).
The following installation areas can give false temperature
measurements and should therefore be avoided:
• Never mount near windows and doors.
• Never install in poorly ventilated or unventilated areas (e.g. corners,
niches).
• Never mount near artificial sources of heat (e.g. external unit air
discharge, fans, flue terminals).
31
COMMISSIONING
6.1
WALL MOUNTING
▶ Drill 2 holes and mount the outside temperature sensor.
6.1.1 SAFETY
2.
6 720 610 967-10.2J
1.
Fig. 39 Installing the outside temperature sensor
[a]
Clearance between drilled holes: 62 mm
5.8.2 CONNECTING THE OUTSIDE TEMPERATURE SENSOR
Refer to the gas boiler installation literature with regards
to the wiring connection of the out door sensor to the gas
boiler.
▶ We recommend the use of screened cables, run inside conduits, e.g.
LIY CY (TP).
– Recommended cross-section: 0.75 mm2 ( 0.5 mm2)
– The two wires are not polarity sensitive.
▶ When extending the sensor leads use the following cross-sections:
Lead length [m]
20
30
30
Cross-section [mm2]
0.75...1.50
1.0...1.50
1.50
Table 10 Cross-sections for sensor leads
5.9
SETTING THE DIP SWITCHES OF THE EXTERNAL UNIT
The DIP switches are correctly set at the factory. These
settings should be checked prior to commissioning.
▶ Set or check the DIP switches in accordance with the table 24 on
page 52 and Fig 80 page 85.
6
COMMISSIONING
NOTICE: Incorrect sequence of turning on power to
units can cause communication issues between outdoor
unit and internal units.
▶ Connect all BUS subscribers to the BUS prior to
connecting the BUS to the power supply.
32
BEFORE COMMISSIONING
Implement all commissioning steps so that the safety of personnel is
ensured at all times and that material losses are prevented. This includes
the following:
▶ The hybrid system and the components may only be commissioned by
a competent person.
▶ Never touch the parts of the refrigerant circuit with bare hands during
operation. The refrigerant pipes are very hot or very cold depending
on the condition of the flowing refrigerant.
▶ Never touch any switch or parts of the electrical system with wet
hands. There is risk of electric shock.
▶ It is vital that the required procedures and waiting periods for switchon and switch-off are adhered to. Otherwise the hybrid system
components could become severely damaged.
▶ For commissioning, the power supply to the external unit must be 'live'
for at least 12 hours prior to switching the hybrid manager 'live'. If this
time frame cannot be achieved, severe damage may occur on the
external unit. Never interrupt the power supply during normal
operation.
▶ The hybrid control module regulates the hours at which the air to
water heat pump and the condensing boiler operate, subject to the
parameters selected at the FW200.
– Never interrupt the power supply to the hybrid manager and the
external unit during normal operation.
▶ Do not interrupt power supply to any units until a minimum of 5
minutes have elapsed since last operation.
6.1.2 COMMISSIONING REQUIREMENTS
WARNING: Risk of injury through rotating, hot or other
components that carry 'live' high voltage.
▶ Prior to starting the appliance ensure that all panels,
plates and safety equipment has been fitted
correctly.
Only operate the hybrid system when all conditions for a safe and
intended operation have been met.
• The hybrid manager has been correctly mounted and connected.
• The external unit has been securely positioned, correctly installed and
connected.
• The condensate drain of the external unit has been connected.
• The heating system has been flushed and filled to correct operating
pressure.
• The refrigerant circuit is correctly installed and has been filled with
R410A refrigerant. Tightness has been verified.
• The shut-off valves on the liquid side and the gas side are fully open.
• The electrical connections are correctly made. All essential fuses/
MCBs and safety switches are installed.
• All other system components that are not described here are also
installed, connected and ready to operate ( installation instructions
of the components).
• At outside temperatures in excess of 21 °C or below -9 °C, the air to
water heat pump will not start in standard mode. Commissioning the
heat pump in this temperature range is only possible via the “Service
mode” ( chapter 6.2.24, page 46).
6 720 803 687 (2012/11)
COMMISSIONING
6.2
COMMISSIONING THE SYSTEM FOR THE FIRST TIME
▶ Undo three screws and remove the small cover for the internal
connections at the back.
NOTICE: Damage when starting the compressor in the
external unit from cold!
▶ For commissioning:
The Power supply to the external unit must be
“Live”for at least 12 hours before starting operation.
This is to ensure that the compressor is warmed up
sufficiently to avoid any liquid refrigerant from
entering the compressor. This is particularly
important during colder periods.
The 12 hour period also compensates for any
unsettling of the lubricating oil within the compressor
which may have occurred during transportation.
If this 12 hour time period cannot be met damage to
the outdoor unit may result.
6.2.1 PROVIDING THE EXTERNAL UNIT WITH A POWER SUPPLY
AHEAD OF COMMISSIONING
The BUS cable is not connected at this point so the outdoor unit can be
powered on for the 12 hour period.
▶ After the 12 hour period, the power to the outdoor unit can be briefly
interrupted (i.e. 5 minuets) to allow connection of the BUS cable to
the hybrid manager.
▶ Once the BUS cable from the outdoor unit has been connected to the
hybrid manager the outdoor unit and the hybrid manager can be
powered on (within 3 minutes of each other).
6 720 646 970-30.3ITL
Fig. 41 Removing the small cover
▶ To provide splashed water protection (IP), always trim the strain relief
fitting in accordance with the cable diameter.
8-9
5-7
6.2.2 PROVIDING THE EXTERNAL UNIT WITH A POWER SUPPLY
DURING COMMISSIONING
All units must be powered up within a 3 minute time period to prevent
any communication issues, therefore there will be a need to interrupt the
power supply to the external unit upon commissioning.
10-12
13-14
6 720 612 259-30.1R
Fig. 42 Trimming the strain relief
▶ Guide the BUS cable through the strain relief fitting and connect it to
terminals S2/S3.
6.2.3 CONNECTING THE CANBUS CABLE TO THE HYBRID
MANAGER UNIT
▶ Interrupt the power supply to the external unit.
▶ Undo screws at the top and bottom of the appliance.
▶ Remove casing.
▶ Undo fixing screw on the left [1] of the hybrid control module.
▶ Push out the spring plate [2] and tilt the hybrid control module
forward.
1
6720646970-31.4Wo
2
Fig. 43 Terminals at the interface to the external unit
[1]
Terminal S2/S3
▶ Refit the cover after connection.
▶ Re-establish power supply to external unit
6.2.4 MAKING THE POWER SUPPLY CONNECTION
▶ Connect the2m pre-installed flexible cable on the hybrid manager unit
to the power supply (230 V AC, 3 A).
6.2.5 SWITCHING ON THE HYBRID SYSTEM
1
6 720 646 970-104.1ITL
Fig. 40 Tilting the hybrid control module forward
[1]
[2]
Fixing screw
Spring plate
▶ Ensure that the shut-off valves on the liquid and gaseous refrigerant
pipe work are open.
▶ Make the power supply to the hybrid manager and the external unit.
The external unit's compressor runs for 5 minutes at stage 1 (selftest).
The fan must move freely and not be obstructed.
▶ Check whether system components start correctly.
6 720 803 687 (2012/11)
33
COMMISSIONING
▶ Route the cable through the cable guide behind the insulation.
6.2.6 CONNECTING THE PROGRAMMING UNIT TO THE HYBRID
CONTROL MODULE
Use only one FW200 programming unit per hybrid system. Connect this
to the hybrid control module.
Mount the FW200 programming unit separately on a wall, if the unit has
been previously fitted in the front of the boiler unit, it must be removed
and fitted externally as stated.
3
2
1
CONNECTIONS INSIDE THE HYBRID MANAGER
2
3
BUS
6720646970-107.2Wo
1
BUS
14 15 16 17 18 19 20
Fig. 46 Cable guide inside the hybrid manager
▶ Connect the two-core CANBUS cable of the FW200 programming unit
to terminals 16 and 17 to the hybrid control module and the
programming unit.
– Recommended wire size: 0.75 mm2 (≥0.5 mm2)
2
3
4
M2
5
6
TSR
7
8
TSC
9 10 11 12 13
BUS
BUS
0...10V
14 15 16 17 18 19 20 21 22 23 24
Fig. 44 Connections at the hybrid manager
[1]
[2]
[3]
6720803687-36.1Wo
M1
1
Terminals
14, 15
16, 17
18, 19
Connections
Additional ISM module unit
FW200 programming unit
Heat source
Table 11 Connections at the hybrid control module
Connections for the ISM CANBUS cable
Connections for the FW200 programming unit
Connections for the heat source
▶ Remove the front cover of the hybrid control module.
– Undo fixing screws.
– Flip up and remove front cover.
▶ Replace cover when finished.
6.2.7 CONNECTING THE HEAT SOURCE TO THE HYBRID
MANAGER
▶ Route the cable through the cable guide behind the insulation.
▶ Connect the two-core CANBUS cable from the heat source to
terminals 18 and 19 at the hybrid control module and the heat source.
For Connection's to the heat source always consult the
installation manual.
▶ Press and hold the back button for approximate 5 seconds to reset the
hybrid control module ( Fig 51, page 44).
6.2.8 COMMUNICATION ERROR FROM EXTERNAL UNIT ON
INITIAL POWER ON OF EXTERNAL UNIT AND HYBRID
MANAGER
6 720 646 970-29.3ITL
Fig. 45 Removing the front cover of the hybrid control module
It may be necessary to adjust Dip switch SW8-3 on the
External Unit controller circuit board if a communication
error from the External Unit is present during power on
of the External unit and the Hybrid Manager.
It may be necessary to adjust Dip switch SW8-3 on the External Unit
controller circuit board if a communication error from the External Unit
is present during power on of the External unit and the Hybrid Manager.
Because the Hybrid Manager and External Unit have separate power
supplies, it may not be possible for both units to be powered ON at the
same time.
The External Unit and Hybrid Manager are separately located and if only
one installer is available to switch on both units, the timing to switch ON
the External Unit and Hybrid Manager will be different.
34
6 720 803 687 (2012/11)
COMMISSIONING
If the External Unit is powered ON first, its controller tries to establish
the communication with the Hybrid Manager but until the Hybrid
Manager is powered ON, the communication cannot be established.
If this status continues for a period of time, the External Unit judges this
status as a ‘communication error’ and this error can not be reset until the
External Unit is powered OFF once.
The same thing can happen when the Hybrid Manager is powered on first
and the External Unit can not be powered on within a certain period of
time.
In order to avoid this ‘false’ communication error, SW8-3 is available on
the External Unit controller circuit board. If switch SW8-3 is set to ON,
the Hybrid Manager/External Unit communication error is ignored and
the External Unit keeps waiting until the Hybrid Manager is powered ON
and responds to the External Unit.
In other words, even though it could take a long time from when the
External Unit is powered ON until the Hybrid Manager is powered ON,
the communication error is never detected as far as SW8-3 is set ON.
If SW8-3 is NOT set ON, the Hybrid Manager/External Unit
communication error will be detected in 3 minutes at the earliest case.
If you are sure that both the Hybrid Manager and the External unit
can be powered on within 3 minutes, you do not need to set SW8-3
ON.
If the communication error is caused not only by this power supply issue
but by electrical noise etc, the error can be detected by the indoor board
side even if SW8-3 is ON and the error code can be displayed on the
FW200.
6.2.9 ADJUSTING THE HYBRID MANAGER CIRCULATING PUMP
IN THE HYBRID MANAGER
The Hybrid manager circulating pump in the hybrid manager is set
subject to the system configuration.
ADJUSTING THE HYBRID MANAGER CIRCULATING PUMP CURVE
The Hybrid manager circulating pump can be set up in different ways:
• I Constant pressure curve, speed stage I
• II Constant pressure curve, speed stage II
• III Constant pressure curve, speed stage III.
Constant pressure curve, speed stage III is the standard
setting. Pump must be used in fixed speed mode only.
▶ Select and set the speed stage in line with the procedures described
in section 6.2.9
▶ Press arrow button [1] on the Hybrid manager circulating pump to
select the required stage.
Set the Hybrid manager circulating pump to the lowest
speed stage possible subject to system pressure drop.
We recommend speed stage II or III.
6.2.10 SYSTEM WITH SERIES BUFFER TANK
Does the installation have a single or a multi heating circuit with a serial
buffer tank? As shown in Fig. 7 8, 9 and 10.
1. The pump in the accessory box should be set on Constant Speed III,II
or I.
The pump should be set on the lowest setting which matches P the
Total System Pressure Drop.
2. The Available Pump Head, see figure 49 (Available head), must
overcome A the Heating Circuit Resistance and B the resistance of any
Additional Pipe work between the Accessory Box and the heating
system
3. What is the maximum condensing boiler heat output Q for the heating
system in kW?
4. What is T the required design Delta T (Flow temperature - Return
temperature) across the system?
NOTICE: The typical design Delta T is 20K
5. What is V the required system flow rate to achieve T the design Delta
T at the maximum CH heating output Q?
V = 14.3 x Q /T
6. What is the pressure drop of the heating circuit at flow rate F [l/min]
in mbar?
7. What is the equivalent length of additional 22mm pipe work between
the Accessory Box and the heating system in metres?
NOTICE: The equivalent length of pipe work includes all
additional pipe work bends (an elbow is equivalent to
1m length of pipe work)
8. What is B the pressure drop of the equivalent length of additional pipe
work in mbar? - refer to figure 48, Pressure drop/Flow rate
9. Calculate P the Total System Pressure Drop that the pump needs to
overcome, P = A + B
10.From Available Hydraulic Pump Head Chart, refer to figure 49, select
the closest pump setting which provides P the Total pressure at F the
system flow rate.
11.If none of the pump curves match the requirement it may be
necessary to reduced B the equivalent length of additional pipe work
1
6 720 646 970-106.1ITL
Fig. 47 Setting the speed stage at the HE pump
6 720 803 687 (2012/11)
35
COMMISSIONING
8.5
8
7.5
mbar/metre
7
6.5
6
5.5
5
4.5
4
3.5
3
2.5
2
2 1.5
1
0.5
0
0
1
2
3
4
5
6
7
8
9
1
10
11
12
13
14
litres/min
15
16
17
18
19
20
21
22
23
6720646970-130.1Wo
Fig. 48 Pressure and flow rate in the hybrid manager (internal unit)
[1]
[2]
[P]
[A]
[B]
[Q]
[T]
[F]
36
System flow rate (litres/min)
Pressure drop of 22mm OD copper pipe (mbar/metre)
= Total System Pressure Drop - mbar
= Heating Circuit Resistance - mbar
= Additional pipe work - metres
= Maximum Boiler Heating Output -kW
= Delta T (Temperature drop between flow and return) -K
= System Flow rate - litres/minute
6 720 803 687 (2012/11)
COMMISSIONING
600
550
500
mbar
450
400
III
350
300
250
3
II
200
150
100
I
50
0
0
1
2
3
4
5
6
7
4
8
9
10
11
12
13
litres/minute
14
15
16
17
18
19
20
6720803687-07.1Wo
Fig. 49 Available pump head
[I]
[II]
[III]
[3]
[4]
Constant pressure curve for speed stage I
Constant pressure curve for speed stage II
Constant pressure curve for speed stage III
Available pump head - mbar
System flow rate - litres/minute
6 720 803 687 (2012/11)
37
COMMISSIONING
6.2.11 VENTING THE HYBRID MANAGER
6.2.12 SETTING THE BYPASS VALVE
NOTICE: Damage through pump running dry!
▶ Regularly check the water level and top up heating
system with water, if required.
Once the bypass valve is set it is recommended to lock
the valve setting in place.
Set the bypass valve subject to the selected pump curve:
We recommend the installation of a manual air vent valve
near the heating water return of the hybrid manager to
enable the hybrid manager to be vented.
Airlocks in the pump can result in noise, vent the
circulating pump to remove any air lock.
• Speed stage I
 bypass setting = 0.05 bar
• Speed stage II
 bypass setting = 0.18 bar
• Speed stage III
 bypass setting = 0.45 bar
▶ Select the determined bypass setting at the adjusting part of the
bypass valve.
▶ Open manual air vent valve.
▶ Close the manual air vent valve as soon as there is sign of water
present. This prevents air being drawn into the system again.
▶ Select Hybrid manager circulating pump speed stage III.
▶ Select the “Function test” menu at the FW200 programming unit, in
order to operate the Hybrid manager circulating pump ( Operating
instructions of the FW200 programming unit).
▶ Let the Hybrid manager circulating pump run for a short time, subject
to system layout and size.
▶ Stop the Hybrid manager circulating pump via the “Function test”
menu.
▶ Open manual air vent valve.
Reinstate the specified system pressure if a large
amount of air escapes from the system.
6 720 646 970-118.1ITL
Fig. 50 Setting the bypass valve
6.2.13 SETTING PARAMETERS FOR OPTIMISING ENERGY USE AND
COSTS OF THE HYBRID SYSTEM
These parameters can be set either via the FW200
programming unit or via the hybrid control module.
These values are transferred and overwritten
respectively. The following explains the setting using the
FW200 programming unit. For information on setting at
the hybrid control module, see chapter 6.2.23.
▶ Close the manual air vent valve.
▶ Repeat steps 3 to 8 until the system has been completely vented.
▶ After venting the system, adjust the pump ( section 6.2.9).
The hybrid system offers a choice of different operating modes:
Operating mode
Environmental factors
Costs
Environment and costs
Changeover threshold
Description
With CO2-optimised mode, the system
control decides when operating the air to
water heat pump or the condensing boiler
results in the greatest CO2 reduction.
With the cost-optimised operation, the
system control decides on the basis of
current energy prices. Rising gas prices
result in longer operation of the air to water
heat pump, whilst rising electricity prices
result in longer operation of the condensing
boiler.
Mixed operation taking environmental
factors and costs into account.
Environmental and financial aspects are
taken into consideration.
With weather-compensated operation, the
condensing boiler starts from a set outside
temperature.
Table 12 Overview of operating modes
38
6 720 803 687 (2012/11)
COMMISSIONING
6.2.14 EXPLANATION OF THE PARAMETERS FOR ENERGY AND
COST OPTIMIZATION OF THE HYBRID SYSTEM (CONTROL
STRATEGY)
These parameters can be set either via the FW 200
weather compensated controller or via the hybrid
control module. These values are transferred and
overwritten respectively. The following section will
describe how to make the settings using the FW 200
weather-compensated controller. For information on
making settings on the hybrid control module, see
chapter 6.2.23.
The hybrid system offers a choice of selecting between different control
strategies:
CONTROL STRATEGY: CHANGEOVER
In weather-compensated mode, the boiler delivers the entire heating
energy below a set outside temperature (dual mode changeover
threshold). The heat pump is not in operation.
At temperatures above the set outside temperature, the heat pump
delivers the entire heating energy where possible. The boiler is
operational when the heat output of the heat pump is not sufficient to
cover the heat load.
CONTROL STRATEGY: CO2 COST MIX
Mixed operation of environmental factors and cost.
The environmental factors and the energy price ratio are considered.
Information under the control strategy: CO2 optimised and control
strategy: Cost-optimised, note on page 41.
CONTROL STRATEGY: CO2 OPTIMISED
The CO2-optimised mode (factory setting) uses environmental factors
to determine when the heat pump or boiler is to be operated to achieve
the highest CO2 reduction.
The environmental factors for fossil fuel and electricity must be set. The
environmental factor (or primary energy factor, PEF) indicates the
fossil-fuel consumption incurred until the energy (electricity/gas) is
available at the corresponding heat appliance. A heat pump uses the
input energy more efficiently than a boiler. However, the electricity used
generally involves a larger amount of fossil-fuel consumption. The
following statement applies to both environmental factors: the lower the
values, the better this is for the environment.
Examples:
Electricity from a gas-fired power station that runs at 45 % efficiency has
an environmental factor of:
• 1/45 % = 1/(45/100) = 1/0,45 = 2,2.
Mix with an efficiency of 38.4% has an environmental factor by:
• 1/38,4 % = 1/(38,4/100) = 1/0,384 = 2,6.
Natural gas, which is supplied with a loss of 12% (88% efficiency), has
an environmental factor of:
• 1/88 % = 1/(88/100) = 1/0,88 = 1,1.
The actual environmental factor for the available energy
(electricity/gas) must be checked with the energy
supplier.
CONTROL STRATEGY: COST OPTIMISED
With the cost-optimised mode, the system control decides on the basis
of current energy prices. Rising gas prices result in longer operation of
the heat pump, whilst rising electricity prices result in longer operation
of the boiler.
The cost ratio is the difference between Gross electricity and gas prices
converted to Nett.
Example:
• Cost of electricity: 24 p/kwH
• Cost of Gas:8 p/kwH
Cost ratio (net):(24/8)x0.902=2.7
This is the ratio which must be inputted to the system controller.
This conversion can be made using table 47 on page 82 of this manual.
The energy:price ratio for electricity and fossil fuel must
be adjusted regularly to the actual price ratios.
The appendix includes the weighting factors for different
electricity and gas prices (chapter 13.1, page 82,
table 47).
6 720 803 687 (2012/11)
39
COMMISSIONING
INSTALLER SETTINGS: HYBRID MENU
The parameters for the selected control strategy of the hybrid system
are set in the room controller or the Hybrid Manager.
Knowledge of the following operations should be conveyed to the user at
hand over:
• Basic principles of operation
• Commissioning
• General settings for the heating system
Operation
Display
Normal view of FW200 when running in auto
12 h
9
▶ Open the flap (by pulling the recessed grip on the front).
15
OUTSIDE TEMPERATURE
MPE
9C
Room temperature
6
23.5 C
3
09:43
Tuesday
24 h
18
21
6720803687-10.1Wo
menu
INSTALLER SETTINGS menu appears
9
12 h
15
INSTALLER SETTINGS
Press for 3
seconds
6
< Back
System configuration
Heating parameters
3
24 h
18
21
6720803687-11.1Wo
Scroll down to the Hybrid entry
9
12 h
15
INSTALLER SETTINGS
Turn
6
System configuration
Heating parameters
Hybrid
3
24 h
18
21
6720803687-12.1Wo
The HYBRID SETTINGS menu appears
Press
9
Menu items:
• Control strategy
– CO2 - optimised
– Cost - optimised
– Changeover temperature
– CO2 :cost mix
• *Energy: Price ratio
• *Environmental factor for fossil fuel (1.1)
• *Environmental factor for electricity (2.6)
12 h
15
HYBRID SETTINGS
6
< Back
Control strategy
CO2-optimised
3
24 h
18
21
6720803687-13.1Wo
• Hydraulic connection (factory default, do not adjust)
• Delay time for boiler heating
• Temperature differential for boiler switch ON
Table 13 Hybrid settings menu
* May or may not be available dependent on control strategy selected
40
6 720 803 687 (2012/11)
COMMISSIONING
6.2.15 CONTROL STRATEGY: OPTION CO2 OPTIMISED AND
CO2 :COST MIX
Operation is dependent on a number of factors all of which must be
discussed and agreed to with the customer.
Operation
Display
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
▶ Select Control strategy from the menu
▶ Confirm the selected menu item
▶ Adjust chosen option, for example, CO2 : optimised (description of options  page 39).
▶ Confirm set value
9
12 h
6
< Back
Control strategy
CO2-optimised
3
24 h
18
21
6720803687-13.1Wo
The controller works with the new settings.
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
▶ Select Control strategy from the menu
▶ Confirm the selected menu item
▶ Adjust chosen option, for example, CO2 :cost mix (description of options  page 39).
▶ Confirm set value
15
HYBRID SETTINGS
9
12 h
15
HYBRID SETTINGS
6
Control strategy
trate
egy
CO2 :cost mix
3
24 h
The controller works with the new settings.
18
21
6720803687-14.1Wo
Table 14 Adjust control strategy
6.2.16 CONTROL STRATEGY: CO2 OPTIMISED (ENVIRONMENTAL
FACTORS)
For this control strategy the parameters, Environmental factor electrical
energy and Environmental factor fossil fuel must be set
Operation
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
If previously adjusted CO2 optimised menu, the controller will move to environmental factors
electricity/gas
▶ Select Energy: price ratio from the menu
▶ Confirm the selected menu item
Display
9
12 h
15
HYBRID SETTINGS
6
Environmental factor
for electricity
18
2.6
3
24 h
21
6720803687-15.1Wo
▶ Required value:
– Setting range: 0.0 to 5.0
– Default environmental factor for fossil fuel: 1.1 (natural gas)
– Default environmental factor for electrical energy: 2.6 (mix)
▶ Confirm set value
The controller works with the new settings.
Table 15 Set environmental factor for electricity and fossil fuel
6 720 803 687 (2012/11)
41
COMMISSIONING
6.2.17 CONTROL STRATEGY: CO2: COST MIX
For this control strategy the Energy: Price ratio and the environmental
factors for both fossil fuel and electricity must be set.
Operation
Display
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
If CO2 :cost mix is selected the controller will then display the following menu items.
9
12 h
15
HYBRID SETTINGS
Energy :price ratio
• Energy: price ratio
• Environmental factor fossil fuel
• Environmental factor electrical energy
6
3.3
3
24 h
18
21
6720803687-16.1Wo
▶ Select and adjust each of the menu items to the require values
▶ Confirm the selected menu item
▶ Required value:
• Energy: price ratio
– Setting range: 0.0 to 19.9
– Default: 3.3
• Environmental factor fossil fuel
– Setting range: 0.0 to 5.0
– Default: 1.1
• Environmental factor electrical energy
– Setting range: 0.0 to 5.0
– Default: 2.6
▶ Confirm set value
The controller works with the new settings.
Table 16 Energy price ratio and environmental factors for fossil fuel and electricity set.
6.2.18 CONTROL STRATEGY: OPTION CHANGEOVER
TEMPERATURE
For this control strategy, the parameter changeover are set correctly.
Operation
Display
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
▶ Select changeover temperature from the menu
▶ Confirm the selected menu item
▶ Required value:
– Setting range: -20° to 20°
– Default: 6°
▶ Confirm set value
9
12 h
15
HYBRID SETTINGS
6
Changeover
temperature
18
6 C
3
24 h
21
6720803687-17.1Wo
The controller works with the new settings.
Table 17 Outdoor temperature for switching threshold set
6.2.19 CONTROL STRATEGY: COST OPTIMISED
6.2.20 CONTROL STRATEGY: HYDRAULIC CONNECTION
For this strategy the energy: Price ratio is required (chapter 13.1,
page 82, table 47).
This determines the function of the pump in the Hybrid Manager.
Pump Function
Description
Serial
(factory default)
The pump provides water circulation around the central heating circuit(s) - used for all hydraulics described in this document
Parallel
The pump does not provide water circulation around the central heating circuit(s). For this type os system each heating circuit
has its own pump. (not possible with this system).
Table 18 Hydraulic connection preset
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6 720 803 687 (2012/11)
COMMISSIONING
6.2.21 CONTROL STRATEGY: DELAY TIME FOR BOILER HEATING
Set time delay.
The delay time of the boiler starting if (requested system flow set
temperature - requested heat pump flow set temperature) is equal to or
less than the set Delta T.
Operation
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
▶ Select Delay time for boiler heating from the menu
▶ Confirm the selected menu item
▶ Required value:
– Setting range: 5 to 120
– Default: 20
▶ Confirm set value
The controller works with the new settings.
Table 19 Delay time for boiler heating set
6.2.22 CONTROL STRATEGY: TEMPERATURE DIFF FOR BOILER
SWITCH ON
The temperature difference between the system flow set point
temperature and the heat pump flow set point temperature.
Set the Delta T.
Operation
▶ HYBRID SETTINGS> Control strategy > ( Table 13)
▶ Select Temperature for boiler switch ON from the menu
▶ Confirm the selected menu item
▶ Required value:
– Setting range: 1K to 99K
– Default: 3K
▶ Confirm set value
The controller works with the new settings.
Table 20 Temperature differential for boiler switch on set
6 720 803 687 (2012/11)
43
COMMISSIONING
6.2.23 SETTING PARAMETERS AT THE HYBRID CONTROL MODULE
5
6
4
3
2
1
6 720 646 970-36.2ITL
Fig. 51 Control module of the hybrid manager
[1]
[2]
[3]
[4]
[5]
[6]
Fuse, 5 AT, ceramic, filled with sand
Spare fuse
Service key connection
Rotary selector: turn to scroll, push to select
Display
Back button
Display [5] shows the current status/display code or parameter list. This
can be recognised by the letters on the right hand side of the display.
• “c”: Parameter list
• “e”: Status/display code
▶ With the “Back button”, change between the current status/display
code and parameter list.
▶ Scroll through the parameter list with the “Rotary selector”.
▶ Push “Rotary selector” to select any parameter.
The selected parameter begins to flash.
▶ Set the required value by turning the “Rotary selector”.
▶ Push “Rotary selector” to confirm and save the new parameter setting.
Display
code
Aa
Description
Setting the hydraulic
system
Unit
—
Standard
setting
0
Ab
Heat source delay
min
20
5 - 120
Ac
Heat source delay
temperature
K
3
1 - 99
A5
External unit control
interval
min
1
1 - 30
Input range
0 = In series
1 = In parallel (not
possible with this
system)
This determines the function of the pump in the Hybrid
Manager.
0= the pump provides water circulation around the central
heating circuit(s) - used for all hydraulics described in this
document,
1= the pump does not provide water circulation around the
central heating circuit(s), for this type of system each
heating circuit has its own pump.
The HTH (high temperature heat source) delay time given
to the boiler if; (The required system flow temperature –
the actual system flow temperature) is equal to or less than
the set Delta T.
The delta temperature used by the delay timer.
The temperature difference between the required system
flow temperature and the actual system flow temperature
that will activate the delay time.
The time interval at which the set point is re-calculated,
based on changing external influences.
Table 21 Parameter list of the hybrid control module
44
6 720 803 687 (2012/11)
COMMISSIONING
Display
code
A7
Standard
setting
10
Input range
7 - 10
—
—
—
—
1
C2
Dual mode changeover °C
threshold
6
1 = Environmental
factors
2 = Costs
3 = Changeover
threshold
4 = Environment and
costs
-20 - 20
C3
Cost weighting
—
electricity price — gas
price.
Environmental factors - kWh/
gas.
kWh
3.3
0 - 19.9
1.1
0-5
C5
Environmental factors - kWh/
electricity.
kWh
2.6
0-5
5b
Return to the standard
setting.
Service mode for
commissioning at an
outside temperature
above 21 °C or below 9 °C.
Factory test mode leave set to “0”,
when set to “1” the
Hybrid controller will
not function for 15
minutes or until the
power has been turned
off and on again.
—
0
—
0
1 = Reset
0 = Off
1 = On
0 = Off
–
0
C0
C1
C4
5c
tt
Description
Unit
Temperature
°C
differential towards the
heat source to prevent
the defrost function
Buffer cylinder is being
used.
Environmentally- and
cost-optimised
operation.
This is the minimum outside air temperature at which the
outdoor unit can be operated in order to avoid going into a
defrost mode. Because a buffer tank must always be
installed in the system, defrost operation can always be
allowed and the outdoor unit can operate between -9 to
+21 °C outside air temperature.
A buffer tank must always be installed in the system.
Function not available in the UK
This determines how the control strategy is optimised
If the "Bi-valent set point" control strategy is selected, this
is the outside air temperature below which the Outdoor
unit has to be switched off
The energy price ratio = cost of electricity,P/kWh / cost of
gas, P/kWh. Use the look up table to find the energy price
ratio based on energy prices (see table 47 on page 82)
Primary energy factor for gas = total primary energy
consumed in the generation and distribution, kWh / 1kWh
of energy used based on gas
Primary energy factor for electricity = total primary energy
consumed in the generation and distribution, kWh / 1kWh
of electrical energy used
This resets all parameters to factory settings
When the Hybrid system is in normal use the outdoor unit
can operate between an outside air temperature of -9 to
+21 °C. During commissioning of the system the outdoor
unit is allowed to operate outside of this range using the
“service” function.
0 = Normal operation
1 = Test mode
Table 22 Parameter list of the hybrid control module
6 720 803 687 (2012/11)
45
OPERATION
6.2.24 COMMISSIONING OF THE AIR TO WATER HEAT PUMP AT
OUTSIDE TEMPERATURES OUTSIDE THE STANDARD
OPERATING RANGE
The air to water heat pump must only be commissioned if the entire
system, including condensing boiler, is connected and ready for
operation. At outside temperatures in excess of 21 °C or below -9 °C, the
air to water heat pump will not start in standard mode, as there is no heat
demand [for the heat pump] in this temperature ranges.
The “Service mode” function of the hybrid control module enables the air
to water heat pump to be commissioned outside the standard operating
temperature range.
Setting “Service mode” at the hybrid control module:
▶ Press “Back” until the parameter list is displayed. (“c” is displayed on
the right hand side of the display).
▶ Turn "Rotary selector" until "5C" is displayed.
▶ Push “Rotary selector” once.
default “0” begins to flash.
▶ Turn the “Rotary selector” to change the value to “1”.
▶ Press the “Rotary selector” to set the value.
“Service mode” is now activated.
“Service mode” resets automatically after 20 minutes.
The air to water heat pump only starts if the return
temperature lies between 20 °C and 50 °C. It may be
necessary for the condensing boiler to initially raise the
return temperature to 20 °C before the air to water heat
pump can start.
6.2.25 INFORMING THE CUSTOMER AND HANDING OVER THE
TECHNICAL DOCUMENTS
▶ Make your customer familiar with the entire heating system and the
operating instructions of the hybrid system.
▶ Turn the system off and then back on to show your customer how the
unit works.
▶ Using the operating instructions, explain to your customer how to act
in case of emergencies. e.g. when there is a fire.
▶ Hand over the technical documents to your customer and together
with your customer complete the separate commissioning report and
sign it.
7
7.2
SYSTEM SHUTDOWN
NOTICE: Frost damage!
When the heating system is switched off, it can freeze up
if there is a frost.
▶ In case of a risk from frost, protect the heating system
against frost damage. To do so, drain the heating
water at the lowest drain point of the heating system.
When draining also ensure that the air vent at the
highest point in the heating system is open.
7.2.1 REGULAR SYSTEM SHUTDOWN
The hybrid manager regulates the hours at which the air
to water heat pump and the condensing boiler operate,
subject to the parameters selected at the FW200
programming unit or at the hybrid control module.
▶ Never interrupt the power supply to the hybrid
manager and the external unit during normal
operation.
Taking the hybrid system out of use:
▶ Ensure any current or pending heat demands are removed. To do this
switch the FW200 room controller to frost protection mode (refer to
FW200 installation manual) and allow the system to stop under it's
own control.
▶ When the system has stopped, wait at least 5 minutes before
interrupting the power supply to the hybrid manager. The hybrid
manager, outdoor unit or the boiler could be damaged if the unit is
switched off before 5 minutes of idle time.
7.2.2 SYSTEM EMERGENCY SHUTDOWN
Only interrupt power via the installation room fuse/
circuit breaker in emergencies.
For any other purpose follow the procedure described
above.
Explain to your customer how to act in case of emergencies, e.g. when
there is a fire or when refrigerant escapes.
▶ Never risk your own life. Your own safety is paramount.
▶ Close the main fuel shut-off valve. Only if safe to do so.
▶ Isolate the heating system from the mains power supply by means of
the heating system emergency stop switch or the appropriate
domestic fuse/circuit breaker. Only if safe to do so.
OPERATION
The hybrid control module regulates the hours at which the air to water
heat pump and the condensing boiler operate, subject to the parameters
selected at the FW200.
▶ Never interrupt the power supply to the hybrid manager and the
external unit during normal operation.
7.1
AUTOMATIC DEFROST FUNCTION
At low temperatures ( 7 °C), ice forms on the external unit.
In the outside temperature range from +7 °C to -9 °C the heat from the
heating system water is briefly used to defrost the external unit
automatically. During defrosting, the heat source continues to be
available for heating the heating water.
The defrost process takes approximately 5 minutes.
46
6 720 803 687 (2012/11)
ENVIRONMENTAL PROTECTION/DISPOSAL
7.3
RESTARTING THE HYBRID SYSTEM AFTER AN
INTERRUPTION IN OPERATION
NOTICE: Damage to the external unit from low
compressor operating temperature!
The Power supply to the external unit must be “Live” for
at least 12 hours before any heating demand. This is to
ensure that the compressor is warmed up sufficiently to
avoid any liquid refrigerant from entering the
compressor. This is particularly important during colder
periods.The 12 hour period also compensates for any
unsettling of the lubricating oil within the compressor
which may have occurred during transportation.If this
12 hour time period cannot be met damage to the
outdoor unit may result.
▶ Never interrupt the power supply during normal
operation.
▶ Ensure that the shut-off valves on the liquid and gaseous refrigerant
pipe work are open.
▶ If not already, interrupt the power supply to the hybrid manager and
the external unit.
▶ Undo the outer case screws at the top and bottom of the hybrid
manager (Fig. 23, page 25) and lift off the case.
▶ Undo fixing screw on the left hand. side of the hybrid control module
( Fig. 40, page 33).
▶ Push out the spring plate and tilt the hybrid control module forward.
▶ Undo two screws and remove the small cover at the back ( Fig. 41,
page 33).
▶ Disconnect the BUS cable at terminals S2/S3 ( Fig. 43, page 33).
8
ENVIRONMENTAL PROTECTION/DISPOSAL
Environmental protection is one of the fundamental company policies of
the Bosch Group.
Quality of products, efficiency and environmental protection are equally
important objectives for us. Laws and requirements aimed at protecting
the environment are strictly adhered to.
To protect the environment we will, subject to economical aspects, use
the best possible technology and materials.
PACKAGING
We participate in the recycling programmes of the countries in which our
products are sold to ensure optimum recycling.
All of our packaging materials are environmentally compatible and can
be recycled.
8.1
DISPOSING OF REFRIGERANT
The appliance is charged with R410A refrigerant.
8.2
APPLIANCE DISPOSAL
Old appliances contain valuable materials that must be recycled.
The appliance is marked with the
symbol.
Appliances with this symbol may not be disposed of with
domestic waste at the end of their service life.
▶ Sort and dispose of packaging materials according to the your local
recycling system.
▶ Have this appliance and any accessories disposed of in accordance
with locally applicable regulations by a licensed contractor.
▶ Never dispose of the appliance in the normal refuse (dust bin).
▶ If the appliances have batteries or rechargeable batteries, dispose of
these separately beforehand according to local regulations.
▶ Dispose of electric and electronic equipment separately according to
local requirements.
9
INSPECTION AND MAINTENANCE
HANDLING REFRIGERANT
Compared to previously used refrigerants, the R410A
refrigerant operates at a pressure that is approx. 1.6times higher.
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant system.
▶ During installation work, use the tools and components specifically
designed for handling R410A refrigerant.
▶ Check for leaks in the refrigerant system. Escaping refrigerant coming
into contact with a naked flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
If refrigerant leaks and touches the skin, it can cause frostbite.
▶ In case of a refrigerant leak, never touch any part of the air to water
heat pump.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your skin or in your
eyes.
9.1
PREPARING FOR INSPECTION AND MAINTENANCE
DANGER: Danger to life through electric shock!
▶ Before carrying out work on electrical components,
isolate them from the power supply (230 V AC) (fuse,
circuit breaker) and secure against unintentional
reconnection.
R410A is a greenhouse gas. It must not enter the environment.
CAUTION: Incorrect disposal is an environmental
hazard!
Escaping refrigerant damages the environment.
▶ Refrigerant may be disposed of by qualified installers
only.
▶ If you wish to discard refrigerant, please contact your local authorities
and ask for the correct method of disposal.
6 720 803 687 (2012/11)
WARNING: Risk of injury and material losses through
incorrect inspection and maintenance.
▶ The hybrid system, the heat source and the
components may only be sited and installed by the
manufacturer or an authorised contractor.
▶ Any service work on the refrigerant circuit must be
carried out by an F-Gas qualified refrigeration
engineer whose employer is F-Gas certified.
To ensure low energy consumption and environmental impact over the
long term, we recommend arranging a maintenance service at a regular
interval of 12 months.
47
INSPECTION AND MAINTENANCE
All inspection and maintenance activities must be carried out in such a
way that personal safety is ensured and damage to property is avoided.
This includes the following:
▶ Shut off the gas supply prior to any work on the heat source.
▶ Isolate the system from the power supply.
For commissioning:
The Power supply to the external unit must be “Live” for
at least 12 hours before starting operation. This is to
ensure that the compressor is warmed up sufficiently to
avoid any liquid refrigerant from entering the
compressor. This is particularly important during colder
periods.The 12 hour period also compensates for any
unsettling of the lubricating oil within the compressor
which may have occurred during transportation.If this
12 hour time period cannot be met damage to the
outdoor unit may result.arranged, severe losses may
occur on the external unit.
▶ Switch the power supply to the external unit 'live' for at
least 12 hours prior to switching the hybrid manager
'live' ( chapter 6.2.1, page 33).
9.2
ENTER INTO AN INSPECTION AND MAINTENANCE
CONTRACT
▶ After replacing components, always check for leaks in the refrigerant
circuit and carry out function tests.
▶ Any O-ring or gasket that appears damaged must be replaced.
▶ When reassembling the hydraulic parts, ensure there is no dust or
debris stuck to the O-rings.
▶ Tighten all connections thoroughly after service to avoid any water
leaks and stop connections from coming loose during operation.
▶ Check all bolts, screws and cables are assembled correctly before
starting the system after any service work has been carried out.
▶ When the work is finished, reset the controls to the original settings.
▶ Never touch the parts of the refrigerant circuit with bare hands during
operation. The refrigerant pipes are very hot or very cold depending
on the condition of the flowing refrigerant.
▶ Never touch any switch or parts of the electrical system with wet
hands. There is risk of electric shock.
▶ Observe the specified processes and delays when starting and
stopping the system. Inappropriate ramping down of the appliance
can result in damage.
▶ After stopping operation, wait at least 5 minutes. Interrupt the power
supply to the hybrid manager and the external unit no sooner.
Damage may occur through escaping water or appliance faults if the
[specified] delays are not observed.
9.3
MAINTENANCE INTERVALS
Step
Heat source
Visual inspection of the hybrid manager
Cleaning filters in the hybrid manager
Visual inspection of external unit
Cleaning the external unit air intake
Maintenance interval
 Maintenance instructions of the heat source
Annual
Annual
Annual
Annual
Description
 Chapter 9.4.1
 Chapter 9.4.3
 Chapter 9.5.2
 Chapter 9.5.3
Table 23 Maintenance and maintenance intervals
If any condition requiring maintenance is identified in the
course of the inspection, that work must be carried out
as required.
48
6 720 803 687 (2012/11)
INSPECTION AND MAINTENANCE
9.4
MAINTAINING THE HYBRID MANAGER
9.4.1 VISUAL INSPECTION OF THE HYBRID MANAGER
▶ With the hybrid manager running, pay attention to any unusual noise.
▶ Check the insulation of the refrigerant lines in the hybrid manager for
damage and repair if required.
▶ Check the hybrid manager and pipe work for possible damage.
▶ If the hybrid manager is located inside a compartment or cupboard,
ensure that the specified minimum service clearances are
maintained.
▶ Check all joints in the entire system and replace any leaky
connections.
▶ Check the fill pressure and possibly top up heating water.
▶ Call up fault displays at the FW200 programming unit ( Operating
instructions of the FW200 programming unit).
▶ Turn the wing screw [1] one ¼ turn anti-clockwise to open the drain
valve.
The pressurised portion of heating water escapes from the hybrid
manager.
9.4.2 DRAINING THE HEATING WATER FROM THE HYBRID
MANAGER
NOTICE: Water damage. Escaping water can damage
the appliance and electronic components.
▶ Prior to starting maintenance or repair work, always
drain the water from the hybrid manager.
1
The hybrid manager contains approximately 1.4l of
water.
▶ Ensure no current or pending heat demands are active and the unit is
in idle.
▶ Remove the outer case from the hybrid manager (Fig. 23, Page 25)
▶ Undo the retainer screw and lower the control panel. (Fig 54, Page
49)
▶ Remove the front upper insulation (Fig. 55, Page 50) being careful
not to misplace the small piece of insulation at the side of the pump.
▶ Close all of the shut off valves on the hybrid manager water
connections (Fig. 52, Page 49).
▶ Remove the drain hose from the front of the lower insulation.
▶ Remove the lower insulation (fig 56, Page 50).
▶ Push the drain hose onto the drain valve (fig 53, Page 49).
1
6 720 646 970-59.3ITL
Fig. 53 Draining water from the hybrid manager
▶ Open one of the threaded joints between the shut-off valve and the
hybrid manager.
This drains the remaining water leaving the hybrid manager free of
water.
9.4.3 CLEANING THE FILTER
NOTICE: Damage through incorrect cleaning.
▶ Care should be taken when removing the filter as to
not to damage this.
Clean the hybrid manager filter annually.
▶ Remove the front cover of the hybrid manager.
▶ Undo fixing screw on the left [1] of the hybrid control module.
▶ Push out the spring plate [2] and tilt the hybrid control module
forward.
2
1
6 720 646 970-95.1ITL
6720646970-37.4Wo
Fig. 52 Closing shut-off valves on the hybrid manager
Fig. 54 Tilting the control unit forward
[1]
[2]
6 720 803 687 (2012/11)
Fixing screw
Spring plate
49
INSPECTION AND MAINTENANCE
▶ Remove top insulation panel.
▶ Remove the filter and clean using fresh water.
6 720 646 970-38.2ITL
1
Fig. 55 Removing the top insulation panel
▶ Remove bottom insulation panel.
6 720 646 970-41.2ITL
Fig. 58 Removing the filter
[1]
Filter cover
▶ Replace the filter and re-assemble the unit following the above in
reverse.
9.4.4 CHECKING THE TEMPERATURE SENSOR
▶ Check the position and condition of the following temperature
sensors:
– Temperature sensor at the condenser inlet [1].
– Temperature sensor at the condenser outlet [3].
– Temperature sensor at the pipe work for liquid refrigerant [2].
6 720 646 970-39.2ITL
Fig. 56 Removing the bottom insulation plate
▶ Turn the filter assembly handle forward into the horizontal position.
3
6720646970-61.3Wo
2
1
Fig. 59 Position of temperature sensors
9.4.5 COMPLETING INSPECTION AND MAINTENANCE
6 720 646 970-40.2ITL
▶ Install casing parts.
▶ Complete and sign the inspection and maintenance report in this
manual ( Chapter 9.6).
Fig. 57 Turning the filter assembly handle forward
▶ Undo and remove filter cover [1].
▶ Remove the filter circlip.
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INSPECTION AND MAINTENANCE
9.5
SERVICING THE EXTERNAL UNIT
DANGER: Risk to life due to escaping refrigerant.
Escaping refrigerant can result in asphyxiation and frost
bite in the case of contact at its exit point.
▶ When refrigerant escapes, never touch any
components of the air to water heat pump and ensure
adequate fresh air ventilation.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your
skin or in your eyes.
NOTICE: Damage from wet conditions!
Ingress of rain, humidity or dust can damage the PCB
inside the external unit.
▶ Never work on the external unit when it is raining.
▶ Following work on the terminal strip check that the
service cover sits firmly.
9.5.1 GENERAL NOTES
The system uses R410Arefrigerant only.
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant system.
▶ During installation work, use the tools and components specifically
provided for handling R410A refrigerant.
▶ Check for leaks in the refrigerant system. Escaping refrigerant coming
into contact with a naked flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
▶ Cut or remove vegetation/foliage surrounding the outdoor unit to at
least the specified clearances around the unit. (Fig. 19, Table 6,
page 23)
▶ Switch the external unit back on as soon as possible, and only if safe
to do so.
▶ Check the refrigerant pipe insulation for damage and repair if
necessary.
NOTICE:
▶ If the power to the external unit has been off for a
period of time greater than 5 minutes, the initial
power up period of 12 hours (Chapter 6.1.1,
Page 32) must be followed before a heat demand is
requested. This is to ensure that the compressor is
warmed up sufficiently to avoid any liquid refrigerant
from entering the compressor. This is particularly
important during colder periods. If this 12 hour time
period cannot be met damage to the outdoor unit may
result.
9.5.4 COMPLETING INSPECTION AND MAINTENANCE
▶ Install casing parts.
▶ Complete and sign the inspection and maintenance report in this
manual ( Chapter 9.6).
9.5.2 VISUAL INSPECTION OF EXTERNAL UNIT
Chapter 10 includes an overview of fault displays.
▶ With the external unit running pay attention to any unusual noise.
▶ Check for signs of corrosion and worn or damaged parts. Pay
particular attention to refrigerant lines, insulation and connections.
▶ Check for loose fasteners.
▶ Check for blocked condensate drain or damaged trace heating cable
in the condensate pan.
▶ Check for contamination and clean or repair, if required.
▶ External unit faults are signalled by LED1 (green) and LED2 (red) on
the PCB in the external unit.
▶ Clean away any obstructions i.e. leaves
9.5.3 CLEANING THE EXTERNAL UNIT AIR INTAKE
NOTICE: Damage through incorrect cleaning.
▶ Carefully brush off dirt by hand or with a soft brush.
▶ Never use high pressure cleaners or water hoses for
cleaning the external unit.
▶ If cleaning by hand wear gloves to protect your hands.
▶ Do not use any cleaning products that are abrasive or
contain acid or chlorine.
▶ Check evaporator fins and air intake at the rear and the left hand side
of the external unit and clean, if required. Clearing any obvious
obstructions (i.e. leaves)
▶ Switch off the external unit at the on/off switch.
▶ Use warm soapy water and a damp cloth if necessary.
▶ The evaporator fins can be rinsed off using a watering can fitted with
a rose/spray head if necessary.
6 720 803 687 (2012/11)
51
INSPECTION AND MAINTENANCE
9.5.5 OVERVIEW OF DIP SWITCHES IN THE EXTERNAL UNIT
The table offers an overview of the DIP switches on the
PCB of the external unit that are relevant for the hybrid
system. These DIP switches are correctly set at the
factory. Their setting does not need to be changed by
customers.
Switch position
Type
DIP switch
Name
SW1
No.
1
Function
Forced defrost operation 1) Start
DIP switch
SW5
2
1
2
Cancelling fault displays
No function
Automatic restart following
power failure
No function
Model selection (together
with SW6)
Model selection 3)
No function
Max. operating frequency in
heating mode
Max. operating frequency in
cooling mode
Step control
3—5
6
DIP switch
SW72)
1
2
3
4
5
DIP switch
SW8
DIP switch
SW9
DIP switch
SW6
SW5
Rotary
selector
SWP
6
1
2
3
Defrost function
No function
No function
Response to fault display
E8 "communication fault
between hybrid manager
and outdoor unit"
1
2
3—4
1—5
6
7—8
No function
Function switch
No function
Model selection
Model selection
Model selection
Pumping back
ON
Delete
—
Starts automatically
—
Always leave switched on.
( SW5-6)
Demand function
—
Max. operating frequency
(heating) x 0.8
Max. operating frequency
(cooling) x 0.8
16 A
Changeover
timing
Normal
With the
compressor
operating in
heating mode
Normal
Anytime
—
—
Does not start automatically Anytime
OFF
—
—
—
—
Low-noise function
—
Normal
Anytime
—
Anytime
Normal
Anytime
25 A
When power
supply is
switched on
For high relative humidity Normal
Anytime
—
—
—
—
—
—
Fault indication E8
Failure E8 "communication —
"communication fault
fault between hybrid
between hybrid manager
manager and outdoor unit"
and outdoor unit" is
is displayed on the outdoor
ignored. The controller
unit. Reset the fault
waits until both devices are message is possible by
turned on and the
switching off and on the
communication can be
outdoor unit.
established
—
—
—
Applicable
Normal
Anytime
—
—
—
—
Normal
—
Normal
—
—
—
Normal
—
Start
Normal
Only when
external unit unit
is switched off
Table 24 Assignment of DIP switches in the external unit
1) Manual start of defrost mode — Forced defrost mode for maintenance and test mode
2) Reduce operating frequency. In standard mode, DIP switches SW7-3to SW7-6 must not be changed; they only serve maintenance and test purposes. Incorrect functions and
system failure can be the result of incorrect settings.
3) DIP switches SW7-1and SW7-2 can be used to set the staged switching. These switch settings are only effective during stage switching.
For DIP switch positions see Fig. 80
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INSPECTION AND MAINTENANCE
9.6
INSPECTION AND MAINTENANCE REPORTS
The inspection and maintenance reports are also designed as templates
and may be photocopied.
▶ Sign and date the completed inspection work.
GENERAL INFORMATION
System data
Customer
Installation location
Table 25 Inspection and service reports - general details
Action
General condition of appliances checked
Filter in the hybrid manager cleaned
Air intake of the external unit cleaned
Visual inspection and function tests carried out on the system
Refrigerant and water pipes checked for the following:
Confirmation / values
 Yes
 Yes
 Yes
 Yes
 Yes
• Tightness
• Corrosion
• Signs of ageing
• Insulation and external damage.
Hybrid manager checked for the following:
 Yes
• External damage and blockages
• Flow switch function
• Temperature sensor fittings and function
• Correct adjustment of the hybrid control module.
• Correct adjustment of FW200 programmable controller
External unit checked for the following:
 Yes
•
•
•
•
•
•
External damage and blockages
Cable insulation
Fittings of external unit
Correct installation of ribbon heater (option)
Secure fixing of the external unit on its foundations
Excessive oscillations or vibrations emanating from the external unit or pipe
work
• External damage on the external unit including evaporator, fan and casing.
Outdoor temperature sensor inspected for damage
Correct adjustment of the by-pass valve
Final checks of the inspection tasks carried out
Casing parts installed
Customer instructed and given technical documentation
Correct commissioning by the installing contractor
 Yes
 Yes
 Yes
 Yes
 Yes
Signature: __________________
Signature of customer
Signature: __________________
Table 26 Inspection and maintenance report
6 720 803 687 (2012/11)
53
FAULTS
10
FAULTS
10.1 FAULTS THAT ARE NOT DISPLAYED
10.1.1 GENERAL FAULTS
Appliance faults
Flow noises
Remedy
▶ Set the pump rate or pump parameter field correctly and match it to the maximum
output.
▶ Vent the hybrid manager ( chapter 6.2.11, page 38).
▶ Set the pump rate or pump parameter field correctly and match it to the maximum
output.
Heat-up takes too long
Table 27 Faults that are not shown on the display
10.1.2 EXTERNAL UNIT FAULTS — FREQUENTLY ASKED QUESTIONS
FAQ
The external unit does not work at all.
Steps to be taken
External unit cannot be returned into Wait at least 3 minutes before trying to restart.
operation after an idle period.
The external unit is protected by an automatic safety device. For 3
minutes after the compressor stops it cannot be restarted.
Noise like escaping gas can be heard. This is not a fault. This noise can be heard when the refrigerant enters
the system.
A cracking sound can be heard.
This is not a fault. This noise can be heard when the components in
the external unit contract or expand as a result of temperature
changes.
A humming sound can be heard.
This is not a fault. This noise can be heard when the external unit
starts.
A ticking noise can be heard.
This is not a fault. This noise can be heard when the fan regulates the
air volume to achieve the optimum operating mode.
Noise like water can be heard.
This is not a fault. This noise can be heard when the refrigerant flows
into the external unit.
Water or humidity escapes from the external unit.
It is quite normal that condensate forms at certain parts. The
condensate should be caught and drained off by a condensate drain
or condensate pan.
The external unit develops too much
noise.
Table 28 FAQ
54
6 720 803 687 (2012/11)
FAULTS
10.2 DISPLAYED FAULTS
OVERVIEW OF INTERNAL HYBRID FAULT INDICATORS LOCATIONS
DANGER: Danger to life through electric shock!
▶ Prior to working on the electrical section, isolate the
power supply (230 V AC) (fuse for the external unit,
hybrid manager and heat source) and secure against
unintentional reconnection.
1
WARNING: Risk of injury and damage through incorrect
troubleshooting.
▶ Have troubleshooting carried out only by a competent
person.
▶ Permit only qualified refrigeration engineers (F gas
qualification), whose company holds a valid F gas
certificate) to work on the refrigerant circuit.
2
External unit faults are signalled by LEDs on the PCB in the external unit
Fig. 64, page 60.
Hybrid manager faults are displayed on the hybrid control module
Fig. 61, page 56 and Fig. 63, page 59.
Hybrid system faults are displayed on the FW200 programming unit
Fig 62, page 57.
▶ Identify the fault and have it rectified.
▶ Hold down the Back button on the hybrid control module for
5 seconds to restart the hybrid control module.
3
4
6720803687-34.1Wo
Fig. 60 Overview internal hybrid components fault indicators locations
[1]
[2]
[3]
[4]
Error indicator (hybrid manager)
Display (hybrid manager)
FW200 display
Error indicator (hybrid manager)
10.2.1 FAULT DISPLAYS ON THE HYBRID CONTROL MODULE
Error states are indicated as operating codes by the hybrid control
module.
▶ Display the current error code with Back button [7].
The current operating code is displayed on the right hand side of the
large display [6] (Fig. 61, page 56).
For an explanation of error codes, see table 35,
from page 59.
6 720 803 687 (2012/11)
55
FAULTS
1
2
3
4
Position
1
5
Symbol
Explanation
ON/OFF
(hybrid control module)
Communication with the
programming unit
2
3
Fault
4
Demand to the air to water heat
pump
Boiler communication and boiler
demand
Display
Back button
Rotary selector
Service key
5
6
7
8
9
—
—
—
—
Table 29 Key to Fig. 61
6
Indication of operating states by LED signals on the hybrid control
module:
Status
LED1
Pump pre-run

Preheating

(only air to water heat
pump)
Operation (heat source

and air to water heat
pump)
Only air to water heat

pump operation
Fault air to water heat

pump
Fault, communication

with the heat source
Boiler only mode

Heat source fault

Fault, communication

with the programming
unit
7
8
9
6 720 646 970-46.3ITL
Fig. 61 Display on the external and internal hybrid control module
LED2


LED3


LED4


LED5























m






Table 30 Operating indicators on the hybrid control module
( = LED illuminates,  = LED does not illuminate,  = LED
flashes)
10.2.2 CHECK TEMPERATURE SENSOR OF HYBRID MANAGER
T (°C)
-30
-20
-10
0
10
R ( )
83190
45623
26005
15346
9353
T (°C)
20
30
40
50
60
R ( )
5870
3787
2504
1693
1169
T (°C)
70
80
90
100
—
R ( )
823.4
591.3
431.3
319.6
T (°C)
30
40
50
60
70
R ( )
4364
3024
2138
1538
1126
T (°C)
80
90
100
110
120
R ( )
836.9
631.2
482.5
373.5
292.5
Table 31 Heating water temperature sensor
T (°C)
-20
-10
0
10
20
R ( )
39080
23850
15000
9699
6431
Table 32 Refrigerant temperature sensor
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FAULTS
10.2.3 FAULTS OF THE FW200 PROGRAMMING UNIT
Operating and fault indications of the hybrid manager are displayed on
the FW200 programming unit and on the hybrid manager control
module.
The following information given in the service instructions of the FW200
programming unit is prerequisite.
• Principles of operation
• Troubleshooting
INDICATORS ON THE HYBRID SYSTEM
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Fault
No.1)
LED
fault
Indicators on the hybrid manager are displayed exclusively on the
internal display of the hybrid control module.
5H
Cause
Relay test was activated
Heating and DHW mode in parallel
–
Hybrid system runs in heating and DHW
mode simultaneously (parallel)
Pump pre-run phase in internal unit
–
Heat pump pre-heat phase
–
Heat pump in operation
–
Hybrid manager pump: post-run phase –
Heat pump in defrost mode
–
Only EMS heat appliance in operation –
Heat pump blocked: more than 4 starts –
per hour
Differential temperature outside the
Indicator for low system flow rate. Check
permissible range
filter for blockages
Heat pump operates with the boiler
–
blocked
Heat pump in service mode
The heat pump is running in service mode
(100% heating output)
Remedy (by contractor)
–
–
–
–
–
–
–
–
–
and clean if necessary
–
Switch over to normal mode on completion of
service work. Service mode terminates
automatically after 15 minutes
Table 33 Hybrid manager indicators (internal unit)
1) This fault number is displayed on the hybrid control module.
9
Faults are displayed directly at user level ( Fig. 62).
< Back
If the heat pump or the boiler is the cause of the fault, this is shown on
the controller display with a corresponding message. The fault number
displayed will contain at least one letter, e.g. Fault d1 or Fault CC (
Tab. 34).
Fault A8
If the cause of the fault (the heat pump or the boiler) cannot be identified
directly from the information in the fault display:
▶ Check the display on the boiler:
– If the boiler is displaying a fault ( technical documentation for the
boiler), the heat pump is not faulty.)
– If the boiler is not displaying a fault ( technical documentation for
the FW200), before proceeding to check the heat pump.)
See the technical documentation for the FW 200 weather-compensated
controller or the relevant technical documentation for more detailed
information about faults caused by other system components.
6 720 803 687 (2012/11)
12 h
15
1
2
Boiler
BUS communication
3
fault
3
4
24 h
21
6720803687-38.1Wo
10.2.4 FAULT DISPLAY ON THE FW 200 WEATHER-COMPENSATED
CONTROLLER AT USER LEVEL
Fig. 62 Fault display
[1]
[2]
[3]
[4]
Fault number
BUS device that detected the fault and reported it to all
controllers
Description of fault
Code or additional information about fault
The faults are shown in descending order based on
severity.
If a fault has several causes, the next lower-priority fault
is shown after troubleshooting. Tab. 34 lists the faults
sorted by fault no. and code.
57
FAULTS
LED
fault
Fault
No.1)
Status2)
FW 200
ON
A8
B
ON
A8
B
ON
CC
B
ON
d1
L
ON
d1
L
OFF
B
ON
E2
L
ON
E2
L
ON
EF
L
ON
HP
L
ON
HP
L
On
EF
L
Steps
Description
No communication with
EMS heat appliance
Cause
Communication cannot be established between
the hybrid control module (internal unit) and the
boiler
Check the contacts, cables and connections
between the hybrid control module and the
boiler.
No communication with Check the contacts, cables and connections
system controller
between the hybrid control module and the
system controller
Check the system controller
Outside temperature
Use the voltage and pressure drop values to
sensor faulty
check the sensor
Check the sensor connection
Return temp. sensor
Temperature sensor short circuit - Condenser
contact faulty
inlet
Return temp. sensor
Temperature sensor open circuit - Condenser
contact faulty
inlet
Flow or return
Hybrid manager flow or return temperature
temperature outside the outside the permissible range
permissible range
Flow temperature sensor Temperature sensor short circuit - Condenser
faulty
outlet
Flow temperature sensor Temperature sensor open circuit - Condenser
faulty
outlet
System fault appliance
Check contact between the appliance PCB and
PCB / basic controller
the mounting base along with the base controller
and the base plate, and check all other plug-in
connections
Hybrid system: Component fault in hybrid control
module
External unit / water flow Fault affecting the heat pump / water flow
rate fault
interrupted
Heat pump flow switch
fault during self-test
(Display blank)
Check flow switch
EEPROM error in the hybrid control module
Remedy (by contractor)
Check the EMS connection between the hybrid
control module (internal unit) and the boiler.
Replace damaged cables and contacts, replace
the appliance PCB if necessary.
Repair or replace the bus cable
Replace the system controller if necessary
If the sensor is faulty, replace it
Reconnect the sensor in the correct way
Check and possibly replace contacts, wiring or
temperature sensor
Check and possibly replace contacts, wiring or
temperature sensor
Initially the boiler heats the water before the heat
pump starts.
Check and possibly replace contacts, wiring or
temperature sensor
Check and possibly replace contacts, wiring or
temperature sensor
Rectify contact problem, replace appliance PCB
or boiler identification module if necessary
Check the hybrid control module and replace if
necessary
Check LED signals on hybrid control module.
Check throughput of heat pump.
Check filter and replace if necessary.
Check and possibly replace the flow switch.
Check system
Replace flow switch if necessary
Check and possibly replace hybrid control
module
Table 34 Hybrid manager (internal unit) and weather-compensated controller fault displays
1) This fault number is displayed on the hybrid control module and on the FW200.
2) Status: locking (L); blocking (B)
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FAULTS
10.2.5 FAULT DISPLAY ON THE REAR OF THE HYBRID MANAGER
Indication of operating states by LED signals at the interface to the
external unit:
Status
Standard operation
Fault, communication with the
hybrid manager
LED2
LED3




Table 35 Operating code at the interface to the external unit
( = LED illuminates,  = LED does not illuminate,  = LED
flashes)
1
2
6 720 646 970-63.1ITL
Fig. 63 LED Position at the interface to the external unit
[1]
[2]
LED3
LED2
6 720 803 687 (2012/11)
59
FAULTS
10.2.6 EXTERNAL UNIT FAULTS
EXTERNAL UNIT LED DISPLAY
DANGER: Risk to life through accumulated charges.
With the power supply switched off, electronic
components may still hold an electric charge that is
maintained after switching off and isolation from the
power supply. Contact with such components can result
in severe or fatal injuries.
2
1
▶ Once the green LED on the PCB of the external unit
has extinguished, wait at least a further 10 minutes.
External unit faults are signalled by LED1 (green) and
LED2 (red) on the PCB in the external unit.
6720803687-08.1Wo
Fig. 64 LED position at the external unit
LED
2
1
Colour
Red
Green
Description
Voltage
Requirement
Table 36 LED colour assignment
When a fault display is shown, observe the following:
• When a fault occurs, the fault code will be signalled by two LEDs
flashing on the external unit.
• The fault code will be indicated (P1, E6 etc.) if troubleshooting is
carried out using the service tool.
▶ For description, cause and remedy of a fault, see the following table.
Operating state
If the external unit is switched on
If the external unit stops
If the compressor in the external unit
heats up
If the external unit operates
Indication on the PCB of the external unit
LED green
LED red






Service tool (7-716-161-051)
Code
Display indication
- <---> Alternately flashing display
00, ...
Operating mode
08, ...

C5, H7, ...

Table 37 LED display of the external unit ( = LED illuminates,  = LED does not illuminate)
The cause, remedy or checking of the codes in table 38
are explained in detail in the following table 39. Use the
service tool (7-716-161-051) for a more detailed
diagnosis.
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FAULTS
Fault
Indication on the PCB of the external unit
Description
Code
LED (green) flashes
LED (red) flashes
1x
2x
High pressure switch 63H
F5
2x
1x
Control cable wiring fault between internal and external unit — phases reversed, no contact
Eb
Time limit exceeded for start of operation.
EC
2x
Signalling error between the internal and external units (reception error) recognised by the E6
internal unit.
Signalling error between the internal and external units (transmission error) recognised by
the internal unit.
E7
Signalling error between the internal and external units (reception error) recognised by the —
external unit.
3x
Signalling error between the internal and external units (transmission error) recognised by
the external unit.
—
4x
Unknown fault.
EF
5x
Communication error / serial operating signal.
Ed
No function.
A0-A8
1x
Excessively high temperature at the hot gas temperature sensor TH4 and at the compressor U2
temperature sensor TH32.
Superheating not
U7
possible through hot gas
temperature being too
low.
2x
High pressure too high (63H has responded).
U1
3x
Speed fault at the fan motor.
U8
Overheating protection (overload protection, fan motor fault).
Ud
Safety device to protect against compressor overcurrent: compressor blocked.
UF
Current sensor fault
UH
Compressor overcurrent — safety device has responded
UP
Power module in inverter circuit faulty
U6
4x
5x
Open / short circuit on hot gas temperature sensor TH4 or compressor temperature sensor U3
TH32
Open / short circuit on external unit temperature sensors (TH3, TH32, TH33, TH6, TH7 and U4
TH8)
6x
Temperature fault on inverter radiator panel
U5
7x
Inverter over or undercurrent and fault in the serial PCB communication
U9
Table 38 LED fault display on external unit
6 720 803 687 (2012/11)
61
FAULTS
Code
Description
No indication —
Cause
Possible solution / check
No supply voltage applied to terminal block TB1.
▶ Check mains isolator
• The mains isolator upstream is switched off
▶ Check and correct connection, wiring, phases and contacts
at TB1.
• Poor connection/contacts or terminal loose
• Open phase (L, L1 or N).
No voltage applied to power supply input on power ▶ Check and correct connection, wiring, phases and contacts
circuit board.
at TB1.
• Poor connection/contacts or terminal loose
• Power circuit board open phase
▶ Check connection, wiring, phases and contacts on the
plugs on the power circuit board and correct if required.
• Disconnected plug (R or S).
The PCB receives no power.
▶ Check and repair contact at the CNDC plug on the PCB.
• Poor connection/contacts or terminal loose at
the CNDC plug, or plug pulled.
▶ Check and repair contacts LD1 and LD2 at the power
circuit board and repair if required.
Poor connection/contacts or terminal loose at the ▶ Check and repair contacts at the DCL transformer.
DCL or ACL transformer.
▶ “LO” and “NO” on the interference suppressor board, R and
S on the power circuit board.
Power circuit board faulty.
▶ Replace faulty power circuit board.
PCB at the external unit faulty.
▶ Replace faulty PCB if the steps above have not removed the
problems.
Time limit exceeded for start of operation
▶ Check whether the electromagnetic compatibility of
terminals, power supply or the PCB is being compromised.
▶ Switch the power supply off and on to restart the system.
F5
High pressure switch 63H
Poor connection/contacts or terminal loose at the ▶ Check and repair contact at the 63H plug on the PCB.
63H plug on the PCB of the external unit or plug
pulled.
If no contact is signalled by high
pressure switch 63H for more than
3 minutes after applying the supply Poor connection/contacts or terminal loose on the ▶ Check and repair contacts and cable on the 63H.
voltage, fault display “F5” is shown. 63H.
63L tripped by faulty components.
▶ Test electrical components.
▶ Replace faulty components.
Circuit board faulty.
EA
Control cables between internal
and external unit faulty — too
many internal units connected
▶ Replace faulty PCB.
Poor connection/contacts or terminal loose at the ▶ Check and repair contacts, cables and control cable
control cable connections or wiring error.
connections for all appliances.
Control cables incorrectly sized.
▶ Check and correct control cable cross-section and cable
lengths: max. length 30 m.
A test circuit recognises the number
▶ Check and correct polarity of control cables S1, S2 and S3.
of connected internal units
automatically. Fault message “EA” Transmitter/receiver circuit on external unit faulty. ▶ Switch supply voltage off and on and check if the fault
occurs again.
will be displayed if a control cable
Transmitter/receiver circuit on internal unit faulty.
has a fault for longer than 4 minutes
▶ Replace PCBs of the internal or external units concerned if
after a power supply has gone 'live'.
the fault recurs. Check the control cables.
Noise in the control cables.
Eb
Control cable wiring fault
Poor or detached contacts at the control cable
between internal and external
connections or wiring faults.
unit — phases reversed, no contact Control cables incorrectly sized.
A test circuit sets the number of
connected internal units
automatically. If the control cables
are faulty for more than 4 minutes
after connecting the power supply,
the fault display is “Eb” is shown.
▶ Check the control cables and eliminate cause of noise.
▶ Check and repair contacts, cables and control cable
connections for all appliances.
▶ Check and correct control cable cross-section and cable
lengths: max. length 30 m.
▶ Check and correct polarity of control cables S1, S2 and S3.
Transmitter/receiver circuit on external unit faulty. ▶ Switch supply voltage off and on and check if the fault
occurs again.
Transmitter/receiver circuit on internal unit faulty.
▶ Replace PCBs of the internal or external units concerned if
the fault recurs.
▶ Check the control cables.
Noise in the control cables.
▶ Check the control cables and eliminate cause of noise.
Power circuit board on external unit faulty.
▶ Switch supply voltage off and on and check if the fault
occurs again.
▶ Replace PCBs of the internal or external units concerned if
the fault recurs. Check the control cables.
Table 39 Fault indications, external unit
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FAULTS
Code
Description
Cause
EC
Time limit exceeded for start of
operation
Poor connection/contacts or terminal loose at the ▶ Check and repair contacts, cables and control cable
control cable connections or wiring error.
connections for all appliances.
U1
Possible solution / check
Control cables incorrectly sized.
The system has not initialised
correctly after 4 minutes have
elapsed since start of operation. The
fault display “EC” is shown.
Noise in the control cables.
▶ Check and correct control cable cross-section and cable
lengths: max. length 30 m (internal unit - external unit) or
max. 30 m (internal unit - internal unit).
High pressure too high (63H
tripped)
Faulty ball valve (not completely open).
▶ Check if all ball valves are completely open.
Clogged or broken refrigerant line.
▶ Check pipe work and eliminate fault.
The high pressure switch 63H
tripped because the high pressure
rose above 4.14 MPa during
compressor operation.
Blocked fan motor on external unit.
▶ Check external unit and replace or repair faulty
components.
Faulty functioning of external unit fan motor.
▶ Check and correct polarity of control cables S1, S2 and S3.
▶ Check the control cables and eliminate cause of noise.
Air short circuit on external unit.
Contamination on the external unit's heat
exchanger.
Reduced air flow rate due to faulty temperature
measurement on outside temperature sensor
(measurement too low).
▶ Check outside temperature sensor including connections
and cable, and replace if required.
Faulty contact on plug 63H on the PCB of the
external unit.
▶ Switch the supply voltage off and on again.
Faulty connection of 63H.
▶ Check whether fault code “F5” is then displayed.
If yes, see “Possible solution / check” for “F5”.
Faulty external unit PCB
Faulty linear expansion valve (LEV).
▶ Check linear expansion valve (LEV).
Faulty fan operation.
▶ Replace faulty external unit PCB.
Table 39 Fault indications, external unit
6 720 803 687 (2012/11)
63
FAULTS
Code
Description
Cause
Possible solution / check
U2
(1) Hot gas temperature too high
Temperature increase in compressor due to
insufficient refrigerant.
▶ Check inlet overheating.
Faulty ball valve (not completely open).
▶ Check if all ball valves are completely open.
Faulty temperature sensor TH4, TH5.
▶ Switch the supply voltage off and on again.
Faulty external unit PCB
▶ Check if fault code “U3” is shown.
If yes, see “Possible solution / check” for “U3”.
Faulty linear expansion valve (LEV).
▶ Check linear expansion valve (LEV).
On the hot gas temperature sensor
TH4, over 125 °C is measured or
over 110 °C is measured for a period
of 5 minutes. In defrost mode, on
TH5 over 40 °C and on the hot gas
temperature sensor TH4 over
110 °C is measured.
U2
(2) Insufficient refrigerant
Temperature increase in compressor due to
Faulty if hot gas overheating rises in insufficient refrigerant.
cooling mode TH4 to TH5 or in
heating mode TH4-TH6 as follows. Faulty ball valve (not completely open).
Faulty temperature sensor TH4, TH5.TH6
All conditions must be met for
10 minutes (at least for 6 minutes
after compressor start).
Conditions 1:
▶ Check for leaks on the refrigerant lines and seal, if
required, then refill the system.
▶ Check inlet overheating.
▶ Check for leaks on the refrigerant lines and seal, if
required, then refill the system.
▶ Check if all ball valves are completely open.
▶ Switch the supply voltage off and on again.
Faulty external unit PCB
▶ Check if fault code “U3” is shown.
If yes, see “Possible solution / check” for “U3”.
Faulty linear expansion valve (LEV).
▶ Check linear expansion valve (LEV).
• Compressor is running in heating
mode
• Hot gas overheating is 70 °C or
higher
• TH6 > TH7 - 5K
• TH5 < 35 °C.
Conditions 2:
• Compressor is running
• Hot gas overheating is 80 °C or
higher in cooling mode
• Hot gas overheating is 90 °C or
higher in heating mode
• Condensation temperature
TH6 < -40 °C in cooling mode.
Table 39 Fault indications, external unit
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FAULTS
Code
Description
Cause
U2
(3) Compressor temperature too
high
See U2 (2), but replace temperature sensors TH4, See U2 (2)
5 and 6 with temperature sensor TH32
Possible solution / check
Faulty if temperature sensor TH32
exceeds 125 °C or 110 °C for
5 minutes.
U3
Open / short circuit on hot gas
temperature sensor TH4 or
compressor temperature sensor
TH32
Poor connection/contacts or terminal loose at the ▶ Check and repair plug and contacts of the temperature
cables and plugs on the PCB.
sensor of the PCB.
▶ Check temperature sensor connecting leads for cable
breaks or the like.
Faulty temperature sensor.
If the hot gas temperature sensor
TH4 cannot capture any
temperature ( 3 °C) or indicates an Faulty external unit PCB
infinite resistance (> 217 °C) whilst
the compressor is working, fault
display “U3” will be shown.
▶ Check temperature sensors TH4 and TH32 with service
tool (7-716-161-051).
▶ Replace faulty external unit PCB.
This function is not available in the
following situations:
• In the first 5 to 10 minutes after
the compressor starts
• At the end of the defrost mode
• When defrost mode is running
U4
Open / short circuit on external
unit temperature sensors (TH3,
TH32, TH33, TH6, TH7 and TH8)
Poor or loose contacts at the cables and plugs on
the PCB.
If a temperature sensor does not
Faulty temperature sensor.
measure any resistance (0 ) or
measures an infinitely large
resistance (8 ) when the
Faulty external unit PCB
compressor is running, fault display
“U4” is shown.
U5
▶ Check and repair plug and contacts of the temperature
sensor of the PCB.
▶ Check temperature sensor connecting leads for cable
breaks or the like.
▶ Check temperature sensors TH32 with service tool (7-716161-051).
▶ Replace faulty external unit PCB.
Temperature fault on inverter
radiator panel
Blocked fan motor.
▶ Check fan motor.
If the temperature at TH8 (heat
deflector) reaches or exceeds the
specified value, fault display “U5”
will be shown.
Ventilation and extract air apertures dirty or
blocked.
▶ Check and clean ventilation and extract air apertures.
Rising outside temperature.
▶ Check if causes other than the weather are responsible for
the temperature increase.
Upper temperature limit 46 °C. Switch the supply voltage
off and on again.
Fan motor fault.
• RP35 84 °C.
▶ Within 30 minutes, check if fault display “U5” is shown
again.
If fault display “U4” is shown instead of “U5”, follow the
descriptions provided for “U4”.
Faulty temperature sensor.
▶ Check resistance of temperature sensor TH8 (should be
between 39 and 105 k ).
▶ Replace faulty temperature sensor.
U6
Power module in inverter circuit
faulty
Faulty input circuits (supply voltage) on external
unit power circuit board.
▶ Replace faulty external unit power circuit board.
Faulty drive circuitry of external unit fan.
▶ Replace faulty PCB.
Faulty ball valve (not completely open).
▶ Check and completely open all ball valves.
Reduced supply voltage.
▶ Check supply voltage (mains side).
Poor connection/contacts or terminal loose on
compressor supply cable or phases swapped.
▶ Check and correct compressor wiring.
If overcurrent is detected in the
inverter circuit (“UF” or “UP” is
shown), the inverter circuit is faulty Faulty power circuit board.
and fault display “U6” is shown.
Faulty compressor.
▶ Replace faulty external unit power circuit board.
▶ Replace external unit.
Table 39 Fault indications, external unit
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65
FAULTS
Code
Description
Cause
U7
Overheating faulty due to
insufficient hot gas temperature
Poor connection/contacts or terminal loose at the ▶ Check and repair contacts, cables and connections for
cables and plugs of hot gas temperature sensor
temperature sensor TH4.
TH4 on the PCB.
Fault display “U7” is shown when
superheating of -15 °C lasted longer
than 3 minutes, with the LEV almost
closed (lowest pulse rate) and
10 minutes have passed since the
compressor started.
U8
Faulty fixing of hot gas temperature sensor TH4.
Possible solution / check
▶ Secure temperature sensor TH4 correctly.
Poor connection/contacts or terminal loose at the ▶ Check connections, contacts and terminals on the LEV
cables and plugs on the LEV drive.
drive and repair or replace if required.
Poor or loose contacts at the LEV cables on the
PCB.
▶ Check and repair contacts, cables and connections of the
LEV cables.
Faulty linear expansion valve (LEV).
▶ Check linear expansion valve (LEV) and replace if required.
Fan motor speed fault
Fan motor faulty.
▶ Check fan motor and replace faulty motor.
The speed on the fan motor is
determined to be faulty if
Circuit board faulty.
▶ Check PCB and replace, if faulty.
• a maximum of only 100 rpm is
measured for a period of 15
seconds at an outside
temperature of 20 °C or above
• less than 50 rpm or more than
1500 rpm is measured for a
period of one minute
U9
Inverter over or undercurrent and Increase in supply voltage (mains side).
fault in the serial PCB
Wiring detached from compressor.
communication
▶ Check supply voltage on mains side.
▶ Check and correct wiring on compressor and power circuit
board.
• Sudden drop in bus voltage
below 200 V
Faulty PFC module on external unit power circuit
board.
▶ Replace PCB.
• Increase in bus voltage above
420 V
Faulty ACT module.
▶ Replace ACT module.
CNAF plug detached or disconnected.
▶ Check and correct fit and wiring of CNAF.
• External unit power consumption
drops to only 0.1 A at an
operating frequency of 40 Hz or a
compressor current of 6.0 A.
Faulty 52C circuit on PCB.
▶ Replace PCB.
CN5 plug on power circuit board detached or
disconnected.
▶ Check and correct fit and wiring of CN5.
CN2 plug on power circuit board detached or
disconnected.
▶ Check and correct fit and wiring of CN2.
Table 39 Fault indications, external unit
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FAULTS
Code
Description
Ud
Overheating protection (overload Temperature sensor TH3 faulty.
protection, fan motor fault)
UF
UH
Cause
Possible solution / check
▶ Check temperature sensor, replace faulty temperature
sensor.
If the line temperature (TH3)
exceeds 70 °C, fault display “Ud” is
shown.
Circuit board faulty.
▶ Check PCB, replace if faulty.
Protective equipment against
compressor overcurrent:
compressor blocked
Shut-off valves closed.
▶ Open shut-off valves.
Reduced supply voltage (mains side).
▶ Check supply voltage on mains side.
Plug detached or disconnected, cable break,
If overcurrent is measured in the DC- phases reversed.
Compressor faulty.
BUS or in the compressor 30
seconds after the compressor start, Power circuit board faulty.
fault display “UF” is shown.
DIP switches set incorrectly.
▶ Check and correct wiring on compressor and power circuit
board and replace faulty components.
Current sensor fault
▶ Check and correct compressor wiring.
Fault display “UH” is shown if the
voltage sensor captures a voltage
between -1.5 V and +1.5 V. This
fault is ignored in test mode.
Poor connection/contacts or terminal loose on
compressor supply cables.
▶ Replace external unit.
▶ Replace power circuit board.
▶ Check settings on the external unit PCB.
Faulty circuit (current sensor) on the external unit ▶ Replace faulty external unit power circuit board.
power circuit board.
Table 39 Fault indications, external unit
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FAULTS
Code
Description
Cause
Possible solution / check
UL
Low pressure fault
Shut-off valves closed.
▶ Open shut-off valves.
Fault “UL” is shown if the following
conditions are met for 3 minutes in
10 following compressor start in
heating mode.
Insufficient refrigerant or leak.
▶ Check amount of refrigerant and additional charge.
Faulty linear expansion valve (LEV).
▶ Check linear expansion valve (LEV).
• TH7 - TH3  4 K
Refrigerant circuit blocked by foreign objects or
contaminated by water.
▶ Vacuum out refrigerant.
• TH5 - Room temperature  2 K.
▶ Check pipe system for leaks and eliminate any leaks.
▶ Check increased heat through superheating.
This means:
▶ Subject the refrigerant circuit to the vacuum for at least one
hour to remove the water.
▶ Refill with clean refrigerant.
TH3: liquid line temperature in the
external unit in °C.
TH5: evaporator/condenser
temperature in the internal unit in
°C.
TH7: outside temperature in °C.
UP
Compressor overcurrent — safety Ball valve closed in operation.
device has responded
Reduced supply voltage (mains side).
If the protective equipment is
tripped 30 seconds after the
compressor start due to DC
overcurrent, fault display “UP” is
shown.
E6
Signalling error between the
internal and external units
(reception error)
The internal unit cannot receive any
signals within 6 minutes from start
or after 3 minutes in operation. Fault
display “E6” is shown.
▶ Check and completely open all ball valves.
▶ Check supply voltage (mains side).
Poor connection/contacts or terminal loose on
compressor supply cables.
▶ Check and correct compressor wiring.
Fan faulty.
▶ Check fan.
Air short circuit on internal or external unit.
▶ Eliminate air short circuit.
Faulty input circuit (voltage) on the external unit
PCB.
▶ Replace faulty PCB.
Faulty compressor.
▶ Check compressor and replace external unit if required.
Inverter board faulty.
▶ Replace faulty PCB.
DIP switch settings incorrect on the external unit
PCB.
▶ Check DIP switches and correct settings.
Poor connection/contacts or terminal loose on the ▶ Check and correct wiring for all control cables between
control cables, cable break.
internal and external unit.
Faulty transmitter/receiver circuit on external unit ▶ Check whether the fault display E6 will still be issued after a
PCB.
restart.
Faulty transmitter/receiver circuit on internal unit ▶ Check PCBs of the internal and external units and replace if
PCB.
faulty.
Noise in the control cables.
Fan motor faulty.
▶ Isolate the external unit from the power supply, and undo
terminal CNF1 on the fan motor. Restart external unit.
– Replace fan motor if the fault message is no longer
displayed.
– Replace the external unit PCB if the fault message
continues to be displayed.
Faulty starting current limiter on the external unit
PCB.
E7
Signalling error between the
internal and external units
(transmission error)
Faulty transmitter/receiver circuit on internal unit ▶ Check whether the fault display E7 will still be issued after a
PCB.
restart.
Noise in the voltage system.
Fault display “E7” will be shown if it Noise in the control cables.
has been recognised 30 times that
“1” is being received constantly,
however the internal unit sends “0”.
E8
▶ Check starting current limiter and replace if required.
▶ Check PCBs of the internal and external units and replace if
faulty.
Communication error between
internal and external unit —
reception error
Poor connection/contacts or terminal loose on the ▶ Check and correct wiring for all control cables between
control cables, cable break.
internal and external unit.
If the external unit cannot receive
any signals within 3 minutes, fault
display “E8” is shown.
Faulty transmitter/receiver circuit on internal unit. ▶ Check if fault display “E8” is shown again after the restart.
Faulty transmitter/receiver circuit on external unit. ▶ Switch the supply voltage off and on again (reset system).
Noise in the control cables.
▶ Check PCBs of the internal and external units and replace if
faulty.
Table 39 Fault indications, external unit
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FAULTS
Code
Description
Cause
E9
Communication error between
internal and external unit —
transmission error
Poor connection/contacts or terminal loose on the ▶ Check and correct wiring for all control cables between
control cables, cable break.
internal and external unit.
Possible solution / check
Faulty transmitter/receiver circuit on external unit. ▶ Switch the supply voltage off and on again (reset system).
Noise in the voltage system.
Fault display “E9” is shown in the
following cases (on the external unit Noise in the control cables.
only).
▶ Check if fault display “E9” is shown again after the restart.
▶ Check PCBs of the internal and external units and replace if
faulty.
• Failed 30 times to receive a “0”
when a “1” is expected.
• The external unit cannot transmit
a signal within 3 minutes because
the lines are busy.
EF
Unknown fault
Noise in the control cables between internal and
An unknown fault was received and external unit.
fault display “EF” is shown.
The external unit is not a power inverter model.
Ed
▶ Switch the supply voltage off and on again (reset system).
▶ Check if fault display “EF” is shown again after the restart.
▶ Check PCBs of the internal and external units and replace if
faulty.
▶ Use a power inverter external unit.
Communication error — serial
operating signal
Poor connection/contacts or terminal loose at the ▶ Check wiring and plug CN2 and CN4 between the PCBs and
terminal of the connection cables between the
correct if required.
PCB and the power circuit board of the external
There has been a fault in the
communication between the power unit (CN2). Cable break.
Poor connection/contacts or terminal loose at the
circuit board and the PCB in the
terminal of the connection cables between the
external unit.
PCB and the power circuit board of the external
unit (CN4). Cable break.
Faulty power circuit board communication circuit. ▶ Check power circuit board.
Faulty PCB communication circuit.
P8
▶ Check PCB.
Pipe work temperature TH
Slow increase of temperature differential between ▶ Check internal unit temperature sensor using the system
monitor (external unit PCB or “PAC-SK52ST” diagnostic
Ten seconds after the compressor room temperature and pipe work temperature
(line
or
heat
exchanger)
in
the
internal
unit
due
to:
device).
start, the “Hot Adjust” heat-up mode
▶
TH1
= 7 K  (equals 18 °C)
is already completed, fault display • Refrigerant shortage
“P8” is shown if the heating
• Temperature sensor in the internal unit
temperature is out of range for at
detached from its holder.
least 20 minutes.
• Refrigerant circuit fault.
To identify these faults takes 27
minutes. This check is not
implemented in defrost mode. The
check restarts after the defrost
mode has terminated. Permissible
temperature range in heating mode:
3 K  pipe work temperature of the
internal unit (TH5) — 18 °C (TH1).
Capturing error at temperature sensor TH5.
Refrigerant lines reversed.
▶ Check pipe work and wiring.
Control lines reversed.
4-way valve faulty.
▶ Check functioning of 4-way valve.
Table 39 Fault indications, external unit
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FAULTS
10.2.7 CHECK COMPONENTS
Component
Temperature sensor:
•
•
•
•
•
•
•
Liquid line TH3
Hot gas TH4
Evaporator TH6
Fresh air TH7
Heat deflector TH8
Compressor shell TH32
Outdoor pipes TH33
4-way valve
Compressor motor MC
Points and criteria to check
▶ Check the temperature sensor resistance (sensor
temperature range from 10 °C to 30 °C).
TH3, TH6, TH7, TH33:
Illustration
—
• Standard: 4.3 k  – 9.6 k 
• Faulty: circuit open / short circuit
TH4, TH32:
• Standard: 160 k  – 410 k 
• Faulty: circuit open / short circuit
TH8:
• Standard: 93 k  – 105 k 
• Faulty: circuit open / short circuit
▶ Check resistance across terminals (20 °C ambient
temperature).
• Standard: 2350  170 
• Faulty: circuit open / short circuit
▶ Check winding resistance across terminals (20 °C winding
temperature).
• U-V: 0.64 
• U-W: 0.64 
• V-W: 0.64 
• Faulty: circuit open / short circuit
—
U
V
W
Linear expansion valve (LEV-A / LEV- ▶ Pull plug and check winding resistance across contacts (20 °C
B)
ambient temperature).
• Red-white: 46  4
• Red-orange: 46  4
• Brown-yellow: 46  4
• Brown-blue: 46  4
• Faulty: circuit open / short circuit
M
Red
1
2
Blue
3
Orange
4
Yellow 5
White
6
Brown
Table 40 Check components
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FAULTS
10.2.8 DC FAN MOTORS/CHECK PCB
Start
Check fuse:
Checking fuse F5 on the PCB
Fuse blown?
Yes
Replace PCB and fan motor.
No
Check wiring and contacts at motor plugs CNF1, CNF2
Contacts loose?
Plug pulled?
Yes
Correct wiring.
No
Check supply voltage:
Check voltage across the following contacts on the external unit PCB:
• TEST POINT [1]: VDC (across 1(+) and 4(–) at the plug): VDC DC 250 — 330 V
• TEST POINT [2]: VCC (across 5(+) and 4(–) at the plug): VCC DC 15 V
Is the voltage as it should be?
Yes
Correct wiring.
No
Yes
Replace PCB.
Check fan motor function.
Yes
End
Faulty
Replace PCB
Check fan motor function
Yes
End
Faulty
Replace fan motor.
Table 41 DC fan motors/check PCB
6 720 803 687 (2012/11)
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FAULTS
10.2.9 CHECK EXTERNAL UNIT TEMPERATURE SENSOR
Temperature sensor
TH3, TH33
TH4
TH6
TH7
TH8
TH32
Designation
Liquid line temperature sensor
Hot gas temperature sensor
Evaporator/temperature sensor
Outdoor air temperature sensor
Heat deflector temperature sensor
Compressor casing temperature sensor
Reference curve
A
C
A
A
B
C
Table 42 Temperature sensor overview
Reference curve A
Temperature sensor R0 = 15 k   3 % constant
B = 3480 k   2 %
50

1
1 
Rt = 15 exp  3480  --------------------- – ----------- 
 273 + t 273


(kΩ )
40
Value range
0 °C
10 °C
20 °C
25 °C
30 °C
40 °C
15 k 
9.6 k 
6.3 k 
5.2 k 
4.3 k 
3.0 k 
30
20
10
0
-20 -10 0 10 20 30 40 50
(°C)
Table 43 Reference curve A
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FAULTS
Reference curve B
Temperature sensor R50 = 17 k   2 % constant
B = 4150 k   2 %
(kΩ )

1
1 
Rt = 17 exp  4150  --------------------- – ----------- 
 273 + t 323


Value range
0 °C
25 °C
50 °C
70 °C
90 °C
180 k 
50 k 
17 k 
8k 
4k 
(°C)
Table 44 Reference curve B
6 720 803 687 (2012/11)
73
FAULTS
Reference curve C
Temperature sensor R120 = 7.465 k   2 % constant
B = 4057 k   2 %
500

1
1 
Rt = 7 465 exp  4057  --------------------- – ----------- 
 273 + t 393


400
250 k 
160 k 
104 k 
70 k 
48 k 
34 k 
24 k 
17.5 k 
13.0 k 
9.8 k 
300
(kΩ )
Value range
20 °C
30 °C
40 °C
50 °C
60 °C
70 °C
80 °C
90 °C
100 °C
110 °C
200
100
0
25
50
75
(°C)
100
120
Table 45 Reference curve C
10.2.10CHECK LINEAR EXPANSION VALVES (LEV)
9
DC12V
1
LEV
2
3
6
M
2
1
5
4
8
4
3
4
3
4
3
2
5
2
1
6
1
7
6 720 646 970-116.1ITL
Fig. 65 Wiring diagram, linear expansion valves LE
[1]
[2]
[3]
[4]
[5]
74
Red
Brown
Blue
Orange
Yellow
[6]
[7]
[8]
[9]
White
Drive circuit
CNLEV plug
External unit PCB
6 720 803 687 (2012/11)
FAULTS
CONTROL SIGNAL SWITCHING PATTERN
The extent to which the linear expansion valve opens
depends on the number of pulses that are supplied by
the PCB drive circuit to the LEV drive.
Output (phase)
1
2
3
4
1
ON
OFF
OFF
OFF
2
ON
ON
OFF
OFF
3
OFF
ON
OFF
OFF
4
OFF
ON
ON
OFF
Signal pattern
5
OFF
OFF
ON
OFF
6
OFF
OFF
ON
ON
7
OFF
OFF
OFF
ON
8
ON
OFF
OFF
ON
Table 46 Control signal switching pattern
The switching pattern of the control signals changes as follows, if the
valve:
• should open: 1  2  3  4  5  6  7  8  1
• should close: 8  7  6  5  4  3  2  1  8
All outputs 1 to 4 will be switched off if the current valve position is to
be maintained.
In the case of an error in the output signals, for example if an output is
missing or signals are sent permanently, the valve drive cannot open or
close evenly. Movement will be jerky and vibrations can be heard and
felt.
1
4
FUNCTION AND OPERATION
3
On switching the power supply on, an opening signal of 700 pulses will
be sent to ensure that the valve is in position [5]. The signal remains
active for approximately 20 seconds. The LEV normally operates free of
noise and vibrations. Increased noise can be heard from the valve if it is
blocked or is being moved from [6] to [5].
5
No noise can be heard if the drive is faulty or has a wiring fault.
6
To ascertain whether the valve is making any noise, hold
the tip of a screwdriver against the valve body and listen
with your ear against the screwdriver handle.
x
2
6 720 646 970-117.1ITL
Fig. 66 LEV function diagram
[x]
[1]
[2]
[3]
[4]
[5]
[6]
6 720 803 687 (2012/11)
Complete closing (200 pulses)
Level of opening of the LEV (top open, bottom closed)
LEV pulses (fully open at 500 pulses)
Valve closes
Valve opens
Position 1
Position 2
75
REPLACE COMPONENTS
11
▶ Undo two screws and remove the small cover for the internal
connections at the back.
REPLACE COMPONENTS
11.1 PUMPING REFRIGERANT BACK INTO THE EXTERNAL
UNIT
DANGER: Risk to life due to escaping refrigerant!
Escaping refrigerant can result in asphyxiation and frost
bite in the case of contact at its exit point.
▶ When refrigerant escapes, never touch any
components of the air to water heat pump and ensure
adequate fresh air ventilation.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your
skin or in your eyes.
6720803687-35.1Wo
NOTICE: Damage from wet conditions!
Ingress of rain, humidity or dust can damage the PCB
inside the external unit.
Fig. 68 Removing the small cover
▶ Undo two screws and remove the larger cover at the back.
▶ Never work on the external unit when it is raining.
▶ Following work on the terminal strip check that the
service cover sits firmly.
GENERAL NOTES
In this system, only R410A refrigerant is used.
▶ Only qualified and authorised refrigeration engineers may work on to
the refrigerant system.
▶ During installation work, use the tools and components specifically
designed for handling R410A refrigerant.
▶ Ensure the tightness of the refrigerant system. Escaping refrigerant
coming into contact with a naked flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
PREPARING THE HYBRID MANAGER
6720646970-42.4Wo
The refrigerant must be pumped back into the refrigerant collector in the
external unit, when working on the refrigerant circuit and also when
replacing the external unit or the hybrid manager.
▶ Ensure there are no current or pending heat demands and the system
has been idle for at least 5 minuets.
▶ Disconnect the power supply of the external unit (circuit breaker) and
the hybrid manager (switch off).
▶ Undo screws at the top and bottom of the appliance.
▶ Remove casing.
▶ Undo fixing screw on the left [1] of the hybrid control module.
▶ Push out the spring plate [2] and tilt the hybrid control module
forward.
Fig. 69 Removing the cover
▶ The DIP switches are now accessible.
▶ Put DIP switches in “Pump back refrigerant” position.
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
2
SW 1
X
X
X
X
X
X
X
X
OFF
ON
SW 2
X
X
X
X
X
X
X
X
OFF
X
X
X
X
X
X
X
X
OFF
ON
SW 3
ON
6720646970-60.4Wo
1
Fig. 70 DIP switches in “Pump back refrigerant” position
6720646970-37.4Wo
Fig. 67 Tilting the control unit forward
[1]
[2]
76
Fixing screw
Spring plate
6 720 803 687 (2012/11)
REPLACE COMPONENTS
PREPARING THE EXTERNAL UNIT
Only start refrigerant collection after the external unit
has not operated for a period of 5 minutes or longer.
▶ Connect a pressure gauge to the service port [3] (Fig. 32, page 29) to
check the pressure in the refrigerant system whilst pumping the
refrigerant back to the external unit.
▶ Remove caps from the shut-off valve on the pipe work for liquid and
gaseous refrigerant ( Fig. 32, page 29).
▶ Turn Allen screw clockwise to close the shut-off valve on the pipe work
for liquid refrigerant.
▶ Remove the three top cover fixing screws, and lift the top cover away.
If the external unit is switched off before pump down is complete, or if
the refrigerant was not successfully pumped back into the external unit
(compressor does not run for 2 to 3 minutes):
▶ Completely open shut-off valve on the pipe work for gaseous
refrigerant.
▶ Wait 3 minutes.
▶ Pump back the refrigerant again.
If the external unit stopped normally:
▶ Disconnect the power supply of the external unit (circuit breaker) and
the hybrid manager (switch off).
▶ Replace the top cover on the external unit and secure with the four
screws.
▶ Return the DIP switches at the interface to the external unit in the
hybrid manager into their standard setting.
SW 1
1
2
3
4
5
6
7
8
X
X
X
X
X
X
X
X
OFF
ON
SW 2
1
2
3
4
5
6
7
8
X
X
X
X
X
X
X
X
OFF
SW 3
1
2
3
4
5
6
7
8
ON
X
X
X
X
X
X
X
X
OFF
ON
6 720 646 970-45.2ITL
Fig. 72 DIP switches in normal position
6 720 646 970-44.2ITL
Fig. 71 Lifting the external unit top cover away
PUMPING REFRIGERANT BACK INTO THE EXTERNAL UNIT
WARNING: Risk of injury due to moving parts!
When the “SWP” button is pressed the fan will
immediately start to run.
▶ Ensure no loose clothing or tools can fall into or get
caught in the fan.
▶ Keep hands clear.
▶ Switch on the power supply to the external unit and the hybrid
manager.
CAUTION: Risk of injury from poisonous gases!
Escaping refrigerant coming into contact with a naked
flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
▶ Fit the covers onto the control unit enclosure and control module, flip
up the control unit enclosure and fit the cover of the hybrid manager.
▶ Fit caps to the shut-off valves on the pipe work for liquid and gaseous
refrigerant.
11.2 REMOVING THE CASING FROM THE EXTERNAL UNIT
To remove the service cover, top, front and rear parts, proceed as
follows:
▶ Remove 3 screws (M 10x4) from the top section of casing [1].
▶ Remove top section [1].
▶ Remove screw (M 10x4) from service cover [3].
▶ Pull service cover [3] forward and remove.
▶ Remove 9 screws (M 10x4) from the front section of cover [4].
▶ Remove front section [4].
▶ Remove 7 screws (M 10x4) from the rear section of casing [2].
▶ Remove rear section [2].
1
▶ Press “SWP” on the external unit PCB.
The fan and compressor will both start running and begin pumping
refrigerant back into the external unit.
LED1 and LED2 on the external unit PCB light up.
The refrigerant is pumped back to the external unit via the pipe work
for gaseous refrigerant.
2
As soon as the unit automatically stops (about 2 to 3 minutes after start):
▶ Quickly close the gas shut-off valve.
This prevents refrigerant from flowing back into the refrigerant
circuit.
To ensure that the refrigerant has been completely pumped down:
▶ Check the pressure in the refrigerant circuit at the pressure gauge on
the service port.
The pressure must be 0 Pa (0 mbar (a)).
6 720 803 687 (2012/11)
3
4
6 720 646 970-123.1ITL
Fig. 73 Removing casing from the external unit
77
REPLACE COMPONENTS
11.3 REPLACING THE FAN MOTOR
CAUTION: Damage through electrostatic discharge!
▶ Never touch a PCB without an earthed wristband.
▶ Removing the top section of the casing
▶ Remove front casing panel.
▶ Remove nut (M 6, left-hand thread).
▶ Remove impeller.
1
3
▶ Pull plug CNF1 off the PCB inside the electronics casing ( Fig. 81,
page 87).
▶ Undo fixing for connecting cable on motor bracket.
▶ Remove 4 screws (M 4 x 18) and remove the fan motor.
4
5
6
7
8
9
10
11
12
13
17
14
16
15
6 720 646 970-122.3ITL
Fig. 74 Replacing the fan motor
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[14]
[15]
78
Fan motor
Evaporator
Enclosure for electric components
Temperature sensor TH8
Power circuit board
Controller circuit board
Noise circuit board
Temperature sensor TH7
Temperature sensor TH6
Temperature sensor TH4
Temperature sensor TH32
Linear expansion valve LEV-B
Linear expansion valve LEV-A
Temperature sensor TH3
Temperature sensor TH33
Nut
Impeller
6 720 803 687 (2012/11)
REPLACE COMPONENTS
11.4 REPLACING THE PCB HOUSING
CAUTION: Damage through electrostatic discharge!
▶ Never touch a PCB if you are not wearing an earthed
wristband.
▶ Remove service cover ( Fig. 73, page 77).
▶ Remove top casing panel.
▶ Remove front casing panel.
▶ Pull BUS cable plug to the hybrid manager at the terminal strip (TB1).
▶ Pull the following plugs at the PCB ( Fig. 74, page 78 and Fig. 81,
page 87).
– Fan motor (CNF1)
– Linear expansion valves (LEV-A and LEV-B)
– Temperature sensors TH3, TH33 on the pipe work for liquid
refrigerant
– Temperature sensor TH32 on compressor casing
– Temperature sensor TH4 for hot gas
– Temperature sensor TH6 for evaporator (2-phase cable) and
outside temperature sensor TH7
– High pressure switch (63H)
– 4-way valve
▶ Remove disconnected cables from electronics casing.
▶ Pull compressor plug.
▶ Remove 3 fixing screws from electronics casing.
▶ Remove electronics casing by lifting it clear.
11.5 REPLACING PCBS
CAUTION: Equipment damage due to electrostatic
discharge!
▶ Never touch a PCB if you are not wearing an earthed
wristband.
Temperature sensors TH6 and TH7 form a single unit and
must, therefore, be replaced together ( “Replacing
outside temperature sensor TH7”).
▶ Remove service cover ( Fig. 73, page 77).
▶ Remove top casing panel.
▶ Remove front casing panel.
▶ Remove back casing panel.
▶ Pull plug of temperature sensor TH3 (white), TH6 (red) or TH33
(yellow) off the PCB inside the electronics casing ( Fig. 81,
page 87).
▶ Undo fixing of connecting cables on back of electronics casing.
▶ Take temperature sensor TH3, TH33 or TH6 out of its holder.
11.7 REPLACING OUTSIDE TEMPERATURE SENSOR TH7
CAUTION: Equipment damage due to electrostatic
discharge!
▶ Never touch a PCB if you are not wearing an earthed
wristband.
Temperature sensors TH6 and TH7 are a single unit and
must be replaced at the same time ( “Removing
outside temperature sensor TH6”).
▶ Remove service cover ( Fig. 73, page 77).
▶ Remove top casing panel.
▶ Pull plug of temperature sensor TH7 (red) off the PCB inside the
electronics casing ( Fig. 81, page 87).
▶ Undo fixing of connecting cable on back of electronics casing.
▶ Take temperature sensor TH7 out of its holder.
11.8 REPLACING TEMPERATURE SENSORS TH4 AND TH32
11.5.1 NOISE CIRCUIT BOARD
▶ Undo all connectors.
▶ Undo suppression filter ( Fig. 74, page 78) from the plastic
retainers and remove.
CAUTION: Equipment damage due to electrostatic
discharge!
▶ Never touch a PCB if you are not wearing an earthed
wristband.
11.5.2 POWER CIRCUIT BOARD
REMOVAL
▶ Undo all connectors.
▶ Undo 3 screws from the passive cooler.
▶ Undo inverter PCB ( Fig. 74, page 78) from the plastic retainers
and remove.
INSTALLATION
▶ Apply conducting paste thinly and evenly.
▶ Insert inverter PCB and tighten the 3 screws of the passive cooler.
▶ Remove service cover ( Fig. 73, page 77).
▶ Remove top casing panel.
▶ Remove front casing panel.
▶ Remove back casing panel.
▶ Removing electronics casing
▶ Remove temperature sensor TH4 from the retainer ( Fig. 81,
page 87).
▶ Take temperature sensor TH32 on compressor casing out of its
holder.
11.5.3 CONTROLLER CIRCUIT BOARD
▶ Undo all connectors.
▶ Undo PCB ( Fig. 74, page 78) from the plastic retainers and
remove.
11.6 REPLACING FAULTY TEMPERATURE SENSORS TH3,
TH6 OR TH33
CAUTION: Damage through electrostatic discharge!
▶ Never touch a PCB without an earthed wristband.
6 720 803 687 (2012/11)
79
FILLING THE REFRIGERANT CIRCUIT
11.9 FITTING AND REMOVING THE LINEAR EXPANSION
VALVE
The linear expansion valve LEV ( Fig. 74, Page 78) comprises two
components, i.e. the valve body and the electric drive. The electric drive
can be replaced separately from the valve body.
When fitting or removing the electric drive always ensure
that you hold the valve body tightly to prevent damage to
the refrigerant lines.
Never wind the control and power cables around the
valve body.
▶ Route cables free of stress and connect the terminal with the PCB.
11.10 REMOVING THE TRANSFORMER (ACL)
The transformer is in the Outdoor Unit and attached to
the rear of the electrical parts box.
REMOVING THE ELECTRIC DRIVE
Never use force to remove the electric drive. If the
electric drive is difficult to remove, move it lightly to and
fro until it can be removed easily.
▶ Hold valve body [2] tightly and remove the electric drive [1] upwards.
At the Outdoor Unit (ODU):
▶ Remove the service panel.
▶ Remove the top panel.
▶ Remove the front panel.
▶ Remove the back panel.
▶ Remove the four reactor fixing screws and remove the reactor.
Replace the items in the reverse order.
1
12
FILLING THE REFRIGERANT CIRCUIT
CAUTION: Damage from unsuitable refrigerant!
▶ Fill the system exclusively with R410A refrigerant.
▶ Never mix R410A refrigerant with other refrigerants.
Never add lubricant to the system.
▶ Never use a charging cylinder. If a charging cylinder is
used, the composition of the refrigerant will change
and the efficiency will be lowered.
2
6 720 646 970-120.1ITL
The refrigerant circuit is pre-charged with 2.5 kg of R410A refrigerant.
This amount is adequate for a pipe run of between 0.5 and 30 m in both
directions. Refrigerant only needs to be topped up if refrigerant was
discharged during maintenance work.
Fig. 75 Removing the electric drive
▶ Undo the drive terminal on the PCB.
FITTING THE ELECTRIC DRIVE
▶ Hold valve body [2] tightly and fit the electric drive on top so that the
guide tabs [1] click into the recesses in the valve body.
Observe the following information if the refrigerant circuit needs to be
refilled:
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant circuit.
▶ Use only the specified refrigerant (R410A) to charge the refrigerant
lines.
▶ Never allow air to remain in the lines.
▶ After completing service, charge the refrigerant circuit with specified
amount of refrigerant.
▶ Never use a charging cylinder. If a charging cylinder is used, the
composition of the refrigerant will change and the efficiency will be
lowered.
1
2
6 720 646 970-121.1ITL
Fig. 76 Fitting the electric drive
▶ Ensure that the electric drive is correctly locked in place and sits
tightly.
80
6 720 803 687 (2012/11)
FILLING THE REFRIGERANT CIRCUIT
12.1 EVACUATING AND DRYING THE REFRIGERANT
CIRCUIT
12.3 OPENING THE SHUT-OFF VALVES OF THE EXTERNAL
UNIT
WARNING: Personal injury from rupturing refrigerant
pipes!
Air bubbles trapped in lines can result in pressure peaks
which can result in pipes bursting.
NOTICE: Damage from closed shut-off valves!
Compressor and control valves will suffer damage if the
shut-off valves remain shut during the operation of the
external unit.
▶ Never allow air to remain in the lines.
▶ Open shut-off valves for liquid and gaseous
refrigerant.
The external unit is pre-charged with 2.5 kg of R410A
refrigerant. Commissioning does not require topping up
with refrigerant.
Remove air from the refrigerant circuit by a the correct vacuum drying
process. In the case of inadequate vacuum drying air and water vapours
remain in the refrigerant circuit. These may result in an abnormal rise in
positive pressure or in a drop in negative pressure as well as to a loss of
quality in the refrigerant oil through moisture. This may have a negative
effect on the compressor service life.
12.2 VACUUM DRYING
Open the shut-off valves on the liquid and gaseous refrigerant pipe work:
▶ Remove valve cap [2].
▶ With an Allen key (4 mm) turn the valve head [3] anti-clockwise as far
as it will go (approx. 10 turns).
Stop turning once the end-stop has been reached.
▶ Turn valve head [3] ½ one turn back (clockwise).
▶ Attach valve cap [2]. When doing this ensure that the inside remains
undamaged as this serves as a sealing face.
▶ Tighten valve cap [2] with a torque of between 20 and 25 Nm.
Failure to replace and tighten the caps may result in refrigerant
leakage.
Never use the refrigerant from the external unit to purge
air from the refrigerant lines.
▶ Connect a high performance vacuum pump to the Schrader valve
( Fig. 77, [1]).
▶ With the vacuum pump build a pressure of 101 kPa(g) (5 Torr).
▶ Maintain this pressure for at least 1 hour.
– During this time check the vacuum pressure constantly at the
pressure gauge.
– If the vacuum pump is only used for a short time, it may not be
possible to bring about a complete evacuation. In addition it may
result in moisture remaining in the pipe work.
▶ Switch off the vacuum pump and close the distributor valve.
▶ Observe the pressure for 15 minutes.
Should the pressure rise during that time (vacuum reduces), evacuate
and repeat the final test.
▶ Separate the vacuum pump from the refrigerant circuit.
6 720 803 687 (2012/11)
1
5
2
3
4
6 720 646 970-28.2ITL
Fig. 77 Shut-off valve on the liquid refrigerant pipe work
[1]
[2]
[3]
[4]
[5]
Schrader valve
Valve cap
Valve head
Pipe work to building
Pipe work to the external unit
81
APPENDIX
13
APPENDIX
13.1 COST WEIGHTING ELECTRICITY PRICE — GAS PRICE
Gas price [P/kWh]
30.0-30.9
29.0-29.9
28.0-28.9
27.0-27.9
26.0-26.9
25.0-25.9
24.0-24.9
23.0-23.9
22.0-22.9
21.0-21.9
20.0-20.9
19.0-19.9
18.0-18.9
17.0-17.9
16.0-16.9
15.0-15.9
14.0-14.9
13.0-13.9
12.0-12.9
11.0-11.9
10.0-10.9
Electricity price [P/kWh]
3.0-3.9
2.8
3.0
3.3
3.5
3.8
4.1
4.3
4.6
4.9
5.1
5.4
5.7
5.9
6.2
6.4
6.7
7.7
7.2
7.5
7.8
8.8
4.0-4.9
2.1
2.3
2.5
2.7
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
5.2
5.4
5.6
5.8
6.0
6.2
5.0-5.9
1.7
1.9
2.1
2.2
2.4
2.6
2.7
2.9
3.1
3.2
3.4
3.6
3.7
3.9
4.1
4.2
4.4
4.6
4.7
4.9
5.1
6.0-6.9
1.5
1.6
1.8
1.9
2.0
2.2
2.3
2.5
2.6
2.7
2.9
3.0
3.2
3.3
3.4
3.6
3.7
3.9
4.0
4.2
4.3
7.0-7.9
1.3
1.4
1.5
1.6
1.8
1.9
2.0
2.1
2.3
2.4
2.5
2.6
2.7
2.9
3.0
3.1
3.2
3.3
3.5
3.6
3.7
8.0-8.9
1.1
1.2
1.3
1.4
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3.0
3.1
3.2
3.3
9.0-9.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.4
2.5
2.6
2.7
2.8
2.9
10.0-109
0.9
0.9
1.1
1.2
1.3
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.6
11.0-11.9
0.8
0.9
1.0
1.1
1.1
1.2
1.3
1.4
1.5
1.5
1.6
1.7
1.8
1.9
1.9
2.0
2.1
2.2
2.3
2.3
2.4
12.0-12.9
0.8
0.8
0.9
1.0
1.1
1.1
1.2
1.3
1.3
1.4
1.3
1.6
1.6
1.7
1.8
1.9
1.9
2.0
2.1
2.2
2.2
13.0-13.9
0.7
0.8
0.8
0.9
1.0
1.0
1.1
1.2
1.2
1.3
1.2
1.4
1.5
1.6
1.7
1.7
1.8
1.9
1.9
2.0
2.1
14.0-14.9
0.7
0.7
0.8
0.8
0.9
1.0
1.0
1.1
1.2
1.2
1.2
1.3
1.4
1.5
1.5
1.6
1.7
1.7
1.8
1.9
1.9
15.0-15.9
0.6
0.7
0.7
0.8
0.9
0.9
1,
1.0
1.1
1.1
1.1
1.3
1.3
1.4
1.4
1.5
1.6
1.6
1.7
1.7
1.8
16.0-16.9
0.6
0.6
0.7
0.7
0.8
0.9
0.9
1.0
1.0
1.1
1.0
1.2
1.2
1.3
1.4
1.4
1.5
1.5
1.6
1.6
1.7
Table 47 Example: Cost weighting electricity price — gas price
82
6 720 803 687 (2012/11)
APPENDIX
13.2 SYSTEM WIRING (HEATRONIC III BOILER CONNECTIONS) WITH A BYPASS VALVE AND ONE UNMIXED HEATING CIRCUIT
2
230V AC
230V
R2
R1
≤ 24V
R3
TB
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NTC1NTC2NTC3 BUS
1 2 3 4 5 6 B B
M
~AC
A
B
C
D
E
F
G
H
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3
4
3
4
1
3
TB61
230V AC
S1 S2 S3 PE N L
TB6
230V AC
PE N L
PE 4 8 9 10 11 12
15 16
5
4
~AC
6
~AC
~AC
*
LR LS NS N
FR FS NP LP
L
7
B
B
4
2
1
A
F
FSK
ZP
T
20
15
16
17
11
SF
8
14
19
A
VF
~AC
18
13
12
10
9
B
C
6720803687-06.1Wo
T2
Fig. 78 Wiring example
[A]
[B]
[C]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
4-core wiring
2-core wiring
3-core wiring
Outside temperature sensor (fitted on north facing wall)
ISM1
Interconnecting cables between hybrid manager and air to water
heat pump
Connections, air to water heat pump
Connections, hybrid manager
Temperature sensor (condenser outlet)
Temperature sensor (condenser inlet)
Heating circuit
Automatic by-pass valve
Buffer tank
FW200 control unit
Expansion vessel
WHM hybrid manager (internal unit)
Boiler
Heatronic III boiler connections
DHW cylinder
Cylinder pump
External unit
Temperature sensor, refrigerant
PSS1 solar circuit pump
6 720 803 687 (2012/11)
83
APPENDIX
13.3 SYSTEM WIRING (CUS BOILER CONNECTIONS) WITH A BYPASS VALVE AND ONE UNMIXED HEATING CIRCUIT
2
230V AC
230V
R1
R2
≤ 24V
R3
TB
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NTC1NTC2NTC3 BUS
1 2 3 4 5 6 B B
M
~AC
A
B
C
D
E
F
G
H
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3
4
3
4
1
3
TB61
230V AC
S1 S2 S3 PE N L
TB6
230V AC
PE N L
PE 4 8 9 10 11 12
15 16
5
4
~AC
6
~AC
7
~AC
*
*
FSK
EMS
FR FS LR LR 230V
OUT
ZP
N
230V
IN
L
N
L
N
L
N
L
N
L
T
16
17
20
21
11
SF
8
14
19
A
VF
~AC
18
13
12
10
9
B
C
6720803687-30.1Wo
T2
Fig. 79 Wiring example
[A]
[B]
[C]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[16]
[17]
[18]
[19]
[20]
[21]
84
4-core wiring
2-core wiring
3-core wiring
Outside temperature sensor (fitted on north facing wall)
ISM1
Interconnecting cables between hybrid manager and air to water
heat pump
Connections, air to water heat pump
Connections, hybrid manager
Temperature sensor (condenser outlet)
Temperature sensor (condenser inlet)
Heating circuit
Automatic by-pass valve
Buffer tank
FW200 control unit
Expansion vessel
WHM hybrid manager (internal unit)
Boiler
DHW cylinder
Cylinder pump
External unit
Temperature sensor, refrigerant
PSS1 solar circuit pump
CUS boiler connection
6 720 803 687 (2012/11)
APPENDIX
13.4 WIRING TO PCB IN THE EXTERNAL UNIT (HEAT PUMP)
Fig. 80 Wiring to PCB in the external unit
[1]
[2]
[3]
[4]
M-NET adaptor (not installed)
Hybrid manager (internal unit)
Supply voltage 230 V, 50 Hz
SW5-1 to 5: function switches
6 720 803 687 (2012/11)
85
APPENDIX
Symbol
TB1
MC
MF1, MF2
21S4
63H
63L
SV
TH3
TH4
TH6
TH7
TH8
LEV-A, LEV-B
DCL1, DCL2
ACL
52C
RS
ACTM
CE
P. B
R/S
SC-R/S
SC-P1, P2
SC-N1, N2
U/V/W
CN2-5
PFC
IPM
CB1-3
CNDC
CNAF
IGBT
LED1
Description
Terminal strip (supply voltage for internal and
external unit)
Compressor motor
Fan motor 1 and 2
4-way valve
High pressure switch
Low pressure switch
Bypass solenoid valve
Temperature sensor (liquid)
Temperature sensor (hot gas)
Temperature sensor
(evaporator/condenser)
Temperature sensor (outside air)
Temperature sensor (inverter)
Expansion valves
DC link coil
Reactor
Contactor
Voltage peak protection
Filter module
Trimmer
Power supply circuit board
Terminals (L/N)
Screw terminals (L/N)
DC voltage screw terminals
DC voltage screw terminals
Terminals (U/V/W)
Plug
Converter
Inverter
Trimmer
Plug
Inverter
LED, inverter status
Symbol
C. B
Description
Printed circuit board (PCB)
FUSE1-4
SW1
SW4
SW5
SW7
SW8
J1-6
SWP
CN31
Fuse (6.3 A)
DIP switch — settings
DIP switch — test mode
DIP switch — function selection
DIP switch — function selection
DIP switch — switch
Jumper, module selection
Pump empty switch
Emergency mode plug
LED1, 3
LED5, 6
CNAC
CNDC
CNS
FAN11
FAN12
FAN21
FAN22
SS
SV2
CNM
CNMNT
CNVMNT
CNDM
X51, 52, 54
FET1
LED operating status
LED motor status
Plug
N. F
LI/LO
NI/NO
E, EI
CNAC 1/2
CN5
CN52C
52C
Fan motor plug
Plug options
Plug
Plug for A-Control service tool
Plug for M-NET adapter
Plug for M-NET adapter
Plug for external signals
Relays
Motor drive, servo amplifier
Interference suppressor
L-phase terminals
N-phase terminals
Earth terminals
Plug
Contactor
Table 48 Key to wiring diagram
86
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APPENDIX
13.5 CONTROLLER CIRCUIT BOARD IN EXTERNAL UNIT
Fig. 81 Power circuit board (see following page for key)
6 720 803 687 (2012/11)
87
APPENDIX
No.
1
Symbol
DNDM
Description
1-2: Quiet running input (unavailable on this model)
2
3
4
5
6
7
CN51
CN52C
CN4
SV2
21S4
CN2
1-3: External signal input
External output signals (compressor operation signal, fault displays)
Connection to interference suppressor
Control signals to inverter board
Bypass valve
4-way valve
Connection to power circuit board of external unit
1-5: control signals to the PCB (0 — 5 V DC)
2-5: Zero-cross signal (0 — 5 V DC)
3-4: Not used
6-5: 16 V DC
8
9
10
11
12
CNAC
7-5: 16 V DC
2-4: PCB power supply (220 — 240 V AC)
CNS
+/CNDC
CNF1, CNF2
1-3: power supply from the control cable to the hybrid manager (220 — 240 V AC)
S1-S2: 220 — 240 V AC
Supply voltage for communication D71 V, voltage 24 V DC
280 V DC (inverter board 140 V)
Connection for fan motors
1-4: 280 V DC
5-4: 15 V DC
6-4: 0 — 6.5 V DC
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
VSP
VFG
TH33
TH32
63H
TH7/6
TH3
TH4
LEV-A, LEV-B
CNVMNT
CNMNT
CNM
SW8
SW5
SWP
SW4
SW6
SW1
SW7
7-4: 15 V DC at idle, 7.5 V DC during rotation, 0 — 15 V pulsed
Voltage of pins on C5A, C5B: 0 V DC at idle, 1.5 V DC during rotation
Voltage between the right-hand pins on PC5C and PC5D, pin 3 and pin 4 (same as CNF1)
Temperature sensor (liquid line)
Temperature sensor (compressor casing)
High pressure switch
Temperature sensor (heat exchanger, 2-phase mixture)
Temperature sensor (liquid line)
Temperature sensor (hot gas)
Linear expansion valves
M-NET adapter (optional)
M-NET adapter (optional)
A-Control service tool
Function switch
Pump back mode
Test mode
Model selection
Forced defrost mode, delete fault list, appliance address
Step control
Table 49 Key to inverter PCB
88
6 720 803 687 (2012/11)
APPENDIX
13.6 ALTERNATIVE PIPE WORK LENGTHS AND T
Additional pipe length
[m]
20
10
6
0
20
10
6
0
Maximum flow
rate [l/min]
15.3
16.3
16.8
17.6
15.3
16.3
16.8
17.6
Heating
output [kW]
21.86
23.29
24.00
25.14
23.96
25.03
25.80
27.03
T [K]
20
20
20
20
21.5
21.5
21.5
21.5
Residual
pressure
[mbar]
200
200
200
200
200
200
200
200
Table 50 : Alternative T between the heating system flow and
return based on additional pipe length
Heating
output [kW]
28
30
28
30
28
30
28
30
Additional pipe
length [m]
Maximum flow
rate [l/min]
20
15.3
10
16.3
6
16.8
0
17.6
T [K]
25.62
27.45
24.05
25.77
23.33
25.00
22.27
23.86
Table 51 : Alternative T between the heating system
flow and return based on heating output
The maximum length of refrigerant pipework must be
maximum 30m each way and therefore must be taken
into account when extending CH system pipework.
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89
GENERAL DETAILS
14
GENERAL DETAILS
CLIENT / HEATING CONTRACTOR
Name:
Commission number:
Street / House
number:
Postcode / Town:
Telephone:
Fax:
Mobile:
Email:
COMMISSIONING
Initial comm
Repeat comm
Comm terminated
SYSTEM LOCATION
Name:
Street:
Postcode:
Town:
HEATING INSTALLATION
Name:
Street:
Postcode:
Town:
ELECTRICAL INSTALLATION
Name:
Street:
Postcode:
Town:
Table 52 General details
APPLIANCE AND ACCESSORY (to be completed by installer)
The following was/were installed
 Hybrid Manager |  External unit |  Control unit
Usage
 Private |  Office |  Other:
Designation
Appliance type
Serial number / Software version
Hybrid Manager (internal unit)
External unit
Heat appliance
Table 53 Installed appliance and accessory
90
6 720 803 687 (2012/11)
GENERAL DETAILS
APPLIANCE AND ACCESSORY (to be completed by installer)
Control system
Hybrid control module
Bypass valve
Table 53 Installed appliance and accessory
6 720 803 687 (2012/11)
91
ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER
15
ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER
The assembly and installation report is designed as a confirmation that
the assembly and installation have been carried out correctly by a
competent person.
CONTROL
FW200 programming unit
INSTALLATION
Hybrid Manager (internal unit) fitted and connected
Outdoor unit installed and connected
"Correctly carried out" means "in accordance with the installation
instructions and in compliance with currently applicable standards".
The assembly and installation report is completed and signed by the
installer.
Customer shown how to use control  Yes
 Yes |  No
 On foundations  With floor mounting bracket
 Wall
 Wind  Salt  Snow  Other:
• Special considerations regarding the installation location
( chapter 5.2.7, page 21)
• External unit securely fastened to the foundations.
 Yes |  No
• Anti-vibration mounts firmly secured
 Yes |  No
(only in the case of roof mounting)
• Checked that there are no excessive vibrations emitted from the  Yes |  No
external unit or pipework.
• External unit, including evaporator, fan
 Yes |  No
and casing checked for external damage.
• Ribbon heater (option) correctly fitted
 Yes |  No
and connected
• Condensate drain installed
 Yes |  No.
– Frost protection implemented
• Air routed to the:
 top  bottom  left  right
• Refrigerant lines connected, insulated
 Yes |  No
and tightness of the refrigerant circuit checked
( chapter 5.6.6, page 28):
– Step 1 — tightness at 5 bar(g)
– Step 2 — tightness at 15 bar(g)
– Step 3 — tightness at 41.5 bar(g)
• Refrigerant circuit evacuated and dried ( chapter 5.6.8,
 Yes |  No
page 29)
• Continuous pressure (vacuum)
__________________ mbar (a)
Power supply connected ( chapter 5.7, page 5.7)
 Yes |  No
Safe access for maintenance
 Yes |  No
Minimum installation clearances maintained
 Yes |  No
Appliances installed on even surface
 Yes |  No
Evaporator freely accessible
 Yes |  No
and not near to sources of dust and dirt
HYDRAULIC SYSTEM
 New installation |  Modernisation measure |  Appliance replacement |  Other:
Use of other heating appliances together
 Yes |  No
Type:
with Hybrid Split in the same system
If yes: output of additional heat generator
Specified accessories installed
Pipe material used:
Pipework cleaned
Water quality of fill and top-up water checked
• Water hardness
• Water treatment agent that may have been used
Compliant with system requirements
__________ kW
 Safety valve (3 bar)
 Expansion vessel
 Pressure gauge
 Shut-off valve
 Anti-vibration mounts
____________________________________
 Yes |  No
 Yes |  No
__________________ °dH
__________________; __________________
 Yes |  No
Table 54 Assembly and installation report
92
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ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER
• Pipework length of heating system
• Total pipework pressure drop
• Installation room volume (min. 5.7 m3)
Additional components installed
• Bypass valve
• Expansion vessel, capacity, pre-charge pressure
Pipes insulated correctly
Buffer tank
__________________ m
__________________ bar
__________________ m³
 Yes |  No
__________________ l
 Yes |  No
 Yes |
Capacity: _______________________l
Buffer cylinder
connected in accordance with the hydraulic diagram
Domestic hot water heating (DHW) with Hybrid Split
DHW cylinder
 Yes |  No
 Yes |  No
 Yes |  No
Capacity: _______________________l
Number of mixed heating circuits:
Heat distributor
Heat exchanger surface: _______________m2
Number of unmixed heating circuits:
 Radiators |  Underfloor heating system
 Other
Primary circuit is properly installed, filled, vented and checked for  Yes |  No
tightness
Hydraulic balancing been done
 Yes |  No
Table 54 Assembly and installation report
NOTICE:
▶ Check filter valve after commissioning for debris and
clean filter.
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93
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER
16
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER
The commissioning report will be completed and signed by the
commissioning engineer.
Action
Refrigerant lines connected, insulated and tightness
of the refrigerant circuit checked.
Power supply established and BUS cable connected
to the external unit.
DIP switches of the external unit set and checked.
The power supply to the external unit has been 'live' for at least 12 hours prior
to commissioning the overall system.
Heating system filled with water and pressure checked.
• Expansion vessel supply pressure
• Heating system charge pressure
Power supply to the external unit isolated, BUS cable connected to the hybrid
Manager (internal unit).
Overall system switched on.
FW200 programming unit connected to the Hybrid Manager.
Heating pump set up in the heat appliance.
FW200 programming unit configured
in accordance with the system set up
( separate operating instructions).
High efficiency pump in the Hybrid Manager (internal unit) set up.
Vented.
Bypass valve set up.
Confirmation / values
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
Value: __________________ bar
Value: __________________ bar
 Yes |  No
 Yes
 Yes
 Yes
 Yes
|
|
|
|




No
No
No
No
 Speed stage I  Speed stage II  Speed stage III
T = _____ K; heating output = _____kW
 Yes |  No
Value: __________________
Table 55 Commissioning report for the commissioning engineer
Action
Parameters set.
• Boiler / air to water heat pump switched subject to:
Confirmation / values
 Yes |  No
 Cost-optimised  Environmental factors
 Environment and costs  Changeover threshold
• Energy price ratio of electricity / fossil fuel
Setting value: __________________
• What is the primary energy factor for the fossil fuel?
Setting value: __________________
• What is the primary energy factor for electricity?
Setting value: __________________
• What should the dual mode switching threshold be?
All casing parts fitted.
User instructed and technical documentation handed over.
Setting value: __________________
 Yes |  No
 Yes |  No
Table 56 Commissioning report for the commissioning engineer
94
6 720 803 687 (2012/11)
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER
Commissioning and handover of the heat pump by the commissioning engineer:
Commissioning completed successfully.
Commissioning terminated;
follow-up date required.
User instructed.
Commissioning completed, faults noted under
"Comments" must be removed.1)
Faults removed on the:
Client signature:
1
) The faults recorded in the commissioning report must be actioned with out delay.
Company:
Service engineer:
Street:
Postcode / Town:
Telephone:
Fax:
Date:
Signature
Commissioning engineer:
Date:
Signature
Client/user:
ATTACHMENTS
 Hydraulic diagram
 Electrical connection diagram
Miscellaneous:
Table 57 Commissioning report - handover
6 720 803 687 (2012/11)
95
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER
96
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COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER
6 720 803 687 (2012/11)
97
AIR TO WATER HEAT PUMP COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the heat pump and associated equipment as a means of
demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name
Address
Telephone Number
Heat Pump Make and Model
Heat Pump Serial Number
Commissioned by (print name)
Certified Operative Reg. No. [1]
Company Name & Address
Commissioning Date
Telephone No.
Building Regulations Notification Number (if applicable) [2]
CONTROLS - SYSTEM AND HEAT PUMP Tick the appropriate boxes if applicable
1. Time & Temperature
Control to Heating
Room Thermostat &
Programmer/Timer
Programmable
Roomstat
Load/Weather
Compensation
Optimum Start
Control
2. Time & Temperature
Control to Hot Water
Cylinder Thermostat &
Programmer/Timer
Combined with Heat
pump main controls
3. Heating Zone Valves (including underfloor loops)
Fitted
Not Required
4. Hot Water Zone Valves
Fitted
Not Required
5. Thermostatic Radiator Valves
Fitted
Not Required
6. Heat Pump Safety Interlock [3]
Built In
Provided
7. Outdoor Sensor
Fitted
Not Required
8. Automatic Bypass System
Fitted
9. Buffer Vessel Fitted
Yes
Not Required
No
If YES,
Volume
Litres
ALL SYSTEMS
The heating system has been filled and pressure tested
Yes
Expansion vessel for heating is sized, fitted & charged in accordance with manufacturer’s instructions
Yes
The heat pump is fitted on a solid/stable surface capable of taking its weight
Yes
The system has been flushed and cleaned in accordance with BS7593 and heat pump manufacturer’s instructions
Yes
What system cleaner was used?
What inhibitor was used?
Qty
Is the system adequately frost protected?
Yes
litres
OUTDOOR UNIT
Are all external pipeworks insulated?
Yes
Is the fan free from obstacles and operational?
Yes
Has suitable consideration been made for waste water discharge?
Yes
CENTRAL HEATING MODE
Heating Flow Temperature
DOMESTIC HOT WATER MODE
°C
Heating Return Temperature
°C
Measure and Record
Is the heat pump connected to a hot water cylinder?
Hot water has been checked at all outlets
Yes
Unvented
Vented
Thermal Store
Not Connected
Have Thermostatic Blending Valves been fitted?
Yes
Not required
ADDITIONAL SYSTEM INFORMATON
Additional heat sources connected:
Gas Boiler
Oil Boiler
Electric Heater
Solar Thermal
Other
ALL INSTALLATIONS
The heating, hot water and ventilation systems complies with the appropriate Building Regulations
Yes
All electrical work complies with the appropriate Regulations
Yes
The heat pump and associated products have been installed and commissioned in accordance with the manufacturer’s instructions
Yes
The operation of the heat pump and system controls have been demonstrated to the customer
Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm demonstration of equipment and receipt of appliance instructions)
Notes: [1] Installers should be members of an appropriate Competent Persons Scheme. [2] All installations in England and Wales must be
notified to Local Area Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance
Certificate will then be issued to the customer. [3] May be required for systems covered by G3 Regulations
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Service Record
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the
manufacturer’s instructions.
Always use the manufacturer’s specified spare part when replacing controls.
Service 1
Date:
Service 2
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Operative ID No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 3
Date:
Service 4
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Operative ID No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 5
Date:
Service 6
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Operative ID No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 7
Date:
Service 8
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Operative ID No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 9
Date:
Service 10
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Operative ID No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
WORCESTER, BOSCH GROUP:
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 0844 892 9900
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
6 720 803 687 (2012/11)
TECHNICAL SUPPORT:
0844 892 3366
APPOINTMENTS:
0844 892 3000
SPARES:
01905 752571
LITERATURE:
0844 892 9800
TRAINING:
01905 752526
SALES:
01905 752640