WORCESTER GREENSTORE 6kW, 7kW, 9kW & 11kW Combi INSTRUCTION MANUAL HEAT PUMP

WORCESTER GREENSTORE 6kW, 7kW, 9kW & 11kW Combi INSTRUCTION MANUAL HEAT PUMP

WORCESTER GREENSTORE

6kW, 7kW, 9kW & 11kW Combi

HEAT PUMP

INSTRUCTION MANUAL

INSTALLA TION, COMMISSIONING

& SERVICING

Table of contents

BUILDING REGULATIONS ..................................................................................................................................3

For the Installer ................................................................................................ 5

Important information to the installer ................................................................. 6

Technical support ...................................................................................................................................................6

Checklist .......................................................................................................... 6

What the deliver y includes ................................................................................ 7

Dimensions and plumbing connections ............................................................... 8

The heat pump and collector hose in general ....................................................... 9

Transporting the heat pump ....................................................................................................................................9

Positioning the heat pump .......................................................................................................................................9

Maximum working temperatures ............................................................................................................................9

Minimum working temperatures .............................................................................................................................9

Fit the fi lters ............................................................................................................................................................9

Collector hose ........................................................................................................................................................10

Installing the expansion vessel ...............................................................................................................................12

Compact collector ..................................................................................................................................................13

Connecting the heat pump to the heating system ............................................... 14

Fitting the unvented kit .........................................................................................................................................14

Use in hard water areas ........................................................................................................................................17

Connecting to the heating system without a bypass: ................................................................................................17

Connect heat pump Combi model to the heating system .........................................................................................18

Individual temperature control in each room and increasing volume of internal water .........................................19

Filling the heating system ......................................................................................................................................20

Filling the collector circuit ....................................................................................................................................20

Connecting the heat pump to the power supply ................................................. 23

Installation of sensors ............................................................................................................................................23

External connections to the heat pump ..................................................................................................................24

Connecting the general alarm, external input and softstart ...................................................................................25

Installer and ser vice menu (I/S) ...................................................................... 26

How to use the control panel .................................................................................................................................26

Commissioning the heat pump ......................................................................... 27

Manual test run of the heat pump .........................................................................................................................27

Start the heat pump ..............................................................................................................................................27

Menu displays which may need adjustment or checking .........................................................................................28

Drying program for fl oor screed .............................................................................................................................31

Start the heat pump with only additional heat.......................................................................................................32

Important points to check after start up .................................................................................................................32

Maintenance ................................................................................................... 33

Unscrew the front cover ........................................................................................................................................33

Sight glass .............................................................................................................................................................33

Filters ...................................................................................................................................................................34

Protective anode ...................................................................................................................................................34

Expansion vessel....................................................................................................................................................35

What to do if a fault occurs .............................................................................. 36

Menu display dimmed ...........................................................................................................................................36

Fuses and reset buttons on the heat pump .............................................................................................................37

All alarms ............................................................................................................................................................37

Technical information ...................................................................................... 46

2

BUILDING REGULATIONS

This appliance must be installed and serviced only by a competent person in accordance with the current: IEE Regulations,

Building Regulation, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 63S (The Electricity at Work Regulations 1989), IS 813 (Eire) and other local requirements.

The relevant Standards should be followed, including:

BS7074:1 : Code of practice for domestic and hot water supply

EN:12828 : Central heating for domestic premises

BS7593 : Treatment of water in domestic hot water central heating systems

BS EN 14511

BS EN 814

BS EN 378

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 specifi c instruction is given, reference should be made to the relevant codes of Practice.

Potable water:

All seals, joints, compounds (including fl ux 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 BBT Thermotechnology have been tested and found to comply with –

1.

2.

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). The Building Regulations

(Northern Ireland) 2000.

Installation manual for the Worcester Greenstore Combi heat pumps

Worcester, 05.02.07

Part number: 8-716-113-342

Issue: b

Copyright © 2007.

3

PRODUCT CONTENTS LIST

Greenstore Combi Heat Pump.

Components included in deliver y:

Rubber feet

Outdoor sensor T2 (GT2) with cable

Room sensor T5(GT5)

Return sensor T1 (GT1)

4 bar Pressure Relief Valve

Valve with fi lter

Circlip pliers

Drain plug

Ball valve

Expansion vessel

Filling link with insulation and fi lter

Literature pack:

User manual

Installation manual

Guarantee card

Unvented cylinder kit:

DHW expansion vessel

Expansion Vessel Hose

Wall mounting kit for expansion vessel

High fl ow rate inlet control set

Acetal tundish

600mm

600mm

1800mm

4

For the Installer

Installation of the heat pump should be performed by a qualifi ed installer.

This chapter includes a section recommending how the heat pump installer should install, commission and service the heat pump. The installation manual consists of a plumbing section and an electrical section. These provide technical data such as measurements, wiring diagrams and installer menus.

Contents:

Important information to the installer

Checklist

What the delivery includes

Dimensions and plumbing connections

The heat pump and collector hose in general

Connecting the heat pump to the heating system

Connecting the heat pump to the power supply

External connections to the heat pump

Commissioning the heat pump

Maintenance

Note

It is important that the installer also reads through the User manual. It contains the information necessary to get a comprehensive understanding of the heat pump.

5

Important information to the installer / Checklist

Important information to the installer

This manual provides all the information necessary to install the heat pump.

The manual is divided into several sections. The order of these is based on the recommended installation sequence. Use the supplied checklist during installation.

Before installation remember:

Warning

The main power supply must be disconnected before working on the heat pump.

Installation of the heat pump should be performed by a qualifi ed installer.

If the heat pump needs to be tilted during transit it may be temporarily tilted with the compressor downwards.

However, never lay the heat pump down or transport it horizontally.

Before the heat pump is commissioned, the heat transfer systems, the hot water cylinder and the heat pump must be fi lled and vented.

Check that pipe connections on the collector and primary circuits are intact and have not shaken loose during transport.

Heat pump installation and collector installation must be carried out in accordance with applicable regulations.

Technical support

For technical support please contact:

Technical Pre & Post sales

Tel: 08705-266241

Fax: 01905-752741

Checklist

Each heat pump installation is unique. However, the following checklist gives a general description of how the installation should be carried out.

1. Stand the heat pump on a fl at surface. Adjust the height using the rubber feet.

2. Ensure that the bore hole (if used) for the collector hose is bored according to applicable regulations (responsibility of the drilling company). Check that the horizontal collector (if fi tted) has been installed correctly.

3. Fit the incoming and outgoing pipes for the heating and heat transfer fl uid circuits as well as the expansion tank.

4. Fit the particle fi lters and valves.

5. Connect any additional circulation pump, if required, to the heating system. Follow the instructions for the pump in question.

6. Install the outdoor sensor and a room sensor if used.

7. Fill and vent the primary and collector systems before commissioning.

8. Connect the heat pump to the electrical system via an external isolation switch. Use the appropriate wiring diagram.

9. Connect a general alarm and external control if used.

10. Commission the heat pump by making all the necessary settings on the control panel.

11. Check the heat pump after commissioning. Top up the collector system if required.

6

What the shipment includes

What the delivery includes

The following components are included in the delivery of the heat pump:

Rubber feet

Quantity: 4

Return sensor T1 (GT1)

Quantity: 1

Cable: 4 m

Filling link with insulation and fi lter

Quantity: 1

Valve with fi lter

Quantity: 1

Outdoor sensor T2 (GT2) with cable

Quantity: 1

Room sensor T5 (GT5) with cable:

Quantity: 1

Circlip pliers

Quantity: 1

Literature pack

User manual

Installation manual

Guarantee card

Expansion vessel

Quantity: 1

Drain plug

Quantity: 1

4 bar pressure relief valve

Quantity: 1

DHW expansion vessel

Quantity: 1

Expansion vessel hose

Quantity: 1

Wall mounting kit for expansion vessel

Quantity: 1

Ball valve

Quantity: 1

High fl ow rate inlet control set

Quantity: 1

Acetal tundish

Quantity: 1

7

Dimensions and connections

Dimensions and plumbing connections

The following illustrations show the dimensions of the heat pump and plumbing connections. All measurements are stated in millimetres.

Required installation space

In front of the heat pump a free area of 800 mm is required for installation and servicing.

Allow a side clearance of at least 100 mm on the sides and behind the heat pump.

≥ 100 ≥ 100

568,5

506

79 198

596

298 471 538

1

5

6

517

470

4 3

280,5

69

2

398 494 554

8

3

4

1

2

5

6

CH return

CH fl ow

Mains cold water in

Domestic hot water out

Heat transfer fl uid (HTF) in

Heat transfer fl uid (HTF) out

The heat pump and collector hose in general

The heat pump and collector hose in general

Transporting the heat pump

The heat pump should always be transported and stored in an upright position, never horizontally. Otherwise the suspension fi ttings inside the compressor can be damaged. If the heat pump must be tilted during entry to the installation site, this should be done for as short a time as possible. The outer cover panels should be removed to avoid damage, if the heat pump is moved without using the supplied pallet.

The heat pump must not be stored at temperatures below -10ºC.

Positioning the heat pump

It is important that the heat pump stands on a fl at surface as it contains sensitive parts. The fl oor must be stable and have a strength to carry at least 500 kg. Adjust the rubber feet so the heat pump does not lean.

The temperature surrounding the heat pump should be between 0ºC and 35ºC.

The installer should take sound insulation into consideration when positioning the heat pump.

Maximum working temperatures

The heat pump can work at a maximum return water temperature of approximately 57ºC. If the temperature rises above this value the heat pump will stop for safety reasons.

The electric heater will stop if the temperature rises above 55ºC. The maximum outgoing temperature to the heating system is around 65°C.

Minimum working temperatures

The heat pump supplied is preset to a minimum temperature of collector fl uid -10°C inlet and -10°C outlet. The heat pump can operate at inlet temperatures down to -5°C, lower inlet temperatures are not recommended.

The preset values can be changed during commissioning.

Fit the fi lters

The task of the fi lters is to fi lter out dirt before it can enter the heat pump.

Fit the fi lter for the collector circuit on the incoming pipe from the collector.

Fit the fi lter for the primary circuit on the incoming pipe from the heating system.

Both fi lters should be fi tted as close to the heat pump as possible and placed horizontally. Make sure that the direction of fl ow is correct.

9

The heat pump and collector hose in general

Collector hose

The task of the collector hose is to convey the heat transfer fl uid through the ground to gain a few degrees of heat. The hose is a thin-walled plastic hose of type PEM 40 x 2.4 PN 6.3. SDR11.

Installation and backfi lling around the collector hose

Installation of the collector and backfi lling the soil around the collector hose should follow applicable material and working descriptions and regulations.

It is important that the fi lling material does not contain stones or other sharp objects that can damage the collector hose.

Use hose pliers, not a saw, when cutting the collector hose. Deburr the end of the pipe internally and externally. It is important that no dirt or debris enters the system. Dirt and debris can cause a blockage in the heat pump.

Minimum permitted bending radius

Minimum permitted bend radius is 1 metre. If sharper bends are required an elbow connector must be used. If the collector hose is damaged by too sharp a bend, it can be repaired by using a straight coupling.

Maximum length of the collector hose

The maximum length of the collector hose is based on the heat transfer fl uid pressure drop. A heat transfer fl uid consisting of bioethanol or glycol and water is recommended.

Hose pliers

Heat pump model

Greenstore 6

Greenstore 7

Greenstore 9

Greenstore 11

Maximum length of collector hose with a single circuit (m)

PEM 40x2.4 PN 6.3.

600

500

400

400

Collector hose with 2 circuits in parallel: Maximum length per circuit (m)

PEM 40x2.4 PN 6.3.

-

1000

800

800

Note

The maximum collector hose lengths for heat pump models are provided in the table.

In situations where the length of the collector hose needs to exceed the permitted value, you can connect the hoses in parallel.

10

The heat pump and collector hose in general

Outline drawings for the collector hose in the ground and through a wall

The drawings below show how to run the collector hose in the ground and through a wall. The soil fi lling around the hose must not contain stones.

Collector in the ground

200 mm

800-1000 mm

800-1000 mm

Example of the collector through the wall

(from the side)

House wall

Collector hose

Insulation

Filling of sand or stone free soil approximately 100 mm around the collector hose.

Collector, PEM 40 x 2.4 PN 6.3.

Example of the collector through the wall

(cross section)

Insulation of pipework

All collector pipework should be insulated a minimum of 2 metres from the property. Pipework should also be insulated where the fl ow and return are closer than 800 mm to each other.

Connecting the collector hose to the heat pump

It is important that the collector hose has been leak tested before it is connected to the heat pump. The hose should be tested to 3-4 bar for a minimum of 1 hour to ensure there are no leaks. The leak test can be performed using an air compressor. The collector is usually pressurised during the laying process.

11

Note

Non-combustable pipe material must be used when routing the pipes indoors.

The heat pump and collector hose in general

The collector hose can be connected to the heat pump with one or more circuits. In a multi-circuit system, the collector pipes are connected in parallel as illustrated below. The parallel pipes are connected to two manifolds. Each coil should have a shut off valve and a fl ow control valve. The fl ow control valve is adjusted so that the fl ow rate is the same in each coil. The coils should have the same length.

After the manifolds and the fl ow control valves, the coils are connected to a collecting pipe. A fi lling link, fi lter and the plastic expansion vessel supplied with the heat pump are connected to the collecting pipe. A pressure relief valve is connected to the outgoing pipe.

One circuit at a time is fi lled with heat transfer fl uid. Keep the valves closed in the other loops during the process. Read more about fi lling under the heading Connecting the heat pump to the heating system.

Single circuit system Multi-circuit system

Expansion vessel

Filling link

Collector

Expansion vessel

Filling link

Control valves

Collector

Manifolds

Heat pump Heat pump

Installing the expansion vessel

The plastic expansion vessel for the collector circuit is supplied with the heat pump. It is important to position it at the highest point in the circuit, preferably above the heat pump. If there is a low ceiling making it impossible to fi t the expansion vessel above the pump, it can be positioned as illustrated in the diagram to the left. It is important to install the expansion vessel so that any air disperses upwards. Air will remain in the circuit if the expansion vessel is fi tted incorrectly

(see the fi gure to the right).

Correct

Wrong

12

The heat pump and collector hose in general

Compact collector

The following equipment is used for the collector installation:

Compression connector

Pipe coupling

1 inch BSP

Hose pliers

Install the collector as follows:

1. The compact collectors are installed horizontally. The collector should lean with the connection side at least 30 cm above the bottom to aid the venting process. Trench measurements: depth: 1 - 1.3 m, width: 2.5 m.

Minimum distance between two rows of compact collectors is 1 m.

Minimum distance between collectors and the house is 3 m. Trench digging must adhere to applicable regulations.

2. Installation of the collectors can be simplifi ed by joining up to fi ve collectors on the ground before they are positioned in the trench.

3. Place the collector modules in the trench, joined together using fusion welded or compression fi ttings.

4. Pressure test the system with air for 3-4 hours up to 4 bar prior to fi lling with heat transfer fl uid. Reduce to 2 bar when backfi lling.

5. Refi ll using sand or soil without stones.

6. Route the return line, 40 mm PEM, at a depth of 1 m.

7. Route the collector hoses up to the house wall. Hoses must be insulated over the fi nal 2 metres towards the house. Non-combustable pipe material must be used when routing the pipes indoors.

Insulation of pipework

All collector pipework should be insulated a minimum of 2 metres from the property. Pipework should also be insulated where the fl ow and return are closer than 800 mm to each other.

Hose welding equipment

Fusion weld sleeve

Ø40 mm

Horizontal installation

Note

A maximum of 11 compact collectors can be installed in each row.

Note

Health and safety requirements to ensure that the sides of the trench are not liable to collapse must be observed.

13

Connecting the heat pump to the heating system

Connecting the heat pump to the heating system

It is important that all previously mentioned preparations have been carried out before the heat pump is connected to the heating system. Also ensure the system has been power fl ushed before it is connected to the heat pump. Flushing protects the heat pump from contamination.

Oxygen must not enter the system. The heat pump is only intended to work in oxygen free systems. If oxygen enters the system it causes corrosion in the heat pump which could block the fi lter on the heating system side.

Note

Only qualifi ed installers may carry out the installation. The installer should observe applicable regulations.

Fitting the unvented kit

Parts to assemble:

Expansion vessel

High fl ow rate inlet control set

Expansion vessel hose

Wall mounting kit for expansion vessel

Tundish

Connection:

Mount the expansion vessel with the wall mounting kit. Connect the expansion vessel hose to the expansion vessel.

Connect the expansion vessel, inlet control set and tundish as shown in the schematics on page 16-17.

Note

The relief valve connections should not be used for other purpose.

14

Connecting the heat pump to the heating system

Detailed discharge pipe installation requirements

The discharge pipework must be routed in accordance with part G3 of schedule 1 of the building Regulations.

The tundish should be vertical, located in the same space as the unvented hot water cylinder and be as close as possible and within 500mm of the safety device e.g. the temperature relief valve. The discharge pipe from the tundish should be:

made of metal

at least one pipe size larger than the nominal outlet size of the safety device (larger sizes may be required if the equivalent hydraulic resistance exceeds that of a straight pipe 9m long - refer to BS6700)

terminate in a safe place where there is no risk to persons in the vicinity of the discharge, and position safely from electrical devices.

have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework

installed with a continuous fall

visible at both the tundish and the fi nal point of discharge or where this is not possible or practically diffi cult there should be clear visibility at one or the other of these locations

15

Connecting the heat pump to the heating system

Valve outlet size

Size of discharge pipework D1

Size of discharge pipework D2

G1/2

<G3>/4

G1

15 mm

22 mm

28 mm

22 mm

28 mm

35 mm

28 mm

35 mm

42 mm

35 mm

42 mm

54 mm

Maximum length of straight pipe

(no bends or elbows)

Up to 9 m

Up to 18 m

Up to 27 m

Up to 9 m

Up to 18 m

Up to 27 m

Up to 9 m

Up to 18 m

Up to 27 m

Deduct the fi gure below from the maximum length for each bend or elbow in the discharge pipe

0.8 m

1.0 m

1.4 m

1.0 m

1.4 m

1.7 m

1.4 m

1.7 m

2.3 m

How to drain the hot water cylinder

1. Turn off the main water supply to the cylinder.

2. Open a hot water tap with a position as low as possible in the building, in order to reduce the pressure.

3. Remove the pipe connection 3 - Mains cold water in and connect one end of the hose pipe to the connection. Terminate the other end of the hose to a drain or to outside. Ensure that the drain end of the hose is at a lower level than the bottom of the cylinder. The greater the fall on the hose, the higher the fl ow rate.

5. Start the siphon effect by pumping or sucking at the drain end of the hose.

6. Let the whole volume drain out.

568,5

506

280,5

69

79 198

596

298 471 538

1

5

6

517

470

4 3

Elanslutningar

2

398 494 554

>0cm

How to fl ush the system & tank

To fl ush the tank use the above proposed setup, add a hose onto the hot water outlet position number 4 (in the above diagram) and then fl ush the hot water tank.

16

Connecting the heat pump to the heating system

Use in hard water areas

Normally there is no need for water treatment to prevent scale formation.

In areas where temporary water hardness exceeds 200ppm, consideration may need to be given to the fi tting of a scale prevention device. In such circumstances the advice of the local water authority should be sought.

Connecting to the heating system without a bypass:

The heat pump can be connected to the heating system without a bypass, as the circulation in the heat pump and the heating system is managed by the integrated pump G2 (P2). However minimum fl ow of at least 70% of the nominal fl ow

(see the table below) must be maintained throughout the year. Thermostatic radiator valves should be fully open and underfl oor heating systems should have at least half of the coils fully open at all times. The control unit gives an alarm when the return differential temperature exceeds 13ºC.

If the heating system is designed so that at least 70% of the nominal fl ow cannot be guaranteed, the heat pump should be connected using a bypass and an external main pump G1 (P1).

Hot water function:

Hot water production is started by the hot water sensor T3 (GT3), and is stopped by the return sensor T9 (GT9).

Heating system pump

The circulation pump G2 (P2) is a Wilo Star 25/6-130.

Maximum system pressure drop in the heating system

The maximum system pressure drop and the minimum fl ow that the integrated circulation pump can operate with is presented in the table. If the minimum fl ow cannot be guaranteed a

bypass and an external main pump G1 (P1) should be

installed. Ensure that TRV’s cannot close down and restrict the required fl ow.

Heat pump model

Greenstore 6

Greenstore 7

Greenstore 9

Greenstore 11

Nominal fl ow [*]

0.20 l/s

0.25 l/s

0.31 l/s

0.38 l/s

[*] litres/second

[**] kiloPascal

Minimum fl ow [*]

0.14 l/s

0.18 l/s

0.22 l/s

0.26 l/s

Max system pressure drop [**]

36.0 kPa

36.0 kPa

34.0 kPa

32.0 kPa

17

Flow (Q)

Connecting the heat pump to the heating system

Connect heat pump Combi model to the heating system

The built-in control unit controls the heat pump using the outdoor sensor T2 (GT2) and the return sensor T1 (GT1) according to the outdoor compensated control curve. In the unlikely event the heat pump compressor is unable to meet the heating requirements, the electric heater starts automatically and together with the heat pump provides the required temperature. Hot water production is given priority over central heating. Hot water production is controlled by the sensor

T3 (GT3), which is located in the hot water cylinder. When the water in the cylinder reaches the required temperature, heat is once more supplied to the heating system.

The control unit can also operate a second curve together with a mixing valve. The mixing valve curve must be set lower than the heat curve for the rest of the heating system. This extra function is used, for example, in a heating system that is a combination of radiators (higher temperature demand) and underfl oor heating (lower temperature demand).

Connecting the sensors: Return sensor T1 (GT1) and Outdoor sensor T2 (GT2) must always be connected. Sensor T4

(GT4) is only connected if a mixing valve curve is used. The sensor T5 (GT5) is connected when the heat pump is to be infl uenced by a room sensor. A room sensor is supplied as standard with the heat pump.

An absolute prerequisite for this type of connection is that at least 70% of the nominal fl ow can be maintained throughout the year. Thermostatic valves must remain fully open in order to ensure this.

* If a bypass and external circulation pump is added, the fl ow over the heating system can be reduced down to 40% of the nominal fl ow for the heat pump. This means that at least 30% of the thermostatic valves must be fully open. If none of the above is possible, a 100 litre primary water storage tank should be fi tted.

The length of the bypass should be at least 10 times the inner diameter of the pipe.

heating vessel

G1 (P1): Radiator pump

E22: system pump

Electric water heater

G2 (P2): Heating system pump

Q21: Diverter

V21: Filter heating system

G3 (P3): Heat transfer fl uid pump valve

Q35: Air (manual)

V31: Filter heat transfer fl uid in heating

G4 (P4): Pump for mixed heating system

E60

V60:

W60:

C61:

Domestic hot water system

Hot water draw-off

Cold water cylinder inlet

Expansion vessel *

F61: Pressure relief valve

F62: Temperature and pressure relief valve valve

Q63:

Q64:

Pressure reducing valve

Non return valve

Q65: Tundish

T2 Outdoor

T4 Mixed heating system

T5 Room

T6 Compressor

Symbols according to ISO/FDIS 14617.

Letter codes according to IEC 61346-2.

This is a principal drawing.

* Mixed heating system

There is a possibility to control a second heating system with a mixing valve. This is recommended when a combination of radiators and a fl oor heating system is used.

* Expansion vessel

No valve should be fi tted between the expansion valve and the storage cylinder.

18

Connecting the heat pump to the heating system

Individual temperature control in each room and increasing volume of internal water

This solution is used to control the temperature of each room, for example, where thermostatic valves are used on the radiators in each room. The function of the heat pump is to maintain a temperature in accordance with the heat curve

(depending on outdoor temperature) in the 100 litre primary water storage tank. The water is then distributed from the store to the heating system. This solution also allows the overall volume of the installation to be increased if the volume of the heating system is inadequate, for example with one or two fan-assisted radiators.

This system design is intended to ensure that the heat pump is able to continue operating if the fl ow falls below 70% of the nominal system fl ow.

* Mixed heating system

There is a possibility to control a second heating system with a mixing valve. This is recommended when a combination of radiators and a fl oor heating system is used.

* Expansion vessel

No valve should be fi tted between the expansion valve and the storage cylinder.

19 heating vessel

G1 (P1): Radiator pump

E22: system pump

Electric water heater

G2 (P2): Heating system pump

Q21: Diverter

V21: Filter heating system

G3 (P3): Heat transfer fl uid pump valve

Q35: Air (manual)

V31: Filter heat transfer fl uid in heating

G4 (P4): Pump for mixed heating system

E60

V60:

W60:

C61:

Domestic hot water system

Hot water draw-off

Cold water cylinder inlet

Expansion vessel *

F61: Pressure relief valve

F62: Temperature and pressure relief valve valve

Q63:

Q64:

Pressure reducing valve

Non return valve

Q65: Tundish

T2 Outdoor

T4 Mixed heating system

T5 Room

T6 Compressor

Connecting the heat pump to the heating system

Filling the heating system

1. Open and close the fi lling loop between the cold water system and the heating system in short time intervals whilst observing the pressure guage.

2. Vent the system and refi ll to the correct pressure.

Filling the collector circuit

The collector circuit is fi lled with heat transfer fl uid to be able to collect energy from the ground. A heat transfer fl uid consisting of bioethanol or glycol and water is recommended. The freezing point should be approximately -15°C.

Fill the collector circuit

1. Connect the two hoses from the fi lling pump to the fi lling link as shown in Diagram 1.

Refi lling / de-airing valve

Expansion vessel

Filling link

Note

Care should be taken when fi lling the system, not to get any water on the electrical components. Keep the side panels on the heat pump when fi lling the system.

Heat pump

Collector circuit

Filling pump

Diagram 1: Filling equipment

20

Connecting the heat pump to the heating system

2. Fill the fi lling pump with heat transfer fl uid. If mixing the solution on site, pour water fi rst into the fi lling pump, then anti-freeze liquid. See table 1 and 2 for correct mixture.

Anti-freeze type

Bioethanol

Propylene/ethylene glycol

Table 1: Mixing ratio in litres/metre

Hose type: 40/35

Water (l)

0,71

0,65

Anti-freeze (l)

0,29

0,35

Example:

200 metres of hose with anti-freeze gives 200 x 0.29 litres anti-freeze/ metre = 58 litres of anti-freeze and

200 x 0.71 litres of water/ metre = 142 litres of water.

40/35 indicates 40mm outside diameter PEM pipe with 35mm inside diameter.

Anti-freeze type

Bioethanol

Propylene/ethylene glycol

Water

75%

65%

Table 2: Mixing ratio in percentage by weight

Anti-freeze

25%

35%

Note

If using a premixed solution of glycol and water (e.g. Tyfocor L) the solution must be diluted to suit the requirements above

3. Set the valves on the fi lling link in fi lling mode.

Filling link in fi lling mode

4. Set the valves on the fi lling pump in mixing mode.

Filling pump in mixing mode

5. Start the fi lling pump to start mixing heat transfer fl uid in the barrel.

Mix for two minutes.

Repeat points 6 to 9 for each circuit where applicable. The other circuits must be closed.

6. Set the valves on the fi lling pump in fi lling mode to start fi lling the collector system.

Filling pump in fi lling mode

Note

The fi rst litres of fl uid from the return pipe are often contaminated.

Therefore collect these litres in a separate tank.

21

Connecting the heat pump to the heating system

7. When the barrel is nearly empty, stop the pump and fi ll the barrel with more heat transfer fl uid.

8. When the system is full and air no longer comes from the return pipe, run the system for at least a further 60 minutes. Use the internal HTF pump to speed up the air venting. Enter manual operation on the heat pump control panel under menu 5.3 and start the circulation pump

G3(P3). See Commissioning the heat pump\Manual test run of the heat pump.

9. When venting is complete, set the valves on the fi lling link in pressurize mode and pressurize the system to 2 bar. Make sure that the expansion vessel has an air pocket corresponding to approximately

1/3 of the total volume, by using the de-airing valve on the expansion vessel.

10. Set the fi lling link in normal operation mode and stop the fi lling pump.

Disconnect the hoses and insulate the fi lling link using the supplied insulation.

Commiss./Service

Manual operation of all functions 5.3

Return Select

Filling link in pressurize mode

Filling link in normal operation mode

Adaptor fi ttings for different fi lling links

New type fi lling link

Old type fi lling link

Hose connection points, two female G25" threads.

Hose connection points, two female G20" threads.

Two male to male G25" adaptor connections used to connect fi lling bin hoses to new fi lling link.

Two male G20" to G25" adaptor connections for old fi lling links.

22

Connecting the heat pump to the power supply

Connecting the heat pump to the power supply

Ensure the electricity has been switched off before connecting the heat pump to the mains. Check that cables and printed circuit boards are intact and connected.

High and low current cables should be routed separately in order to avoid interference on the sensors.

A wiring diagram is supplied with the heat pump.

A description of external connections is given in this section.

Examples of external connections include room and outdoor sensors and mixing valves.

The mains connection as well as the material used to make this connection must comply with current electrical regulations.

The heat pump electrical supply must be protected with an MCB or fuse as specifi ed in the table on page 41. Wiring must be H07RNF type. Supply must be L+N+E 230V single-phase. Also a residual current device (RCD) with a rating of

ΔI=300 mA should be installed in the supply to the heat pump.

Installation of sensors

Install the Return sensor T1 (GT1) in direct contact with the return pipe, approximately 1-2 m from the heat pump and, if possible, after a 90° bend.

Install the Outdoor sensor T2 (GT2) on the North side of the house at least 50 cm from ground level.

Hot water sensor T3 (GT3) is factory fi tted in the integrated hot water cylinder.

Install the Room sensor T5 (GT5) in a room in the center of the house.

The room sensor should not be infl uenced by other heat sources or direct sun light.

Warning

The electrical installation may only be performed by a qualifi ed electrician.

The main power supply must be disconnected before working on the heat pump.

Note

A combined overcurrent and residual current device (RCBO) can be used in place of the two separate devices.

Note

Only the room where the room sensor is located can infl uence regulation of the temperature.

23

Connecting the heat pump to the power supply

External connections to the heat pump

The external connections must be made for the heat pump:

Power supply 1-phase:

The power supply is connected to terminals L, N, and Earth.

Mixing valve on the heating circuit:

If a second heat curve with a mixing valve is to be used, the mixing valve is connected to terminal block SV1.

External main pump in the heating system G1 (P1):

The external main pump must be connected to the terminal block if a bypass is required. The pump is connected to terminal P1.

Return sensor T1 (GT1):

Must always be connected. Connect to terminal GT1.

Outdoor sensor T2 (GT2):

Must always be connected. Connect to terminal GT2.

Hot water sensor T3 (GT3):

Is connected to terminal GT3 X on the terminal block.

Mixing valve sensor T4 (GT4):

Is connected when a mixing valve for a second heat curve is to be used. Connect to terminal

GT4.

Room sensor T5 (GT5):

Is connected if room sensor infl uence is required.

Terminal board for external connections

Terminal board

230 V

24

Connecting the general alarm, external input and softstart

General alarm

The general alarm is activated irrespective of which alarm has occurred.

When a general alarm is required on the heat pump, it is connected according to the diagram opposite. The contact for the general alarm output carries no current and it closes at a general alarm.

Connect max 24 V and 100 mA on the contact.

Connecting the heat pump to the power supply

Terminal board for external connections

External input

The heat pump includes prepared functions to permit the heating to be controlled externally. The input to the heat pump can be programmed for different functions on the control unit. These Terminal functions are available from menu 5.7 (Select external controls).

The input must be short circuited to activate the function. Note that the contact must carry no current.

Softstart

The softstart reduces the compressors starting current.

The softstart wiring can be found on the electrical connection diagram supplied in the heatpump

Terminal board for external connections

25

Connecting the heat pump to the power supply

Installer and service menu (I/S)

The controls contain an installer section of menus for settings, e.g. for commissioning. These are accessed from the control panel by holding down the menu button for approximately ten seconds.

The menu displays are divided into lines and each display has a number to make it easy to fi nd. If there is no activity for 30 minutes the menu display automatically returns to Customer level 1.

The Installer level also includes Customer levels 1 and 2.

How to use the control panel

The following example shows how to use the control panel. The example shows how you move to menu display 5.13 and confi rm the external sensors. More information about the control panel is found under the heading Control Panel in the

User section.

1. Press and hold the menu button for approximately ten seconds until Access =

SERVICE is shown on the menu display. Press the Menu button again.

Warning

The Installer and service menu (I/S) is intended for use only by installers.

Under no circumstances should the user access this level.

Rego 637W I/S

060822 16:08:15 Tu

Heat Info Menu

(10 sec)

2. The menu display Indoor temperature settings (menu 1) is shown.

Main menu

Indoor temperature settings 1

Return Select

3. Turn the menu dial clockwise (to the right) until the menu Commiss./Service for installer (menu 5) is reached. Now press the Select button.

Main menu

Commiss./Service for installer 5

Return Select

4. Turn the menu dial clockwise until the menu Extra sensor/Anode in operation

(menu 5.13) is reached. Now press the Select button again.

Commiss./Service

Extra sensor/Anode in operation. 5.13

Return Select

5. The menu display Extra sensor(s) is shown. Confi rm the extra sensors that have been connected by pressing the Confi rm button.

Extra sensor(s)

GT4 GT5

Return Confi rm

setting is being registered in the heat pump.

Extra sensor(s)

Confi rming…

7. When the setting has been registered the previous menu display is shown.

Press the Return button twice to return to the main menu again.

Extra sensor(s)

GT4 GT5

Return Confi rm

26

Commissioning the heat pump

Commissioning the heat pump

The heat distribution and heat transfer fl uid circuits should be fi lled and fully vented before commissioning. Always check that there are no leaks before back fi lling with earth.

If radiators are used, they should be fully open when connecting to an existing heating system. When connecting to an underfl oor heating system at least half of all the fl oor coils should be open. When connecting a fanassisted radiator system the fans are started fi rst and then the valves on the fan-assisted radiators are opened fully.

Manual test run of the heat pump

Instead of starting the heat pump directly in normal mode, manually test run the circulation pumps and valves. This is recommended as in this mode possible faults can be found. In the menu display Manual operation of all functions (menu 5.3) all functions can be run manually. Press the Select button to start test operations. When exiting from the menu display the heat pump returns to normal mode.

Seized circulation pumps

Check that the circulation pumps have not seized before starting the heat pump for the fi rst time.

Fully remove vent plug, check and if necessary free the pump rotor by turning the slotted end of the shaft with a screwdriver

Note

Further important information on the control unit can be found in the user guide.

Therefore read the entire documentation before commissioning is started.

Commiss./Service

Manual operation of all functions 5.3

Return Select

Start the heat pump

1. Connect mains to the heat pump and press the ON/OFF switch on the control panel.

2. Activate the Installer/Service menu by pressing the Menu button until the text Access = SERVICE is shown on the menu display.

3. Temporarily adjust Temp. incr. / decr. to maximum value. To avoid having to wait for the heat pump restart timer go to the menu Fast restart of heat pump (menu 5.6) and quickly restart the heat pump. If the heat pump does not start, press the Info button to see if a heating demand exists.

4. Check the sight glass inside the heat pump during start up. Bubbles may appear in the sight glass for up to fi ve minutes during start up after which time they should disappear. Bubbles present when the heat pump is running after this period are an indication of a fault. They are probably due to insuffi cient refrigerant. Read more about the fault symptom under the heading What to do if a fault occurs.

27

Press the power switch ON/OFF

Rego 637W I/S

060822 16:08:15 Tu

Heat Info Menu

Commiss./Service

Fast restart of heat pump 5.6

Return Select

Check the sight glass

Commissioning the heat pump

5. Make the necessary settings on the control panel.

(GT5) have been connected, confi rm these in the control panel so the control unit knows they are installed. The displays presented by the sensors are only shown if the sensors have been confi rmed.

b. Set the maximum output to be used by the electric heater. Choose between

1/3, 2/3 and 3/3. It is important that the electrical installation is adapted to handle the maximum electrical output. On delivery the control unit is set to 2/3.

For more information about this see section Technical information. Setting 1/3 provides an additional 3kW, 2/3 provides 6kW and 3/3 provides 9kW.

Commiss./Service

Extra sensor/Anode in operation. 5.13

Return Select

Commiss./Service

Select conn capacity electrical cass. 5.2

Return Select

Menu displays which may need adjustment or checking

Temperature settings

Set the hysteresis for heat pump on/off switching on the return sensor T1 (GT1).

A lower value gives a shorter range between start and stop. Less than 5ºC should be avoided when using regular radiators. For underfl oor heating 3-4°C is recommended.

Set the neutral zone for the mixing valve in a heating system with two heat curves.

In the neutral zone the mixing valve receives no signal to open or close. Only applies when the sensor T4 (GT4) is connected.

Set the maximum temperature in the mixing valve circuit. Set a maximum temperature for the underfl oor heating system if applicable. On delivery of the heat pump the value is 60ºC. Only applies when the sensor T4 (GT4) is connected.

Hot water settings

Set the temperature in the hot water cylinder.

Temperature settings

Heat curve hysteresis 1.4

Return Select

Temperature settings

Mixing valve curve neutral zone 1.8

Return Select

Temperature settings

Mixing valve curve max at GT4 1.9

Return Select

Hot water setting

Setting of hot water temperature

Return Select

Clock setting of electric heater

The control unit can be set so that the electric heater is fully blocked during certain periods of the day. Read more under the heading Extra functions (Customer level

2)/Timer control about how to set the control unit.

Clock setting

Clock sett. add heat accord. to clock 4.2

Return Select

28

Commissioning the heat pump

Commissioning/Ser vice

Set when the electric heater should be activated, if necessary. On delivery the heat pump is set to activate the heater when necessary. Choose between yes or no. If no is chosen, the electric heater only engages during alarms, extra hot water and hot water peaks.

Commiss./Service

Select function add.heat yes/no 5.5

Return Select

Commiss./Service

Fast restart of heat pump 5.6

Return Select

The Fast restart function avoids having to wait for the normal restart time to start the heat pump. If there is a need for heating or hot water the heat pump starts within 20 seconds. The setting must be repeated each time a fast restart is made.

Wait approximately 5 minutes after switching off the compressor before activating

Fast restart of the heat pump, to allow the cooling circuit time to equalise pressure.

In the menu 5.7 set whether the heat pump, additional electric heater and hot water charging should be controlled externally. When the external input on the control unit is short circuited one of the following choices can be made:

Commiss./Service

Select external controls 5.7

Return Select

0 : No effect (factory setting).

1 : HP, electric heater and hot water stop.

2 : HP no effect, electric heater and hot water stop.

3 : HP and hot water no effect, electric heater stops.

4 : HP and electric heater no effect, hot water stops.

Select the language required for the menu texts. The default is English.

Commiss./Service

Selection of language menu 5.8

Return Select

The heat pump is set for continuous operation of the heating system pump on delivery. In systems with a bypass, you can choose whether the heating system pump starts and stops with the compressor.

Commiss./Service

Select operation alt. for P2 5.10

Return Select

Choose whether the heat transfer fl uid pump shall run continuously or start and stop with the compressor. The heat transfer fl uid pump should in normal mode always start and stop with the compressor.

Select this menu to see the version number of the control unit.

Confi rm the extra sensors T3 (GT3), T4 (GT4) and T5 (GT5) that are connected externally. On confi rmation, the control unit stores information about the sensors to be used.

Commiss./Service

Select operation alt. for P3 5.11

Return Select

Commiss./Service

Display software version number 5.12

Return Select

Commiss./Service

Extra sensor/Anode in operation. 5.13

Return Select

29

Commissioning the heat pump

Timer readings

There are a number of different menu displays to help check the status of the heat pump. The heat pump status is shown by the timer readings in menu 6.

Read the electric heater timer

The function shows the amount of time remaining before the electric heater is activated. If there is no countdown then there is no need of additional heat.

Read the start delay

The function shows the time remaining until the heat pump starts again after a previous stoppage. The heat pump will not start if there is no heating or hot water demand.

Setting the electric heater

Additional heat timer

The function gives the possibility to set the time that should elapse before the electric heater starts if the heat pump cannot produce suffi cient heat on its own. On delivery the timer is set to one hour.

Ramp time open

Here you set the time that is required for the electric heater to go from 0 to

100%.

Ramp time close

Here you set the time that is required for the electric heater to go from 100 to 0%.

Show connected electric capacity

Check how much the electric heater (in percent) has been enabled. See more information under the heading Technical information.

Return to factor y settings

Return to the factory settings in menu 12. If on Customer level 2 when selecting Return to factory settings, only the settings in the displays accessible from Customer level 1 and 2 will be reset. If on the Installer/Service level when selecting Return to factory settings only the displays accessible from Installer / Service level are reset.

Timer readings

Read add. heat timer 6.2

Return Select

Timer readings

Read start delay 6.4

Return Select

Additional heat

Setting additional heat timer 8.1

Return Select

Mixed add. heat

Setting of ramp time open 8.3.4

Return Select

Mixed add. heat

Setting of ramp time close 8.3.5

Return Select

Additional heat

Show connected elec. capac. in op. 8.5

Return Select

Main menu

Return to factory settings 12

Return Select

30

Drying program for fl oor screed

When the heat pump has been installed in a newly built house with underfl oor heating, the Drying for fl oor screed function can be used.

The function is designed to slowly heat up the fl oor for a set number of days. The temperature is then maintained for a set number of days, fi nally allowing the fl oor to cool slowly for a set number of days. The heat pump works during drying operations with the hysteresis set in the display 1.4.

Set how many days you want the heating phase to last.

Set how many days you want the fl oor heating system to maintain the maximum drying temperature.

Set how many days you want the cooling phase to last.

Set the start and stop temperatures for the drying program.

Set the maximum temperature that the drying program should work at.

The function is activated and deactivated here. Drying program.

Temperature

Time

Commissioning the heat pump

Note

Due to the continuous operation which this function requires the electrical energy usage will be more than in normal operation. This will be refl ected in the heat pump running costs during the drying process.

During drying operations the heat pump does not produce any hot water and is not affected by timer controls.

Once the drying program has fi nished the heat pump returns to normal mode.

Drying program

No. of days for heating 5.14.1

Return Select

Drying program

No. of days for max temp 5.14.2

Return Select

Drying program

No. of days for cooling 5.14.3

Return Select

Drying program

Start/stop temperature 5.14.4

Return Select

Drying program

Max temp. during drying 5.14.5

Return Select

Drying program

Active drying 5.14.6

Return Select

Note

When a second heat curve with mixing valve is installed, it works according to the normal heat curve. The mixing valve must be opened manually when this circuit is to be included in the drying program.

31

Commissioning the heat pump

Start the heat pump with only additional heat

It might be necessary to run the heat pump before work on the heat transfer fl uid circuit is complete. Start the heat pump with heat from the electric heater only. The heating system must have been fi lled and vented to run the heat pump with electric heater only. Go to the menu display Select function only add. heat (menu 5.4) and press the Select button. If the arrow points towards Normal operation press the Adjust button. Turn the menu dial until the arrow points towards Only add. heat. Now press the Save button. This function ensures that the electric heater heats both the central heating water and the domestic hot water (DHW).

Commiss./Service

Select function only add. heat 5.4

Return Select

Note

Do not forget to return this function to normal mode.

Important points to check after start up

In the fi rst period after commissioning particular attention should be paid to the pressure and levels in the heat distribution and heat transfer fl uid circuits. After a short period of operation it may be necessary to top up the heat transfer fl uid.

On delivery the motor cut-out setting is determined by a value produced during hot water charging and a stable voltage. The recommended motor cut-out setting may not always be suitable as the voltage in the mains can fl uctuate. The setting may therefore, from case to case, need to be adjusted. Adjust the setting using a clip-on ampmeter when the heat pump is producing hot water. Set the motor cut-out level 10% above the highest measured value.

For the heat pump to perform at its best, it is important to check the fl ow on the primary circuit of the heat pump. Usually, the heating system pump has a speed selector switch. This must be set correctly for the pressure drop in the systems. A recommended temperature difference over the heat pump on the primary circuit is between 7-10 °C and on the collector circuit between 2-4 °C. Check this by going to menu display 3 and reading the sensors T8 (GT8) and T9 (GT9) as well as T10 (GT10) and T11 (GT11).

It is important in systems with a bypass that the fl ow in the heating system exceeds the fl ow over the heat pump. If this is not the case, the heat pump fl ow goes back via the bypass to the heat pump return, which may cause the heat pump to give an alarm for a high return temperature. The fl ow over the heating system should be enough to ensure that the entire radiator surface is kept warm. In this way the heat emitting surface increases and in doing so the fl ow temperature from the heat pump is kept down.

The heating system should be vented once again after test operations and the system pressure checked and topped up if necessary.

Motor cut-out setting

32

Maintenance

Maintenance

The heat pump requires a minimum of maintenance, however, it is recommended that the heat pump is checked annually by a qualifi ed installer.

Unscrew the front cover

Open the front cover to access some of the maintenance areas, e.g. the sight glass and fi lter. The front cover is secured at the top by two screws.

To remove the front cover from the heat pump:

1. Unscrew the two screws on the top. (See picture)

2. Tilt the front cover forwards.

3. Lift the front cover up to release the lower edge.

Sight glass

Bubbles may be seen for several minutes during the initial start up of the appliance. If bubbles are there continuously during operation, contact the customer service department.

Sight glass

Warning

The main power supply must be disconnected before working on the heat pump.

Only an accredited refrigeration company is permitted to work on the refrigerant circuit.

Remove the front cover by unscrewing the screws on the top.

If the sight glass shows green this means there is no moisture in the system. If it is yellow, there is moisture in the system. If this happens, contact the customer service department.

33

Maintenance

Filters

The fi lters ensures that no debris enters the heat exchangers. Over time the fi lters can become blocked and will require cleaning. There are fi lters on both the primary and collector circuits. To clean the fi lters:

1. Disconnect the heat pump from the mains electricity supply.

2. Close the valve and unscrew the sealing cap.

3. Remove the circlip holding the fi lter in the valve using the circlip pliers supplied.

4. Lift out the fi lter from the valve and wash clean with water.

5. Refi t the fi lter, the circlip and sealing cap.

6. Open the valve and start the heat pump.

Note

The fi lters may be concealed by insulation material or an enclosure.

Filter Circlip Sealing cap

Protective anode

A protective anode is located in the top of the cylinder with the task of preventing corrosion. The hot water cylinder must be fi lled with water in order for the anode to work.

If an error occurs, an alarm is activated in the control unit.

34

Expansion vessel

A plastic expansion vessel is connected to the heat pump heat transfer circuit (collector circuit). The level in the expansion vessel should not fall below the minimum level of 1/3 of the volume in the vessel.

The heat pump must be operating all the time while fi lling.

1. Remove the plug from the valve on top of the tank. Now carefully open the valve (fi gure 1).

2. Check that the valve is fully open (fi gure 2).

3. Fill with anti-freeze or water (to 2/3) with a clean watering can or similar (fi gure 3).

4. Close the valve and refi t the plug (fi gure 4).

Figure 1 Figure 2 Figure 3 Figure 4

Maintenance

Max. level

Min. level

35

What to do if a fault occurs

What to do if a fault occurs

The control unit has an advanced monitoring system that gives alarms if anything unforeseen happens in the heat pump. Most alarms are rectifi ed by the user without any damage to the heat pump. Contact the Technical support in case of repeated alarms.

Technical support

Technical Pre & Post sales

Tel: 08705-266241

Fax: 01905-752741

Example of an alarm:

Time when the alarm occurred.

Info button:

Press the Info button and turn the menu dial to display information of possible actions to rectify the alarm.

Cause.

Ackn. button:

Press the Ackn. button, the alarm indicator on the control panel goes out and the heat pump starts again within 15 minutes if there is a heating requirement. If the fault has not been rectifi ed the indicator will remain illuminated. Should several alarms have occurred on the heat pump, turn the menu dial clockwise for more information of each alarm.

Date when the alarm occurred.

[yymmdd]

ALARM (MB1)

Compr. circ. switch

060822 16:08:15

Info Ackn.

Info Acknowledge

Menu display dimmed

Possible cause 1: Power failure in the property consumer unit.

Action: 1. Check the fuses in the property consumer unit.

2. If a miniature circuit-breaker has tripped, reset the circuit breaker. Change the fuse if necessary.

3. The heat pump automatically returns to its operating mode 15 minutes after the fault has been rectifi ed.

Possible cause 2: The heat pump’s miniature circuit-breaker has

Action:

tripped.

1. Reset the heat pump’s miniature circuit-breaker by pushing up the centre toggle switch.

2. The heat pump automatically returns to its operating mode 15 minutes after the fault has been rectifi ed.

Miniature circuit-breaker

Note

For technical reasons the heat pump does not restart until 15 minutes after a stoppage.

36

What to do if a fault occurs

Fuses and reset buttons on the heat pump

Fuse 1

Reset for motor cut-out on compressor.

Fuse 2

Reset switch for the heat pump’s miniature circuit-breaker.

Fuse 3

Reset switch for the electric heater’s miniature circuit-breaker.

Fuse 4

Reset button for the electric heater overheat protection.

Note: The button must be pressed in fi rmly.

All alarms

There are many reasons why an alarm occurs. However, there is never a risk involved in resetting an alarm. All the alarms that can appear in the menu display are described on the following pages.

The descriptions give an idea about the nature of the alarm and how to rectify it. The text often refers to different fuses and reset buttons on the heat pump as shown in the diagram above.

List of all alarms:

Motor cut-out compressor

Motor cut-out HTF pump

Low pressure switch

High pressure switch

High return temperature to the heat pump

Heat transfer fl uid temperature

High heat transfer fl uid delta

Heat transfer fl uid temperature in under limit and heat transfer fl uid temperature out under limit

37

What to do if a fault occurs

Motor cut-out compressor (MB1)

Possible cause 1: Intermittent fault or overload on the power supply.

Action: 1. Press the Ackn. button.

The alarm indication goes out even if the fault has not been rectifi ed.

2. Reset the motor cut-out on the heat pump (Fuse 1).

3. Wait for the heat pump to start.

Possible cause 2: Current level (A) on the motor cut-out is set too low.

The current drawn by the compressor varies during summer/winter operations.

Action: 1. Contact the Technical Support Department.

Possible cause 3: Contactor or cut-out faulty, or loose electrical connections to the compressor.

Action: 1. Contact the Technical Support Department.

Possible cause 4: Compressor error.

Action: 1. Contact the Technical Support Department.

Motor cut-out HTF pump (MB2)

Possible cause 1: The HTF pump is blocked due to contamination.

Action: 1. Press the Ackn. button.

2. Loosen the vent screw and remove the dirt.

3. The pump may be freed with the aid of a small screwdriver. The alarm indication goes out even if the fault has not been rectifi ed.

Possible cause 2: Faulty electric motor on HTF pump.

Action: 1. Contact the Technical Support Department.

Possible cause 3: Temporar y error.

Action: 1. Contact the Technical Support Department at repeated alarms.

The menu display shows:

ALARM (MB1)

Compr. circ. switch

060822 16:08:15

Info Ackn.

Note

The reset switch for the compressor can be found under heading

Fuses and resetting buttons on the heat pump.

The menu display shows:

ALARM (MB2)

HTF c-pump switch

060822 16:08:15

Info Ackn.

Note

The alarm indication goes out when acknowledging the alarm even if the fault has not been rectifi ed.

38

Compressor temperature T6 (GT6)

Possible cause 1: The working temperature of the compressor is too high.

Action: 1. Press the Ackn. button.

2. Contact the Technical Support Department at repeated alarms.

Possible cause 2: Intermittent temperature rise due to abnormal

Action:

operating conditions.

1. Press the Ackn. button.

2. Monitor to see if fault clears.

Low pressure switch (LP)

Possible cause 1: The HTF pump has stopped or is set at too low a speed.

Action: 1. Press the Ackn. button.

2. Check that the pump has not stopped or is set at the wrong speed.

Possible cause 2: The fi lter on the collector circuit is blocked.

Action: 1. Check the fi lter.

2. Clean the fi lter if necessary.

3. Press the Ackn. button.

Possible cause 3: Air in the collector system.

Action: 1. Press the Ackn. button.

2. Check the expansion vessel.

3. Fill with fl uid if necessary.

4. Listen for air in the system. If air is heard constantly, contact the Technical Support Department.

Possible cause 4: Ice formation in the evaporator due to a lack of anti-freeze in the collector circuit.

Action: 1. Contact the Technical Support Department.

Possible cause 5: Faulty expansion valve (the alarm appears in

Action:

time periods of 3-4 weeks).

1. Contact the Technical Support Department.

Possible cause 6: Lack of refrigerant in the refrigerant circuit.

Action: 1. Press the Ackn. button.

2. Wait for the heat pump to start.

3. Check whether it bubbles continuously in the sight glass.

4. If it bubbles continuously, contact the Technical

Support Department.

What to do if a fault occurs

The menu display shows:

ALARM (GT6)

Compr. superheat

060822 16:08:15

Info Ackn.

The menu display shows:

ALARM (LP)

Low pressure switch

060822 16:08:15

Info Ackn.

39

What to do if a fault occurs

High pressure switch (HP)

Possible cause 1: Insuffi cient primar y fl ow over the heat pump.

Action: 1. Press the Ackn. button.

2. Check that the heating system pump has not stopped.

3. Check that all the valves are open. Radiator thermostat valves should be fully open and underfl oor heating systems should have at least half of the coils fully open.

4. Possibly increase the speed of the heating system pump.

Possible cause 2: The fi lter on the primar y circuit is blocked.

Action: 1. Press the Ackn. button.

2. Check the fi lter.

3. Clean the fi lter if necessary.

Possible cause 3: Air in the primar y circuit.

Action: 1. Press the Ackn. button.

2. Check whether there is air in the radiators/underfl oor circuit.

3. Fill the heating system and vent if necessary.

ALARM (HP)

High press. switch

060822 16:08:15

Info Ackn.

Note

Increase the speed of the heating system pump:

Use a screwdriver or a coin to increase the speed of the heating system pump.

Turn one step anti-clockwise.

Electric heater (EK)

(Shown as Electrical cassette in the menu display)

Possible cause 1: The electric heater miniature circuit-breaker has tripped.

Action: 1. Press the Ackn. button.

2. Reset the miniature circuit-breaker button on the heat pump (circuit-breaker 3) by pushing up the toggle switch.

3. Contact the Technical Support Department if the miniature circuit-breaker trips again.

Possible cause 2: The electric heater’s overheat protection has tripped.

Action: 1. Press the Ackn. button.

2. Reset the overheat protector (circuit-breaker 4) by pressing in the button on the electric heater’s protective casing. The circuit-breaker is reset when you hear a clicking sound.

3. Check that the fi lter on the primary circuit is clean.

ALARM (EK)

Electrical cassette

060822 16:08:15

Info Ackn.

Note

The miniature circuit-breaker button for the electric heater can be found under the heading Fuses and reset buttons on the heat pump.

The most frequent cause for the overheat protection tripping is a poor fl ow through the primary circulating pump, which can be due to air in the primary pump or a blocked fi lter.

40

What to do if a fault occurs

High Heat transfer fl uid delta T8/T9 (GT8/GT9)

The heat pump gives an alarm when the temperature difference between the sensors T8 (GT8) and T9 (GT9) is too high.

Possible cause 1: Insuffi cient fl ow over the heat pump.

Action: 1. Check that the heating system pump has not jammed.

2. Check that all the valves are open. The thermostat valves should be fully open and in underfl oor heating systems at least half of the coils should be fully open.

3. Increase the speed of the heating system pump.

If the actions above do not work please refer to page 13 reference fi tting bypass and an external main pump G1(P1).

ALARM GT8/GT9

High HTF delta

060822 16:08:15

Info Ackn.

Note

Increase the speed of the heating system pump:

Use a screwdriver or a coin to increase the speed of the heating system pump.

Turn one step anti-clockwise.

Possible cause 2: The fi lter on the primar y circuit is blocked.

Action: 1. Clean the fi lter.

High return to the heat pump T9 (GT9)

Sensor T9 (GT9) in the heat pump stops the compressor if the temperature of the return water from the radiators becomes too high. The limit is at approximately 57ºC.

Possible cause 1: The temperature setting is too high.

Action: 1. Lower the temperature setting (Temp. incr. / decr.).

Possible cause 2: The hot water temperature is set too high.

Action: 1. An alarm is given in hot water mode. Contact the

Technical Support Department to adjust the hot water temperature.

Possible cause 3: The valves on the radiators or underfl oor heating system are closed.

Action:

(Only applies if a bypass is fi tted)

1. Open all valves.

2. Press the Ackn. button.

Possible cause 4: The fl ow across the heat pump is greater than the fl ow in the heating system.

(Only applies if a bypass is fi tted.)

Action: 1. Reduce the speed of the heating system pump or increase the speed of the main pump in the heating system.

ALARM (GT9)

High return HP

060822 16:08:15

Info Ackn.

Note

The heat pump starts automatically when the temperature drops.

Lower the speed of the heating system pump:

Use a screwdriver or a coin to lower the speed of the heating system pump. Turn one step clockwise. The lowest speed should be avoided.

41

What to do if a fault occurs

Heat transfer fl uid out max T8 (GT8)

Sensor T8 (GT8) in the heat pump stops the compressor if the temperature of the water going out to the heating system becomes too high.

Possible cause 1: Insuffi cient fl ow over the heat pump.

Action: 1. Check that the heating system pump has not jammed.

2. Check that all the valves are open. Radiator thermostat valves should be fully open and underfl oor heating systems should have at least half of the coils fully open.

Possible cause 2: The fi lter on the primar y circuit is blocked.

Action: 1. Clean the fi lter.

ALARM (GT8)

Heat tran fl uid out

060822 16:08:15

Info Ackn.

Note

The heat pump starts automatically when the alarm is reset and the water temperature has dropped to its normal value.

Sensor fault

All sensors connected to the heat pump can give an alarm when defective. In the example to the right it is sensor T1 (GT1), Return radiator, which has given an alarm. All sensors give alarms in the same way. Read more about the sensors under heading Read the temperatures on the heat pump.

Possible cause 1: Temporar y error.

Action: 1. Monitor performance of the heat pump.

Possible cause 2: Short circuit or broken sensor cable.

Action: 1. If you have a multimeter you can disconnect the sensor and check the cable’s resistance. Compare with the sensor table in the section Technical information.

Possible cause 3: Defective sensor or incorrect connection.

Action: 1. Replace sensor/check connection.

ALARM (GT1)

Sensor return rad.

060822 16:08:15

Info Ackn.

Note

Switch off the power before checking the resistance of the cable.

42

What to do if a fault occurs

HTF in under limit T10 (GT10) and HTF out under limit T11 (GT11)

Possible cause 1: Temporar y low heat transfer fl uid temperature.

Action: 1. Monitor performance of the heat pump.

2. If the alarm returns, contact the Technical Support

Department.

Possible cause 2: Too low fl ow on the collector circuit.

Action: 1. Check the fi lter.

2. Clean the fi lter if it is blocked.

Possible cause 3: The minimum heat transfer fl uid temperature has been set too low.

Action: 1. Monitor performance of the heat pump.

2. If the alarm returns, contact the Technical Support

Department.

ALARM (GT10)

HTF (coll) in

060822 16:08:15

Info Ackn.

ALARM (GT11)

HTF (coll) out

060822 16:08:15

Info Ackn.

Anode error

Possible cause 1: Temporar y error.

Action: 1. When large amounts of hot water are used (e.g. with a bath) the alarm may be given without there being a fault. Contact the Technical Support

Department at repeated alarms.

Possible cause 2: Faulty electric anode.

Action: 1. Contact the Technical Support Department.

Alarm

Anode error

040622 16:08:15

Return Info

43

Commissioning report

Client / Installation address:

Installer:

Heat pump description:

Commissioning date: Heat pump serial number:

Type of ground collector (bore hole, horizontal loop, compact collector):

Total length of collector:

Other components of the installation:

Additional heat source

(boiler, solar etc)

Three-way valve

(mixing valve, zone valve)

......................................

Room sensor T5 (GT5)

......................................

Hot water cylinder temperature sensor T3

(GT3)

Mixing valve sensor T4 (GT4)

Others: ........................................................................................................................................................................................................

.............

Points to be checked prior to commissioning

Heating system

(pressurised and vented):

Collector system

(pressurised and vented):

fi lled

fi lled

Electric heater 3 6 9 kW:

set

Filters: checked

Sight glass (green): checked checked checked checked cleaned

Notes: ......................................................

Notes: ......................................................

Notes: ......................................................

Notes: ......................................................

Notes: ......................................................

Heating system pump G2 (P2) working correctly:................

Temperatures after 10 minutes heating or hot water mode:

Heat transfer fl uid pump G3 (P3) working correctly:................

Heat fl ow out T8 (GT8): ............./..............˚C Heat return in T9 (GT9): ............./..............˚C

Collector fl uid in T10 (GT10): ........../...........˚C

Collector fl uid out T11 (GT11): ........../...........˚C

44

Commissioning report

Pressure test of collector carried out .....................................................................................................

Checks on fl uid concentrations carried out (collector hose) .....................................................................................................

System pressure levels checked

.....................................................................................................

Functional test carried out

.....................................................................................................

Ensure that primary circuit has been correctly fl ushed

.....................................................................................................

Menu settings 1.1, 1.4, 5.2 and 5.13. carried out

Heat curve 1.1 and 1.2 set to:

.....................................................................................................

.....................................................................................................

Electricity reading on the house taken

The instructions about how to use the heat pump have been given to the client / to the user

Documentation about the heat pump has been handed over

Date and signature of the installer:

.....................................................................................................

.....................................................................................................

.....................................................................................................

45

Technical information

Technical information

The heat pump’s factory settings

This table indicates the factory settings for all the settings likely to be changed by the installer.

Menu Setting

1.1

1.2

Temp. incr. / decr.

Temp. Fine-tune

1.6

1.7

1.8

1.3

1.4

1.5

Heat curve adjust. (break)

Heat curve hysteresis

Mix. valve incr/decr

Mix. valve fi ne-tune

Adapting the mixing valve curve

Mixing valve curve neutral zone

1.9

Mixing valve curve max at GT4

1.10

Setting the room temperature

1.11

Setting the room sensor infl uence

1.12

Setting of holiday function

1.13

Remote control temperature

1.14

Setting of summer disconnection

2.1

Number of hours for extra hot water

2.2

Interval for hot water peak

2.3

4.1

Setting of hot water temperature

Clock setting HP accord. to clock

4.1.1

Setting level heat pump +/-

4.2

Clock setting additional heat according to clock

4.3

Clock setting hot water according to clock

5.2

5.4

5.5

5.7

Select connection capacity electric heater

Select function only additional heat

Select function additional heat

Select external controls

5.10

Select operation alt. P2

5.11

Select operation alt. P3

8.1

Setting additional heat timer

8.3.4

Ramp time open

8.3.5

Ramp time close

9.4

Min. temp pump inlet

9.5

Min. temp. pump outlet

Factor y setting

4

3º n/a

4

60º

20º

5

0 day

Inactive

18º

0 hours

Inactive

52º

00:00 - 00:00 (inactive)

00:00 - 00:00 (inactive)

00:00 - 00:00 (inactive)

2/3

Normal operation yes

0

P2 running cont.

P3 with Compres.

120 minutes

20 min

3 min

-10º

-10º

Sensor table

This table indicates the values of the sensor resistors to different temperatures.

Temperature (

ºC)

-40

30

35

40

45

50

5

10

15

20

25

-10

-5

0

-35

-30

-25

-20

-15

80

85

90

55

60

65

70

75

k

Ω

154.00

11.900

9.330

7.370

5.870

4.700

3.790

3.070

2.510

2.055

1.696

111.700

81.700

60.400

45.100

33.950

25.800

19.770

15.280

1.405

1.170

0.980

0.824

0.696

0.590

0.503

0.430

46

Technical information

Technical information

Greenstore Combi, Brine/Water heat pump

Emitted/ Supplied output at 0/45°C 1

COP 1

Minimum fl ow heating side

Nominal fl ow heating side

Maximum pressure available heating side (at nominal fl ow)

Nominal fl ow of antifreeze mixture to the collector hose

Maximum pressure available to collector hose (at nominal fl ow)

Type of antifreeze

Freeze protection temperature

Maximum pressure heating side of heat pump

Maximum pressure on collector hose side

Maximum outgoing temperature to the heating system

Maximum return temperature from heating system

Working temperatures on collector hose side

Integrated collector hose and heating system pump

Power supply

Additional heat settings kW l/s l/s kPa l/s kPa

°C bars bars

°C

°C

°C kW

6 7 9 11

5.19/1.80

6.55/2.20

8.20/2.67

9.63/2.92

2.89

0.14

0.20

2.97

0.18

0.25

3.06

0.22

0.31

3.29

0.26

0.38

36

0.30

36

0.38

34

0.46

32

0.57

49 45 44

Bioethanol - water or

Propylene/ethylene glycol - water

80

-15

2.5

4

65

57

-5 to +20

Yes

230V 1N~ 50Hz

3,0 / 6,0 / 9,0

The recommended type of fuse according to electrical output 2

6 kW electric heater

9 kW electric heater

Starting current, soft start

Compressor

Type R-407C HFC refrigerant

Connection for heat fl uid out/in

Out/in collector hose connection

Dimensions of heat pump (LxDxH)

Weight of heat pump (empty)

Weight of heat pump (full)

Integrated hot water cylinder with double shell

Volume of integrated hot water cylinder

Control unit

Ambient temperature (indoor use)

Maximum relative humidity

Sound power level 3

Sound pressure level 4

AaM

AaM

A kg mm mm mm kg kg l

°C rH dB(A) dB(A)

40

50

22,9

1.35

213

438

47.2

34.5

40

63

23,8

50

63

30,9

Scroll

1,4 1.5

Cu 22

Cu 28

600x640x1800

217 219

442 444

Stainless steel

185 / 40

Rego 637W

+10 to +30

50.1

37.4

60%

51.9

39.2

3

4

1

2

Data at 0/45°C according to the European standard EN 14511. Data applies to a new unit with clean heat exchangers.

aM type fuse, D characteristic MCB.

Measurement according to EN ISO 3743-2.

Calculated values at 1 m distance according to EN ISO 11203.

50

63

34,6

1.9

222

447

48.3

35.6

47

Technical information

Supplementary technical information

Maximum water supply pressure to the pressure reducing valve

Operating pressure DHW

Expansion vessel charge pressure

Expansion valve setting

16 bar

3 bar

3 bar

6 bar

Maximum primary working pressure 2,5 bar

Set opening pressure of the combined temperature and pressure relief valve 7 bar / 95°C

Expansion vessel, 19 liters 3 bar

Cylinder reheat times, Inner cylinder 185 Litres of DHW

To heat the full tank volume from 15°C to 60°C takes approx. 144 minutes

To reheat 70% of the tank volume to 60°C takes approx. 47 minutes.

Manufacturer

Appliance:

Cylinder:

IVT Industrier AB, part of BBT Thermotechnik GmbH

Box 1012, SE-57343 Tranås, Sweden

BoRö Pannan AB

Bangårdsv. 1, SE-95231 Kalix, Sweden

48

Part no: 8-716-113-342 Issue b

12168, Issue 1.0

EXCELLENCE COMES AS STANDARD

Worcester, Bosch Group

Cotswold Way, Warndon, Worcester WR4 9SW.

Tel. 01905 754624 Fax. 01905 754619

Worcester, Bosch Group is a brand name of BBT

Thermotechnology UK Ltd.

www.worcester-bosch.co.uk

CONTACT INFORMATION

WORCESTER, BOSCH GROUP:

TECHNICAL: 08705 266241

SERVICE: 08457 256206

SPARES:

LITERATURE:

TRAINING:

SALES:

01905 752571

01905 752556

01905 752526

01905 752640

WEBSITE: www.worcester-bosch.co.uk

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