INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS GREENSOURCE HYDROLIGHT AND HYDROCOMFORT

INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS GREENSOURCE HYDROLIGHT AND HYDROCOMFORT
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
AIR TO WATER SPLIT HEAT PUMP
GREENSOURCE HYDROLIGHT AND HYDROCOMFORT
OUTDOOR UNIT 7.5, 10, 11 AND 12, 1 PHASE AND 3 PHASE MODELS
HYDROLIGHT 8 AND 16 1 PHASE
HYDROCOMFORT 8 AND 16 1 PHASE AND 3 PHASE
6 720 648 135-00.1I
6 720 806 629 (2013/02)
UK/IE
TABLE OF CONTENTS
TABLE OF CONTENTS
1
Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3
1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2
Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3
Pre - installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1
Air source Heat pump operation . . . . . . . . . . . . . . . . . . . 4
3.2
Selection and sizing of a heat pump . . . . . . . . . . . . . . . . . 4
3.3
Heat loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4
Heat emitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5
Regulations and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6
Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1
Information about the heat pump . . . . . . . . . . . . . . . . . . . 8
7.2
Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.4
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.5
Positioning the heat pump . . . . . . . . . . . . . . . . . . . . . . . . 9
7.6
Defrost method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.7
Checks before installation . . . . . . . . . . . . . . . . . . . . . . . . 9
7.8
CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.9
CAN-BUS termination . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.10 Handling circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . 10
8
9
2
Dimensions, clearance and pipe connections . . . . . . . . . . . .
8.1
Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Hydrolight/Hydrocomfort unit . . . . . . . . . . . . . . . . . . .
8.3
Pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3
Preparing the pipe connections . . . . . . . . . . . . . . . . . .
9.4
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5
Connect the heat pump to the heating system . . . . . .
9.6
Flushing the heating system . . . . . . . . . . . . . . . . . . . . .
9.7
Connecting the refrigerant pipe . . . . . . . . . . . . . . . . . .
9.8
Filling the heating system . . . . . . . . . . . . . . . . . . . . . . .
9.9
Connecting a Heat pump DHW cylinder (3rd party) . .
9.10 3-way valve (accessory) . . . . . . . . . . . . . . . . . . . . . . . .
9.11 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12 Installing the temperature sensors . . . . . . . . . . . . . . . .
9.13 Other connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14 Additional mixer group (accessory) . . . . . . . . . . . . . . .
9.15 Disconnecting accessories . . . . . . . . . . . . . . . . . . . . . .
11
11
14
14
16
16
16
16
16
16
16
17
20
21
22
22
22
23
23
23
10 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.1 Connecting the heat pump . . . . . . . . . . . . . . . . . . . . . . . 24
10.2 Connecting the Hydrolight/Hydrocomfort module . . . . 26
10.3 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.4 PCB Layout in control panel, Hydrolight unit . . . . . . . . 27
10.5 Switch settings, Hydrolight unit . . . . . . . . . . . . . . . . . . . 28
10.6 Power supply, Hydrolight unit and additional mixed
heating circuit (accessory) . . . . . . . . . . . . . . . . . . . . . . 29
10.7 Terminal connection diagram, Hydrolight unit with 2nd
heat appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.8 Wiring diagram, Hydrolight unit with 2nd heat appliance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.9 Signal cable, Hydrolight unit with 2nd heat appliance . 32
10.10 Layout in control panel, Hydrocomfort unit with electr.
heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.11 Switch settings, Hydrocomfort unit with electr. heater and
additional mixed heating circuit (acc) . . . . . . . . . . . . . 34
10.12 Power supply, Hydrocomfort unit with electr. heater . 35
10.13 Terminal connection diagram, Hydrocomfort unit with
electr. heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.14 Wiring diagram, Hydrocomfort unit with electr. heater 37
10.15 Signal cable, Hydrocomfort unit with electr. heater . . . 38
11 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.1 Specification - outdoor unit . . . . . . . . . . . . . . . . . . . . . . 39
11.2 Specification, hydrolight unit with 2nd heat appliance 40
11.3 Specification - Hydrocomfort unit with electr. heater . 41
11.4 System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12 General system information . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.1 Heating circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.2 Heating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.3 Control method for compressor . . . . . . . . . . . . . . . . . . 50
12.4 Time control of central heating . . . . . . . . . . . . . . . . . . . 50
12.5 Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.6 Operation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.7 Mixing valve control (mixing valve for 2nd heat appliance
and heating circuit with mixer) . . . . . . . . . . . . . . . . . . . 50
13 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
13.1 Overview of the user interface . . . . . . . . . . . . . . . . . . . . 50
13.2 Control panel function . . . . . . . . . . . . . . . . . . . . . . . . . . 51
13.3 Menu tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14 Installation and service menu (I/S) . . . . . . . . . . . . . . . . . . . . . 51
15 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16.1 Switching on the heat pump . . . . . . . . . . . . . . . . . . . . . . 57
16.2 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.3 Heating settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.4 Domestic hot water settings . . . . . . . . . . . . . . . . . . . . . . 60
16.5 Settings for heating circuit 2 . . . . . . . . . . . . . . . . . . . . . 61
16.6 Other settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
16.7 Fast restart of heat pump . . . . . . . . . . . . . . . . . . . . . . . . 62
6 720 806 629 (2013/02)
KEY TO SYMBOLS AND SAFETY INSTRUCTIONS
16.8
Screed drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17 Timer (timer programs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
18 Error management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.1 Alarm history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.2 Alarm log and Info log . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.3 Example of an alarm: . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.4 Dimmed menu display . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.5 All alarms, warnings and information windows . . . . . . 64
18.6 Alarm window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.7 Warning message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18.8 Information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18.9 Info symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18.10 Checking the heat pump using the diagnostic tool
(accessory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
19 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
19.1 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• WARNING indicates that serious injury may occur.
• DANGER indicates possible risk to life.
IMPORTANT INFORMATION
Important information in cases where there is no risk of
personal injury or material losses is identified by the
symbol shown on the left. It is 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)
Table 1
1.2
SAFETY INSTRUCTIONS
GENERAL
▶ Read the guide carefully and keep it to hand for future use.
20 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.1 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20.2 Setting the operating pressure of the heating system .
20.3 Operating temperatures . . . . . . . . . . . . . . . . . . . . . . . .
73
73
73
73
21 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
22 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
22.1 Particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
22.2 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION AND COMMISSIONING
▶ The heat pump may be installed and put into operation only by a
competent person.
SERVICE AND MAINTENANCE
▶ Only qualified personnel may carry out repairs. Incorrect repairs can
lead to serious risks to the user, and a reduction in savings.
▶ Only use original spare parts.
▶ Service and maintenance must be carried out annually by a competent
person.
HANDLING REFRIGERANT
The air to water heat pump is filled with R410A refrigerant.
23 The guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant circuit.
▶ For all work with refrigerant, wear suitable safety gloves and goggles.
24 Commissioning report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
WHAT TO DO IF REFRIGERANT LEAKS
If refrigerant leaks and touches the skin, it can cause frostbite.
25 Inspection and maintenance reports . . . . . . . . . . . . . . . . . . . 77
26 Benchmark log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1
KEY TO SYMBOLS AND SAFETY
INSTRUCTIONS
1.1
KEY TO SYMBOLS
▶ 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.
▶ If the refrigerant leaks please contact your installer immediately.
WARNINGS
Warnings in this document are framed and identified by
a warning triangle which is printed on a grey
background.
Keywords indicate the seriousness of the hazard in terms of the
consequences of not following the safety instructions.
• NOTICE indicates that material damage may occur.
• CAUTION indicates that minor to medium injury may occur.
6 720 806 629 (2013/02)
3
BENCHMARK
2
BENCHMARK
Benchmark places responsibilities on both manufacturers and
installers. The purpose is to ensure that customers are provided with the
correct equipment for their needs, that it is installed, commissioned and
serviced in accordance with the manufacturer's instructions by
competent persons and that it meets the requirements of the
appropriate Building Regulations. The Benchmark Checklist can be used
to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.
Installers are required to carry out installation, commissioning and
servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hotwater Industry Council who
manage and promote the scheme. Visit www.centralheating.co.uk for
more information.
3
PRE - INSTALLATION
3.1
AIR SOURCE HEAT PUMP OPERATION
As the outside temperature gets colder, the heat demand of a house
increases and the output of an air source heat pump will decrease.
Eventually it becomes so cold outside that the output of the heat pump
alone is not able to heat the building effectively. The Greensource Split
range of air source heat pumps therefore allow for either monoenergetic
(with Hydrocomfort module) or bivalent (with Hydrolight module)
operation.
Monoenergetic means that in the event of very low external
temperatures a 3-stage electrical heater in the indoor unit will
automatically be activated to provide additional heat and keep the
building warm.
In bivalent operation a second heating appliance (e.g. gas or oil boiler) is
used to supplement the heat load.
3.2
SELECTION AND SIZING OF A HEAT PUMP
It is essential that heat pump systems are designed to operate efficiently
in order to meet the building heating needs and the expectations of the
customer. In order to achieve this, the following design activities must
be completed prior to installation:• Pre-design assessment - Determine the suitability of a heat pump
system for the building based on the customer requirements,
expectations and building type.
• Detailed design - Complete building heat loss calculations and
domestic hot water usage assessment.
• Specification - Select a suitable heat pump and system components
based on the detailed design. Calculate and communicate the
predicted energy use and running costs of the system to the
customer.
A suitable design methodology for the above is detailed in MIS3005, the
Microgeneration Certification Scheme (MCS) heat pump installer
standard. Worcester, Bosch Group recommended that this standard is
followed for heat pump systems. The standard covers the design,
installation and commissioning requirements to ensure that 100% of the
building heat loss can be met efficiently by the heat pump system. A heat
pump system must be designed to this standard to be eligible for
government financial incentives e.g Renewable Heat Incentive (RHI).
3.3
HEAT LOSS
The total heat loss of the house is calculated from the addition of fabric
and ventilation heat losses.Fabric heat loss is the transmission of heat by
conduction through the building structure, i.e windows, walls, roof and
floor. Ventilation heat loss is heated air escaping from the house and
being replaced by cold air from outside.
3.3.1 CALCULATING THE HEAT LOSS OF THE HOUSE
It is essential to accurately calculate the heat loss of the house to ensure
correct sizing of the heat pump system. The heat loss is dependent on
the construction of the house, room sizes, external and internal design
temperatures and air change rates. The heat loss calculations should
satisfy the requirements of BS EN 12831.
3.3.2 ESTIMATING HEAT LOSS
Estimating the heat loss of the building is useful in determining the
suitability of a heat pump system. However, assumptions based on floor
area (e.g. 50 W/m² for new build etc.) and SAP (the governments
Standard Assessment Procedure) should not be used for the detailed
design and specification stage. It should be noted that the heat loss for
non standard houses i.e. houses with large areas of glazing, high
ceilings, log burners etc. or houses in exposed locations may deviate
significantly from any rules of thumb.
In existing properties, boilers are often oversized and should therefore
not be used to determine the actual heat requirements of the house.
However, estimates may be made on the basis of the existing energy
consumption of the space to be heated.
This installation manual does not cover all the necessary details to
calculate the heat loss. The information given here is provided to remind
the heating system designer and installer of the process and
considerations.
4
HEAT EMITTERS
Worcester, Bosch Group heat pumps are fitted with weather
compensation controls as standard. However, for a heat pump to
perform to its highest energy efficiency, the central heating emitter
circuit should be designed so that the flow temperature is as low as
possible.
As a guide, the system should be designed using the following maximum
flow temperatures;
• Underfloor heating: 35-40 °C
• Radiators: 45-50 °C
If underfloor heating has been installed, it is important to remember that
the underfloor system designer should have been informed that the heat
source will be from an air source heat pump. It is also important to
remember that radiators should have been correctly sized to work
effectively with lower flow temperatures.
A tool to aid installers and end users to understand the relevance of
building heat loss and heat emitter selection on heat pump performance,
has been created by the joint trade associations. The 'Heat Emitter
Guide' can be downloaded from the following website:
www.microgenerationcertification.org
The Worcester Bosch Group design team offer a heat pump sizing
service which is MCS compliant. To request this service, download and
submit the form using the guidance notes from our website address:
www.worcester-bosch.co.uk/hp
4
6 720 806 629 (2013/02)
REGULATIONS AND STANDARDS
5
REGULATIONS AND STANDARDS
Installation of this heat pump should be done in
accordance with MCS/MIS 3005.
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: Requirements heat pumps for space heating
BS EN 378: Safety and environmental requirements for heat pumps
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).
The Building Regulations (Northern Ireland) 2000.
In accordance with current EU legislation (the F-gas regulation, EC
Regulation No 842/2006 which came into effect on 4 July 2006), a
heat pump that contains more than 3 kg of refrigerant R410A must be
checked regularly by an accredited technician.
It is therefore a requirement that the owner of a Worcester Greensource
Split Heat Pump has the refrigerant circuit checked by an accredited
technician. Leak tests must be performed at installation and then
repeated every 12 months.
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5
STANDARD DELIVERY
6
STANDARD DELIVERY
2
3
4
5
6
T1
T2
7
8
9
Fig. 1
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[T1 ]
[T2]
6 720 648 135-13.2I
Standard delivery, Hydrolight/Hydrocomfort 8 module
Hydrolight/Hydrocomfort module (example)
Installation instructions and operating instructions
Cable gland X 2
Particle filter with strainer
Circlip pliers
Jumpers for 1-phase installation X 21)
Male adapter part 22 mm (Hydrocomfort X 1, Hydrolight X 1)
Female adapter part 22 mm (Hydrocomfort X 1, Hydrolight X 3)
Washer 1” (Hydrocomfort X 2, Hydrolight X 4)
Flow temperature sensor
Outside temperature sensor
1) All hydrocomfort are 3 -phase on delivery, ( Chapter 10.1.2)
6
6 720 806 629 (2013/02)
STANDARD DELIVERY
2
3
4
5
6
T1
T2
7
8
9
Fig. 2
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[T1 ]
[T2]
6 720 648 135-13.2I
Standard delivery, Hydrolight/Hydrocomfort 16 module
Hydrolight/Hydrocomfort module (example)
Installation instructions and operating instructions
Cable gland X 2
Particle filter
Circlip pliers
Jumpers for 1-phase installation X 21)
Male adapter part 28 mm (Hydrocomfort X 1, Hydrolight X 1)
Female adapter part 28 mm (Hydrocomfort X 1, Hydrolight X 3)
Washer 1” (Hydrocomfort X 2, Hydrolight X 4)
Flow temperature sensor
Outside temperature sensor
1) All hydrocomfort are 3 -phase on delivery, ( Chapter 10.1.2)
6 720 806 629 (2013/02)
7
GENERAL
1
6 720 648 125-02.1I
Fig. 3
[1]
Standard delivery, ODU 7.5
ODU 7.5
1
6 720 648 125-84.1I
Fig. 4
[1]
7
Standard delivery, ODU 10 / 11 / 12
ODU 10 / ODU 11 / ODU 12
GENERAL
Only competent persons may carry out the installation.
The installer must follow applicable rules and regulations
and recommendations from the manufacturer.
ODU
7.5
10
11s
12s
11t
12t
Hydrolight
8
16
16
16
16
16
Greensource Split HP Hydrolight
8kW Single-phase
11kW Single-phase
14kW Single-phase
16kW Single-phase
14kW Three-phase
16kW Three-phase
Hydrocomfort
8
16
16
16
16
16
Greensource Split HP Hydrocomfort
8kW Single-phase
11kW Single-phase
14kW Single-phase
16kW Single-phase
14kW Three-phase
16kW Three-phase
Table 2
7.1
INFORMATION ABOUT THE HEAT PUMP
The Worcester Greensource unit consists of one of the following outdoor
units ODU 7.5; 10; 11 or 12 external module and the option of either a
Hydrolight/Hydrocomfort 8 or Hydrolight/Hydrocomfort 16 internal
unit.
This results in the following combinations (s=single phase, t=three
phase):
ODU
7.5
10
11s
11t
12s
12t
Table 3
8
6 720 806 629 (2013/02)
GENERAL
The Hydrocomfort is designed for single input operation with integrated
electric heating element.
7.6
In regions where the air has a high moisture content and
there is a danger of freezing (near lakes, rivers and the
sea), the SW 7-6 switch can be switched to "on". This
shortens the defrosting cycles.
The Hydrolight is designed for dual mode operation with an oil or gas
boiler.
7.2
DEFROST METHOD
APPLICATION AREA
The heat pump must only be used in a sealed heating system according
to BS EN 12828.
Other forms of use are not permitted. Worcester, Bosch group take no
responsibility for damage occurring due to non-permitted use.
The principle of defrosting in the outdoor unit is known as hot gas
defrosting. During defrosting, the flow in the refrigerant circuit is
reversed by means of an electrically-controlled four-way valve.
The heating system to which the heat pump is connected must have a
volume of at least 25L always available, otherwise a buffer tank (primary
water storage) must be installed.
The compressed gas from the compressor is fed into the top of the
evaporator, causing the ice on the outside to melt. During this process,
the water in the heating system is cooled slightly. The time required for
defrosting depends on the amount of ice and the outdoor temperature.
7.3
DATA PLATE
The data plate for the heat pump is on the service hatch. Information
about the heat pump's output, part number, serial number, amount of
refrigerant fluid in the pump and the date of manufacture is stated there.
The data plate for the Hydrolight/Hydrocomfort module is on the electric
box of the unit.
7.4
TRANSPORT AND STORAGE
The outdoor unit and Hydrolight/Hydrocomfort unit must be transported
and stored in an upright position. The outdoor unit may be tilted
temporarily, but must not be laid down.
The Hydrolight/Hydrocomfort module must not be stored or transported
at temperatures below – 10 °C. The outdoor unit must not be stored at
temperatures below – 10 °C.
7.5
POSITIONING THE HEAT PUMP
Heat pump installations should be made in accordance
to the current MIS3005 micro generation installation
standards and including MCS020 planning standards.
There are two options available as accessories for fixing
the outdoor unit:
▶ Floor standing version
▶ Wall-mounted version (only on 8kW unit)
• The outdoor unit is placed outdoors, on a level and stable surface.
Cast slabs are recommended.
• Sound propagation must be taken into consideration when
positioning the outdoor unit.
• When locating of the outdoor unit consideration must be done to
minimise the noise so that neighbouring properties are not adversely
affected.
• The outdoor unit must be positioned so that air is not prevented from
passing through the evaporator.
• The outdoor unit must not be positioned so that the recirculation of
cold air can occur.
• Avoid positioning the outdoor unit so that it is exposed to wind
directly from the front.
• The outdoor unit must not be positioned where there is a risk of snow
and rain drops from eaves. If this is not possible, install a protective
roof with a minimum distance of 1 m.
• The Hydrolight/Hydrocomfort unit is positioned indoors. Pipework
between the outdoor unit and the Hydrolight/Hydrocomfort module
must be as short as possible. The pipes must be insulated.
• Only connect the outdoor unit and internal unit using suitable
refrigerant lines.
• Discharge water from the safety valve must be routed away from the
Hydrolight/Hydrocomfort module to a frost free drain so that any
discharge does not create a risk.
6 720 806 629 (2013/02)
7.7
CHECKS BEFORE INSTALLATION
▶ Installation of the outdoor unit should be performed by a competent
person.
▶ The outdoor unit installation must follow the current applicable
regulations.
▶ Check that all pipe connections are intact and have not shaken loose
during transportation.
▶ Before the outdoor unit is commissioned, the heating system, hot
water cylinder and the heat transfer fluid system, including the
outdoor unit, must be filled and vented.
▶ Wiring should be kept as short as possible to protect the system from
downtime, for example during a thunderstorm.
7.8
CAN-BUS
CAUTION: Interference.
▶ The CAN-BUS cable must be screened and laid with a
minimum distance of 100mm separately from the
power cable.
CAUTION: Do not mix up the 12 V and CAN-BUS
connections!
The processors will be damaged beyond repair if 12 V is
connected to the CAN-BUS.
▶ Ensure that the four cables which are to be connected
to the contacts on the printed circuit boards are made
with their corresponding markings.
The printed circuit boards in the Hydrolight/Hydrocomfort unit, and
accessories board if applicable, are connected via the CAN-BUS
communication line. The CAN (Controller Area Network) is a system that
facilitates communication between microprocessor-based modules/
printed circuit boards.
A room controller is available as an accessory and must be connected by
a CAN-BUS cable.
Suitable cable for external laying is cable type LIYCY (TP) 2x2x0.5.
The cable must be twisted pair and screened. The screen must only be
earthed at one end and to the chassis.
Maximum cable length is 30 m between the internal room controller and
the internal Hydro unit.
The CAN-BUS cable must not be routed together with the mains cable
that carry 230 V or 400 V. The minimum clearance is 100 mm. Routing
of these cable together with the sensor cables is not permitted.
The connection between the circuit boards is by four wires, because the
12V-supply between the circuit boards must also be connected. The
circuit boards have markings for both the 12V and CAN-BUS
connections.
9
GENERAL
7.9
CAN-BUS TERMINATION
1
Term
No Term
A method for good ESD protection is a ground-connected bracelet when
handling electronics. This bracelet must be put on before opening the
screened metal bag/packaging or before exposing an installed board.
The bracelet must be worn until the circuit board is enclosed in its screen
packaging or closed electric box. Replaced, returned circuit boards must
be handled in the same way.
2
6 720 644 816-03.1I
Fig. 5
[1]
[2]
CAN-BUS termination
Terminated CAN-BUS
Non-terminated CAN-BUS
Switch S1 marks the start and end of the CAN-BUS connection. The
display card (labelled with CPU on the wiring diagram) and the
accessories board (IOB-B) in the Hydrolight/Hydrocomfort module must
be terminated by switch S1 (position ON).
If the CAN-BUS connected room controller is used it is terminated, and
S1 on the main circuit board (IOB-A) in the Hydrolight/Hydrocomfort
module must be set to not terminated (position OFF).
When using the Multi Box kit (which is an accessory), the board in this
unit must instead be terminated in the main board of the Hydrolight/
Hydrocomfort unit.
We recommend that all printed circuit boards that are to be connected
to the CAN-BUS are installed first. When this is being done, switch S1
must be in the Term position. (ON position).
6 720 614 366-25.1I
Fig. 7
Using an anti static bracelet
7.9.1 SETTING OF SWITCH S1
When switch S1 is in position ON, the loop is terminated. In position ON,
S1 is placed at the middle position and covers the hole in the board.
When switch S1 is in position OFF, the loop is not terminated. In position
OFF, S1 is placed at one of the side positions and the hole in the board
is not covered.
7.10 HANDLING CIRCUIT BOARDS
CAUTION: Always wear a a ground-connected bracelet
when handling electronics.
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.
6 720 614 366-24.1I
Fig. 6
Anti static bracelet
Damage is usually latent, and a circuit board can operate correctly
during commissioning but show signs of problems later. Charged
objects may only be problematic if they are in close proximity to the
electronics. Keep a distance of at least one metre from expanded
polystyrene, protective plastic and other packaging, synthetic material
(e.g. fleeces) and similar before starting work.
10
6 720 806 629 (2013/02)
DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
8.1.2 SIZE OF OUTDOOR UNIT
8
DIMENSIONS, CLEARANCE AND PIPE
CONNECTIONS
8.1
3
OUTDOOR UNIT
+
30
30
95
0
943
1
2
3
17
5
60
0
37
6 720 644 816-07.1I
Fig. 8
[1]
[2]
[3]
Connections, outdoor unit
Connections, power and signal cable
Refrigerant pipe connection (flare connection) ø 9.52 (3/8”)
Refrigerant pipe connection (flare connection) ø 15.88 (5/8”)
0
6 720 644 816-06.1I
Fig. 10 ODU 7.5, dimensions in mm
Connections apply for all outdoor unit sizes.
3
+
30
30
10
8.1.1 REQUIRED MINIMUM CLEARANCES
FOR THE OUTDOOR UNIT
50
Minimum distance between the outdoor unit and the wall is 150 mm.
Minimum distance in front of the outdoor unit is 500 mm for ODU 7.5,
10 and 11, 1000 mm for ODU 12t.
Any protective roof must be installed at least 1 metre above the outdoor
unit, to prevent recirculation of cold air.
1338
Minimum distance at the sides of the outdoor unit is 150 mm.
1000
22
5
60
0
37
15
0
0
6 720 644 816-10.2I
15
0
150
Fig. 11 ODU 10, 11 and ODU 12, dimensions in mm
6720648125-07.1I
Fig. 9
Dimensions in mm
6 720 806 629 (2013/02)
11
DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
8.1.3 INSTALLATION LOCATION
Heat pump installations should be made in accordance
to the current MIS3005 micro generation installation
standards and including MCS020 planning standards
and Manufacturers instructions, suitable mounting
components are available as accessories.
WARNING: Risk of damage
▶ The floor mounting feet with Anti vibration is designed
to withstand the weight of the outdoor unit. The
installer is responsible for ensuring that the
installation area is appropriate for dealing with the
total weight of the outdoor unit and the floor stand.
▶ It is advisable also to secure some form of safety wire
between the upper section of the outdoor unit and the
wall. This is to prevent the risk of tipping.
WARNING: Risk of damage
▶ The wall mounting bracket is designed to withstand
the weight of the 7.5 outdoor unit only. The installer is
responsible for ensuring that the wall and the selected
fasteners are suitable for handling the total weight of
the outdoor unit and the wall mount.
▶ It is advisable also to secure some form of safety wire
between the upper section of the outdoor unit and the
wall. This is to prevent the risk of tipping.
Make sure that the unit is installed on a stable and even surface, to
prevent rattling noises during operation. Recommended installation
height above ground is a minimum of 100 mm, to compensate for ice
formation.
1
2
3
6720644816-09.1I
Fig. 12 Dimensions in mm
[1]
[2]
[3]
12
> 100 mm above ground
Level subsurface with sufficient load bearing capacity, e.g.
cement slab cast in-situ
Ventilation hole, must not be obstructed
6 720 806 629 (2013/02)
DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
8.1.4 APPLIANCE LAYOUT
1
2
3
4
7
6
5
6720648125-09.2I
Fig. 13 outdoor unit (example shows ODU 12)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Connections, electric and signal cable
Cable terminals
Connection, liquid (during heating mode)
Connection, hot gas (during heating mode)
Shut-off valves, liquid and hot gas
Compressor
Service outlet at shut-off valve for liquid (connection for vacuum
pump)
Connections apply for all outdoor unit sizes.
6 720 806 629 (2013/02)
13
DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
8.2
HYDROLIGHT/HYDROCOMFORT UNIT
8.3
PIPE CONNECTIONS
During the installation, the front panel of the
Hydrolight/Hydrocomfort unit can be removed and
placed on the hooks on the left or the right side of the
module, or underneath the unit.
Adapter parts delivered with the appliance are only for
water connections.
▶ Assemble male adapter part after particle filter,
towards the heating system.
▶ Assemble female adapter part/parts at the pipe
connections of the Hydrolight/Hydrocomfort unit.
The particle filter is installed in the return heating pipe to
the Hydrolight/Hydrocomfort ( [E21.V101], chapter
11.4.3).
50
NOTICE: Risk of leakage!
▶ Use washers delivered with the appliance and teflon
band (not in delivery) when assembling adapter parts
to appliance pipe connections.
50
The following connections must be made in the Hydrolight/
Hydrocomfort unit:
150
▶ Route the discharge water hose from the safety valve downwards to a
frost free drain.
Pipe dimensions
Flow/return, heating system and additional heat
R25,
1”(26x34)
5/8” and 3/8”
Refrigerant pipe gas/liquid, to outdoor unit
Table 4 Pipe dimensions
120
100
70
40
170
190
600
80
120
120
6 720 648 131-24.1I
6 720 644 816-11.1I
Fig. 14 Minimum dimensions of Hydrolight/Hydrocomfort unit
(dimensions in mm)
Fig. 15 Pipe connections of dual mode Hydrolight unit, with mixing valve
for 2. heat appliance.
An installation clearance of at least 50 mm is required between the
Hydrolight/Hydrocomfort unit and the walls.
An installation clearance of at least 600 mm is required in front of the
Hydrolight/Hydrocomfort unit. An installation clearance of at least
150 mm is required above the Hydrolight/Hydrocomfort unit.
14
6 720 806 629 (2013/02)
DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
120
100
70
6
4
170
7
2
3
190
1
8
5
40
6 720 644 816-12.2I
Fig. 16 Pipe connections of dual mode Hydrolight unit, with mixing valve
for 2. heat appliance.
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Liquid line
Discharge water from the safety valve
Return (back to boiler)
Hot gas line
Pressure gauge
Flow (from boiler)
Heating return
Heating flow
320
6 720 648 131-25.1I
Fig. 18 Pipe connections for Hydrocomfort module with electric booster
heater.
1
2
1
6
5
5
6
2
3
4
3
6 720 644 816-16.2I
7
4
6 720 648 135-12.2I
Fig. 17 Pipe connections of dual mode Hydrolight unit, with mixing valve
for 2. heat appliance.
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Pressure gauge
Heating return
Flow (from boiler)
Heating flow
Hot gas line
Liquid line
Return (back to boiler)
6 720 806 629 (2013/02)
Fig. 19 Pipe connections for Hydrocomfort module with electric booster
heater.
[1]
[2]
[3]
[4]
[5]
[6]
Liquid line
Discharge water from the safety valve
Heating flow
Hot gas line
Pressure gauge
Heating return
15
INSTALLATION
9
INSTALLATION
Only competent installers may carry out the installation.
The installer must follow all current rules and regulations
and recommendations from the manufacturer.
9.1
ACCESSORIES
9.4
POSITIONING
▶ Remove the supplied accessories.
▶ Remove the packaging according to the instructions on the packaging.
9.5
CONNECT THE HEAT PUMP TO THE HEATING SYSTEM
Heat losses can be reduced by keeping the lengths of
pipework outdoors short.
If there is a danger of ice formation, a heating cable must
be installed in the condensate pan and condensate
drain. A heating cable is always recommended.
The diagnosis tool is required for troubleshooting at the
outdoor unit available as an accessory.
The following accessories are available:
• Floor mounting feet with Anti vibration
• Wall mounting bracket for assembly of outdoor unit on the wall
• Tray for collecting and discharge of defrost water from the outdoor
unit
• Room temperature controller, CAN-BUS LCD
• Buffer (primary water storage) for heating mode
• 3-way valve (for domestic hot water) plus DHW temperature sensor
• Heating cable
• Multi Box for different heating circuits
• Diagnosis tool (for Service only)
9.2
▶ Insulate the outdoor pipes with a material that does not absorb
moisture, such as Armaflex.
▶ Install the particle filter.
The task of the particle filter is to filter out dirt before it can enter the
heat pump. Accordingly, the supplied filter valve must always be fitted
on the return pipe, between the indoor unit (Hydrolight/Hydrocomfort)
and the heating system. It should be fitted as close to the indoor unit as
possible and be horizontal.
The particle filter is installed in the return heating pipe to
the Hydrolight/Hydrocomfort ( [E21.V101], chapter
11.4.3).
9.6
FLUSHING THE HEATING SYSTEM
FOLLOW THE GUIDANCE OF BS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
CONNECTION PRINCIPLE
The function is based on continuous condensation and booster heating
of the Hydrolight/Hydrocomfort units. The control unit regulates the
heat pump in accordance with the set heating curve with the actual
temperatures captured by the outside temperature sensor T2 and flow
temperature sensor T1.
NOTICE: Artificially softened water must not be used to
fill the central heating system.
At outside temperatures below approx. -20 °C (adjustable value), the
outdoor unit stops automatically and can no longer deliver heat. The
booster heater in the Hydrocomfort module or the auxiliary heat
appliance (boiler) connected to the Hydrolight module automatically
takes over the heating mode and DHW production.
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 heat pump is connected.
▶ Run the 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.
▶ Clean the particle filter.
9.3
INHIBITOR
When the heat pump can no longer meet the entire heating demand on
its own due to the outside air temperature, either the Hydrolight with
boiler support/Hydrocomfort with electric booster heater starts
automatically and together with the heat pump, generates the
temperature required inside the building.
Hot water is prioritized and controlled by the sensor T3 in the heat pump
hot water cylinder. While the water is being heated in the hot water
cylinder, the heating system of the heat pump is temporarily
disconnected by a 3-way valve. The heating operation of the heat pump
continues when the water in the hot water cylinder has reached the set
temperature.
Heating and DHW mode with the heat pump in an idle state:
PREPARING THE PIPE CONNECTIONS
The drain pipe from the safety valve of the internal unit is
to be frost-protected and attached from below.
If the system is exposed to freezing conditions, add a suitable inhibitor
or combined inhibitor/anti-freeze in accordance with the manufacturer‘s
guidelines.
▶ Route the connection pipe for the heating system and cold/hot water
on site up to the installation location of the Hydrolight/Hydrocomfort
unit.
16
6 720 806 629 (2013/02)
INSTALLATION
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.
9.7
CONNECTING THE REFRIGERANT PIPE
The installation must only be carried out by certified
refrigeration engineer (F Gas). The installer must comply
with the applicable rules, regulations and specifications
of the installation and operating instructions.
CAUTION: Do not open the shut off valves before the
refrigerant pipes have been fully connected and the
vacuum-drying is completely finished along with a
strength and tightness test, as per BS EN378. The
outdoor unit is pre-filled with refrigerant R410A which
may leak if the valves are opened too soon.
Observe caution when bending pipes so that they are not
kinked or damaged. A bend radius of 100 – 150 mm is
sufficient.
•
•
•
•
•
•
•
•
Pressure gauge kit
Charge hose
Gas leak detector
Spanners
Flaring tool
Flaring gauge
Vacuum pump adapter
Electronic refrigerant scales
PIPES AND PIPE JOINTS
WARNING: Risk of injury through escaping refrigerant!
Pipes that are not permissible or that are incorrectly
sized can burst.
▶ Only use refrigeration pipe work with the correct wall
thickness.
▶ 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 outdoors.
– Do not unseal the pipe ends until immediately before they are
brazed.
– 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.
▶ After cutting, immediately seal reusable lengths of refrigerant lines.
Use a refrigerant oil with esther, ether or alkyl benzene to
grease pipe flanges and flange nuts.
9.7.1 SAFETY
Use exclusively R410A 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.
▶ 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.
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.
▶ Contact the installer immediately.
9.7.2 PREPARING FOR INSTALLATION
TOOLS
CAUTION: Property damage from incorrect installation!
▶ Use only those tools that are specifically intended for
handling R410A refrigerant.
Tools required to handle R410A refrigerant:
6 720 806 629 (2013/02)
17
INSTALLATION
▶ Put the flange nut on the liquid pipe (measures:  table 5).
9.7.3 CONNECTING THE EXTERNAL AND INTERNAL UNITS
▶ Lay out the connection pipes according to how you intend to install
them between the internal and external unit of the heat pump.
0,5
øA
R0
,4~
▶ Remove the flange nut from the liquid connection on the indoor unit.
Discard the sealing cap.
2
R0
Start connecting the pipes at the indoor unit. Flange and connect the
liquid pipe and the gas pipe as follows:
90
45
,8
6 720 644 816-70.1I
Fig. 20 Angle flange, refrigerant pipe
Liquid side
Gas side
Refrigerant pipe, external diameter
9.52 mm
3/8”
15.88 mm
5/8”
Flange nut, external
diameter
22 mm
29 mm outdoor unit
Pipe flange
(ø A in fig. 20)
12.8 – 13.2 mm
19.3 – 19.7 mm
Torque
34–42 Nm
68–82 Nm
27 mm indoor unit
Table 5 Dimensions, flanges and torques for connection of the refrigerant pipe
▶ Crimp the pipe ( fig. 20 and table 5).
▶ Grease the contact surfaces on the flange nut and the pipe flange with
refrigerant oil.
▶ Fasten the flange nut on the liquid connection of the indoor unit.
▶ Tighten flange nut with spanners. For torque, refer to table 5. Use a
wider wrench as the torque counteracting support ( fig. 21).
▶ Flange the gas pipe and connect it to the gas connection of the indoor
unit in the same way as the liquid pipe.
▶ Pressurise the refrigerant piping little by little to 4.15 MPa (41.5 bar).
Wait a minimum of five minutes, then check the pressure. If the
pressure decreases, there is a gas leak. In which case, do a leak check.
▶ Reduce the pressure to 1.0 MPa (10.0 bar). Wait for an hour and test
the pressure again.
▶ Perform bubble test (leak detecting spray) to search for leaks.
9.7.5 VACUUM EVACUATION
Evacuate the pipework using a vacuum pump, before the refrigerant
flows through it.
▶ Connect the vacuum pump to the service connection on the liquid line
shut off valve ( [1], fig. 22).
▶ Start the vacuum pump and maintain vacuum for at least one hour
after 1 mbar / 0,75 torr / 100 Pa / 750 micron achieved. Longer
drying time may be required depending on the temperature and
humidity of the surrounding air.
▶ Disconnect the vacuum pump.
9.7.6 OPENING THE SHUT-OFF VALVES
6 720 644 816-71.1I
1
Fig. 21 Tighten nut using two wrenches
▶ Make sure that the stop valves for liquid and gas on the outdoor unit
are closed ( [5], fig. 13). Remove the flange nuts. Discard the
sealing caps.
▶ Check that there is no leakage from the valves. Use an electronic leak
tracer or suitable leak detector.
▶ The liquid pipe and gas pipe are flange-mounted and connected to the
external unit of the heat pump in exactly the same way as the internal
unit.
▶ Make sure that the pipes are not in contact with the compressor. If the
pipes are in contact with the compressor this may cause unusual noise
or vibrations and possible damage to the pipe work.
9.7.4 INSPECTION OF REFRIGERANT PIPING TIGHTNESS
Perform tightness test to EN 378-2. Use oxygen free
nitrogen to check the leak-tightness of the refrigerant
pipe.
▶ Make sure that the shut off valves for gas and liquid in the outdoor unit
of the heat pump are closed ( [5], fig. 13). Do not open them.
▶ Connect the pressure gauge and gas tank (oxygen free nitrogen) to
the service outlet on the liquid shut-off valve ([1], fig. 22).
18
2
3
4
6 720 644 816-29.1I
Fig. 22 Shut-off valves
[1]
[2]
[3]
[4]
Service outlet, liquid pipe (connection of vacuum pump)
Shut-off valve for gas
* 7.5 kW: hole for socket wrench, 5 mm
* 10 – 12 kW: handle
Flange nut
Shut-off valve for liquid, hole for socket wrench 4 mm
GAS SIDE
▶ Remove the cover.
6 720 806 629 (2013/02)
INSTALLATION
▶ Open the shut-off valve by turning the screw ( [2], fig. 22) as far as
it will go using a 5 mm socket wrench (7.5 kW), or by turning the
handle (10–12 kW).
▶ Put the cover back on.
LIQUID SIDE
▶ Remove the cover and open the shut-off valve ( [3], fig. 22) by
turning it anticlockwise as far as it will go using a 4 mm socket wrench.
Stop turning as soon as you reach the stop.
▶ Screw the cover back on
Model
Permitted pipe length
8 kW
11 – 16 kW
0 – 50 m
0 – 70 m
Permitted difference
vertically
0 – 30 m
9.7.7 FILLING WITH REFRIGERANT
▶ Subsequent filling of the system is not required if the length of the
pipe does not exceed 30 m.
▶ If the pipe is longer than 30 m, additional refrigerant must be filled in
accordance with table 6.
▶ If the ODU is running, fill liquid refrigerant at the service outlet on the
suction side. Do not fill liquid refrigerant at the shut-off valve directly.
▶ Once you have filled refrigerant in the ODU, enter the amount you put
in on the service label (on the unit).
Top up amount of refrigerant
31 – 40 m
0,6 kg
0,6 kg
41 – 50 m
1,2 kg
1,2 kg
51 – 60 m
Not applicable
1,8 kg
61 – 70 m
Not applicable
2,4 kg
Table 6 Topping up refrigerant
6 720 806 629 (2013/02)
19
INSTALLATION
9.8
FILLING THE HEATING SYSTEM
1
First flush the heating system. If the water heater is connected to the
system, it must be filled with clean water. The heating system is then
filled.
2
9.8.1 FILLING THE HEATING SYSTEM WITH CLEAN WATER
Worcester Bosch recommends the fitting of an inline system filter to help
ensure that the heating system can perform at its optimum level.
▶ Set the pre-pressure for the expansion vessel in the premises
according to the heating unit's static height.
▶ Open the heating system's valves.
▶ Top up the heating water in the system and fill system to appropriate
operating pressure.
▶ Vent the heating system by opening the shut off valve ( [1], fig 24).
This may have to be repeated a couple of times and is very important
to ensure the correct operation of your heat pump.
▶ Also bleed via the heating system's other bleed valves (e.g. radiators).
▶ Refill to the correct pressure. Normal pressure is 1.0 – 2.5 bar, but
depends on the expansion vessel's pre-pressure and the height of the
building.
▶ Shut the heating water filling valve when the correct pressure is
reached.
6
5
4
1
2
3
6 720 804 177-15.1I
Fig. 24 Hydrocomfort unit with electr. booster heater
[1]
[2]
[3]
[4]
[5]
[6]
Air vent valve (manual)
Air vent valve (automatic)
Pressure gauge
Circulation pump
Electric booster heater
Pressure Switch
9.8.2 LEAK TEST
5
▶ Perform a final leak test once the system has been brought into
operation and a flow temperature of between
45 and 55 °C has been reached (the quickest way to achieve this is via
compressor stage 7 in manual mode) and search for fine leaks at the
flare connections on the outdoor unit and Hydrolight/Hydrocomfort
unit using a suitable leak detection spray or electronic tester.
4
9.8.3 PRESSURE SWITCH
The Hydrocomfort unit incorporates a pressure switch ( [6], fig. 24)
which trips if the pressure in the heating system is too low.
3
6 720 804 177-14.1I
Fig. 23 Hydrolight unit with mixing valve for 2. heat appliance
[1]
[2]
[3]
[4]
[5]
20
Air vent valve (automatic)
Electrical switch box
Pressure gauge
Circulation pump
Mixing valve
If the system pressure is less than 0.5 bar, this trips the pressure switch
which switches off the power supply to the electr. booster heater and
triggers the alarm. No pressure in system To remedy the fault:
▶ Check that the expansion vessel and safety valve are designed to
operate with the pressure in the system.
▶ Slowly increase the pressure in the heating system by filling water via
the filling cock.
▶ Acknowledge the alarm by pressing the rotary selector in the user
interface of the Hydrocomfort module ([3], fig. 62).
6 720 806 629 (2013/02)
INSTALLATION
9.9
CONNECTING A HEAT PUMP DHW CYLINDER (3RD
PARTY)
9.9.1 HEAT PUMP HOT WATER CYLINDER, SOLAR
A heat pump solar hot water cylinder can also be connected to either the
Hydro light or the Hydro comfort.
It is very important that only DHW storage cylinders specifically
designed for use with heat pumps are used. Cylinders of this type have a
large heat exchange area, typically at least 3.0m2, and pre-defined
positions for the temperature sensors.
9.9.2 DHW TEMPERATURE SENSOR T3 (ACCESSORY)
If the hot water cylinder is installed and T3 is connected to the system,
this is automatically acknowledged upon start up of the heat pump
control.
Using a heat pump DHW cylinder with surface areas of heat exchange
less than 3m2 or wrong positioning of sensors could result in a drop in
DHW comfort and heat pump efficiency. From test work undertaken the
Kingspan Albion Aerocyl series is particularly compatible with the
Greensource split heat pump range.
▶ Hot water sensor T3 is connected to terminal block T3 on circuit board
IOB-A in the electric box of the indoor unit ( fig. 40 or 46). The
sensor must be properly positioned on the surface of the heat pump
hot water cylinder.
▶ Check the installation guide of the heat pump hot water cylinder for
where to position the T3 sensor (example  fig. 25). Correct
positioning of the T3 sensor is critical for the hot water comfort.
When using an indirect internal coil in the heating
system, an automatic air vent valve must be installed in
the heat pump flow.
1
2
7
3
6
4
5
A
J
I
H G
F
D C
I
E J,K,L
B
F H
20 O
40 O
B
C
G
70 O
A
D
K
E
L
30 O
40 O
50 O
6 720 648 135-23.1I
Fig. 25 Example of tank with position of temperature sensor
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Hot draw - off
Temperature and pressure relief valve (TPRV) boss
Thermostat pocket (not used)
Immersion heater
Thermostat pocket (not used)
Thermostat pocket, preffered position of temperature sensor T3
Secondary return (not always fitted, see table 7)
Capacity (L)
180
210
250
300
Height
1322
1515
1772
2096
Diameter
550
550
550
550
A
135
135
135
135
B
225
225
225
225
C
335
335
335
335
D
355
355
355
355
E
840
905
1065
1130
F
865
930
1090
1155
G
915
980
1140
1205
H
I
JKL
955 N/F 1057
1020 1150 1250
1180 1400 1507
1245 1600 1830
Weight
(kg-empty)
65
68
81
97
Weight
(kg-full)
245
278
331
397
Table 7 Dimensions in mm as reference to fig 25
Pay attention to the angle offset in figure 25 (H = 20°)
when positioning the temperature sensor.
6 720 806 629 (2013/02)
21
INSTALLATION
9.10 3-WAY VALVE (ACCESSORY)
System configuration with DHW cylinder ( fig. 53, 55 and 57)
requires a 3-way valve (E21.Q21).
N
2
Y
6
L
3
6 720 617 643-10.2I
Fig. 29 Connections in Molex plug
[L]
[Y]
Out
3-way valve E21.Q21
For connection to the indoor unit ( fig. 41 or fig. 47).
6 720 617 643-06.1I
9.11 INSULATION
Fig. 26 Flow direction of 3-way valve
All system heat pipe work should be insulated to current standards
where applicable.
[A] to DHW cylinder
[B] to heating system (buffer cylinder)
[AB] from Hydrolight/Hydrocomfort unit
9.12 INSTALLING THE TEMPERATURE SENSORS
When domestic hot water is being heated the contact is closed and gate
A is open ( fig. 27)
9.12.1 FLOW TEMPERATURE SENSOR T1
The T1 sensor is supplied together with the Hydrolight/Hydrocomfort
unit.
▶ Connect the E11.T1 flow temperature sensor to terminal T1 on the
IOB-A printed circuit board in the indoor unit. The temperature sensor
is assigned to the buffer cylinder, if available. If no buffer cylinder is
used, the sensor should be positioned on the flow pipe 1 meter after
the 3-way valve ( Chapter 11.4.3).
9.12.2 T2 OUTSIDE TEMPERATURE SENSOR
If the cable to the temperature sensor runs further than
15 m outdoors, a screened cable must be used. The
screened cable must be earthed in the internal unit. The
maximum length of a screened cable is 50 m.
The cable to the outdoor temperature sensor must satisfy the following
minimum requirements:
6 720 641 553-06.1I
Fig. 27
When heating, the contact is open and gate B is open. ( fig. 28)
Cable cross-section: 0.5 mm2
Resistance: max 50 /km
Number of conductors: 2
▶ Install the sensor on the north side of the house. It must be protected
from direct sunlight, ventilation air or anything that can affect the
temperature measurement. The sensor must not be installed directly
beneath the eaves.
9.12.3 ROOM TEMPERATURE CONTROLLER (ACCESSORY)
The room controller will only operate and control the
relevant heating circuit.
When the room temperature controller is connected and integrated in
the system, this is automatically acknowledged during the initial
configuration.
Requirements for installation location:
• If possible, interior wall without draughts or heat radiation.
• Unimpeded circulation of room air under room controller (dotted area
in fig 30 must be kept clear) this also includes a minimum of 1m from
a radiator.
6 720 641 553-07.1I
Fig. 28
Do not place the room temperature controller in direct
sunlight.
The 3-way diverter valve is equipped with a Molex plug-in connector.
Only terminals 2, 6 and 3 are assigned at the Molex plug. ( fig. 29).
22
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
For the settings in the Hydrolight/Hydrocomfort unit, refer to chapter
16.5.
9.15 DISCONNECTING ACCESSORIES
0,3 m
CAUTION: Before resetting to factory values, make a
note of parameters that were set when the heat pump
was commissioned (heat curve, set point values,
programs...)
0,6 m
1,2 - 1,5 m
TT
If an accessory that has been installed is to be disconnected from the
unit and no longer be used, a factory reset at service level must be
performed. This does not apply when replacing defective accessories/
components.
0,3 m
6 720 806 629- 34.1I
Fig. 30 Recommended installation location for room temperature
controller
▶ Select the installation and service menu ( chapter 14).
▶ Select the Advanced.
▶ Select the Return to factory settings.
▶ Select Yes then Save.
Once the factory settings have been restored, the Hydrolight/
Hydrocomfort unit must be configured again.
9.13 OTHER CONNECTIONS
9.13.1 EXTERNAL INPUTS
CAUTION: All connectors to the external inputs on the
heat pump must be suited for 5 V and 1 mA.
The external inputs E21.B11 and E21.B12 can be used to remotely
control certain functions in the control unit.
The functions that are activated by the external inputs are described in
chapter 16.3.9.
The external input is either connected to a switch for manual activation
or remote control equipment, which is activated via telephone for
example.
10
ELECTRICAL CONNECTION
DANGER: Danger of electric shock!
▶ Switch off the main power supply before starting work
on the electrical part.
DANGER: Danger due to electric shock!
The capacitor in the heat pump must be discharged once
the power supply has been disconnected.
▶ Wait at least 5 minutes.
▶ Check that the green LED, LED 1, has gone out (see
wiring diagram in the heat
pump).
9.14 ADDITIONAL MIXER GROUP (ACCESSORY)
The Hydrolight/Hydrocomfort unit can control a
maximum of one mixed (with Multi Box accessory) and
one unmixed heating circuit.
See the installation manual of the Multi Box accessory
for wiring diagrams.
The standard version of the Hydrolight/Hydrocomfort is configured to
control one unmixed circuit. Control of an additional mixed circuit can be
achieved with the Multi Box accessory. This encompasses the control of
the mixer valve and heating circuit pump. There are inputs for the flow
sensor, room temperature controller and also two external inputs.
▶ Install the mixing valve(E12.Q11) and heating circuit pump(E12.G1)
in accordance with the system solution ( chapter 11.4).
▶ Connect the mixing valve and heating circuit pump as shown in the
wiring diagrams ( Installer manual for Multi Box).
▶ Install the flow sensor (E12.T1) at the flow of the mixer valve in
accordance with the system solution ( chapter 11.4).
▶ Connect the flow sensor as shown in the wiring diagram ( Installer
manual for Multi Box).
▶ Install the room temperature controller.
▶ Connect these as shown in the wiring diagram ( Installer manual for
Multi Box).
6 720 806 629 (2013/02)
WARNING: The unit must not, under any
circumstances, be switched on without water.
▶ Fill and pressurise the hot water heater and the
heating system before powering on the unit.
WARNING: The compressor must be warmed up before
starting for the first time.
▶ Switch on the power to the outdoor unit at least 2
hours prior to commissioning, up to 12 hours for
extreme climate conditions (below -15 °C ambient
temperature).
In order to switch off the power at the internal and
external unit, always switch the power off at the same
time period then wait at least 1 minute before switching
the power back on. Failure to do could cause a
communication error between the outdoor unit and the
Hydrolight/Hydrocomfort.
23
ELECTRICAL CONNECTION
The heat pump's electrical connections must be able to
be isolated safely.
▶ Install a separate safety switch that cuts all current to
the heat pump. A safety switch for each supply is
required for separate power supplies. Worcester
Bosch recommend the fitting of a separate electric
meter on the electrical supply from the Hydrolight/
Hydrocomfort to the main electric meter.
▶ According to the applicable regulations for 230 V/50 Hz connection,
a H05VV-U type 3-core cable must be used as a minimum. For 400V/
50Hz use a 5-core cable of the H05VV-U type. Select the cable area
and cable type that corresponds to the relevant fuse rating and
routing method.
▶ Observe protection measures according to current wiring regulations.
▶ Connect the heat pump to the electric box connection strip according
to BS EN 60335 part 1 and via a switch with a minimum contact
distance of 3 mm (e.g. fuses, LS switch). Other loads must not be
connected.
▶ Follow the relevant wiring diagram when connecting an earth breaker.
Only connect components that are approved for the UK market.
▶ Observe the colour coding when replacing circuit boards.
1
2
3
4
10.1 CONNECTING THE HEAT PUMP
6720648125-10.1I
WARNING: SW8 at the printed circuit board of the
outdoor unit must be set as follows: 3 = ON, 2 = OFF,
1 = OFF ( fig. 32)
CAUTION: Never touch a circuit board without wearing
a ground-connected bracelet ( chapter 7.10).
Fig. 31 Connecting the outdoor unit (example shows ODU 12)
[1]
[2]
[3]
[4]
Strain relief, fasten the cables so they do not come into contact
with the service flap.
Pipe protection
Front pipe protection
Service flap
Installation applies for all sizes.
A signal cable with a minimum dimension of 2 x 0,3 mm2
and a maximum length of 120 m is routed between the
indoor unit and the outdoor unit.
▶ Remove the service flap ([4], fig 31).
▶ Remove the pipe protection ([3], fig 31).
▶ Route the connection cables through the strain relief in the side of the
outdoor unit ([1], fig 31).
▶ Connect the cables according to fig 32, post-tighten all cable
mountings.
▶ Reinstall the service flap ([4], fig 31).
24
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.1.1 ADJUSTMENT OF SW8
10.1.3 ALARM SIGNAL, MIXED ADDITIONAL HEAT
Switch SW8-3 on the printed circuit board of the external unit must
always be in the ON position because connection S1 is not used to
supply power to the PAC board.
With an external 2nd heat appliance, the alarm signal to E71.E1.F21
(230 V) is connected to the terminal J4 of the main board (IOB-A) in the
Hydrolight/Hydrocomfort internal unit.
SW8-3 must be set as shown in fig. 32.
If the 2nd heat appliance does not have an alarm output, E71.E1.F21
must be connected to a different signal (230 V), e.g. L.out at J3 (
fig. 35).
If the 2nd heat appliance features a volt free or 0 V alarm, E71.E1.F21
corresponding technology (e.g. a relay) must be used to establish the
connection.
1
1
2
2
3
6 720 644 816-04.1I
6 720 644 816-05.1I
Fig. 32 Connection designations, outdoor unit
Fig. 35 In-coming alarm signal from mixed additional heat
[1]
[2]
[3]
[1]
[2]
1-phase connection
3-phase connection
Signal cable
10.1.2 JUMPER POSITIONING AT CONNECTION, 1-PHASE AND 3PHASE HYDROCOMFORT
WARNING: The Hydrocomfort is delivered in 3-phase
version.
▶ To change the hydrocomfort to 1-phase version,
insert the jumpers in accordance with Fig. 34.
In-coming alarm signal (230V)
Suggested connection for E71.E1.F21 when the mixed
additional heat has no out-going alarm signal
10.1.4 START SIGNAL FOR 2ND HEAT APPLIANCE
The following points must be observed when using output E71.E1.E1:
▶ Maximum load of 230V signal output: 150W ohmic load with switchon peaks of 5A and switch-off peaks of 3A.
▶ If the load is greater, a supplementary relay must be installed (not
included).
1
6 720 801 699-02.1I
2
Fig. 33 Jumper position in Hydrocomfort at delivery, 3-phase
1
6 720 644 816-63.1I
Fig. 36 J4 connecting terminal
[1]
[2]
Incoming alarm signal, 2nd heat appliance
Start signal, 2nd heat appliance
Be careful not to open the mixer valve immediately after the external 2nd
heat appliance is activated, otherwise the heating system may cool
down. The delay can be set in the installation menu ( chapter 16.3.5).
2
6 720 644 816-18.3I
The external heat appliance may start and stop several times. This is
normal. If there are problems with the external heater because the
operating times are too short, a parallel buffer tank in the flow/return of
the external heater can extend the operating time. For more information,
consult the manufacturer of the external heater.
Fig. 34 Positioning of jumpers in the Hydrocomfort unit, 1-phase
[1]
[2]
Location of jumper at 3-phase (delivery version)
Location of jumpers at 1-phase
6 720 806 629 (2013/02)
25
ELECTRICAL CONNECTION
10.1.5 ZONE VALVE FOR THE HYDROLIGHT UNIT WITH 2ND HEAT
APPLIANCE AND FLOW RATE CONTROL
When using a Hydrolight unit with a mixer and a 2nd heat appliance
equipped with flow monitoring (mainly wall-mounted boilers containing
a small amount of water or modulating boilers), a zone valve must be
installed between the external heater and the internal unit.
The zone valve must be installed in such a way that:
• a start of the boiler circulation pump opens the valve
• a stop of the boiler circulation pump closes the valve
Depending on the sensitivity of the flow monitoring, a fast motor valve
can also be used to reduce noise.
Boilers without flow rate control (such as non modulating boilers) do not
require this function.
10.1.6 CIRCULATION PUMP FOR 2ND HEAT APPLIANCE
A circulation pump is normally not required for the second heat
appliance however, If the flow temperature is too high because the flow
rate is too low or non-existent and the second heat appliance is not
equipped with a circulation pump, a circulation pump must be installed
( [E71.E1.G71], Fig 55).
Consult the manufacturer of the second heat appliance to find out how
the circulation pump needs to be regulated.
10.2 CONNECTING THE HYDROLIGHT/HYDROCOMFORT
MODULE
CAUTION: Never touch a circuit board without wearing
a ground-connected bracelet ( Chapter 7.10).
▶ Remove the front panel.
▶ Remove the electric box cover.
▶ Route the connection cables through the cable grommet at the bottom
of the electric box.
▶ Connect cable as shown in the wiring diagram. Connect the contact of
the signal cable to the terminal in the Hydrolight/Hydrocomfort
module.
▶ Put the lock of the switch box and the front panel of the Hydrolight/
Hydrocomfort unit back in their respective locations.
10.3 EXTERNAL CONNECTIONS
For all external installations ( chapter 16.3.9).
To prevent inductive interference, route all low voltage cables
(measurement current) and cables carrying 230 V or 400 V separately
(at least 100 mm apart).
When extending the temperature sensor cable, use the following
conductor cross-sections:
• Up to 20 m long cable: 0.75 to 1,50 mm2
• Up to 30 m long cable: 1.0 to 1,50 mm2
26
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.4 PCB LAYOUT IN CONTROL PANEL, HYDROLIGHT UNIT
1
2
3
4
6 720 648 135-25.1I
Fig. 37 Layout in control panel, Hydrolight unit
[1]
[2]
[3]
[4]
Interface board (PAC)
Main board (IOB-A)
Accessories board (IOB-B, not included in standard delivery)
Terminal (X1)
6 720 806 629 (2013/02)
27
ELECTRICAL CONNECTION
10.5 SWITCH SETTINGS, HYDROLIGHT UNIT
1
7
2
3
GND
+12V
GND
+12V
CANH
CANL
6
4
CANH
CANL
5
6 720 803 724-12.2I
Fig. 38 Switch settings for Hydrolight unit with additional mixed heating circuit (accessory)
[Solid line = factory connected]
[Dotted line = connected at installation]
[1] Switch
[2] Interface board
[3] Main board
[4] Accessories board in Multi Box
[5] room temperature controller
[6] room temperature controller
[7] Display board
28
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.6 POWER SUPPLY, HYDROLIGHT UNIT AND ADDITIONAL MIXED HEATING CIRCUIT (ACCESSORY)
4
1
2
3
6 720 803 724-15.1I
Fig. 39 Power supply, Hydrolight unit and additional mixed heating circuit (accessory)
[1]
[2]
[3]
[4]
Accessories board (IOB-B, not included in standard delivery)
Main board
Interface board
Mains power supply
6 720 806 629 (2013/02)
29
ELECTRICAL CONNECTION
10.7 TERMINAL CONNECTION DIAGRAM, HYDROLIGHT UNIT WITH 2ND HEAT APPLIANCE
6
1
2
5
4
3
6 720 644 816-24.5I
Fig. 40 Terminal connection diagram, Hydrolight unit with 2nd heat appliance
[Solid line = factory connected]
[Dotted line = connected at installation]
[1]
Hydrolight unit (main board)
[2]
outdoor unit
[3]
Fuse (not included in standard delivery)
[4]
Fuse, outdoor unit
[5]
Fuse, Hydrolight unit
[6]
Accessories board
[E21.B11] External input 1
[E21.B12] External input 2
[E11.T1] Flow temperature sensor
[E10.T2] Outside temperature sensor
[E41.T3] Temperature sensor, domestic hot water
[E11.TT.T5] room temperature controller, heating system
[E11.TT.P1] room temperature controller, LED
30
[E21.E112] Heating cable
[E71.E1.F21]Alarm signal, 2nd heat appliance (~230V)
[E71.E1.E1] Start signal, 2nd heat appliance
[E21.Q21] 3-way valve (accessory)
[E11.G1] Heating circuit pump, heating system
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.8 WIRING DIAGRAM, HYDROLIGHT UNIT WITH 2ND HEAT APPLIANCE
2
Fig. 41 Wiring diagram, Hydrolight unit with 2nd heat appliance
[Solid line = factory connected]
[Dotted line = connected at installation]
[1]
Hydrolight module
[2]
Mains power supply
[E21.B11] External input 1
[E21.B12] External input 2
[E11.T1] Flow temperature sensor
[E10.T2] Outside temperature sensor
[E41.T3] Temperature sensor, domestic hot water
[E11.TT.T5] room temperature controller, heating system
[E11.TT.P1] room temperature controller, LED
[E21.T8] Heating water outlet
[E21.T9] Heating water inlet
[E71.E1.T71]Flow, CH
[E71.E1.F21]Alarm signal, 2nd heat appliance
[E71.E1.E1] Start signal, 2nd heat appliance
6 720 806 629 (2013/02)
6 720 803 724-16.2I
1
[E21.Q21] 3-way valve (accessory)
[E11.G1] Heating circuit pump, heating system
[E21.G2] DHW circulation pump, heating water
[E21.E112] Heating cable
[E71.E1.Q71]2nd heat appliance
31
ELECTRICAL CONNECTION
10.9 SIGNAL CABLE, HYDROLIGHT UNIT WITH 2ND HEAT APPLIANCE
1
2
3
4
5
6
7
15
8
9
10
11
12
13
14
6 720 648 135-09.2I
Fig. 42 Signal cable, Hydrolight unit with 2nd heat appliance
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
32
Mains power supply
Interface board
Terminal S2, S3
Malfunctions
Compressor off/on
defrosting
Central heating
Compressor, stop
Central heating
Com 15+V
Stage/Capacitor
Stage/Capacitor
[13] Stage/Capacitor
[14] Display board
[15] Main board
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.10 LAYOUT IN CONTROL PANEL, HYDROCOMFORT UNIT WITH ELECTR. HEATER
1
2
3
5
7
4
6
6 720 803 724-14.1I
Fig. 43 Layout in control panel, Hydrocomfort unit with electr. heater
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Interface board (PAC)
Main board (IOB-A)
Accessories board (IOB-B, not included in standard delivery)
Relay 1 (K1)
Relay 2 (K2)
Terminal (X1)
Over heat protection
6 720 806 629 (2013/02)
33
ELECTRICAL CONNECTION
10.11 SWITCH SETTINGS, HYDROCOMFORT UNIT WITH ELECTR. HEATER AND ADDITIONAL MIXED HEATING CIRCUIT (ACC)
1
7
2
3
GND
+12V
GND
+12V
CANH
CANL
6
4
CANH
CANL
5
6 720 803 724-12.2I
Fig. 44 Switch settings, Hydrocomfort module with electr. unit heater and additional mixed heating circuit (accessory)
[Solid line = factory connected]
[Dotted line = connected at installation]
[1] Switch
[2] Interface board
[3] Main board
[4] Accessories board (not included in standard delivery)
[5] room temperature controller
[6] room temperature controller
[7] Display board
34
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.12 POWER SUPPLY, HYDROCOMFORT UNIT WITH ELECTR. HEATER
6
5
1
2
3
4
6 720 803 724-10.1I
Fig. 45 Power supply, electr. heater, 3-phase
[1]
[2]
[3]
[4]
[5]
[6]
Thermal Protection
Accessories card (not included in standard delivery)
Main board
Interface board
Electric heater
Mains power supply
6 720 806 629 (2013/02)
35
ELECTRICAL CONNECTION
10.13 TERMINAL CONNECTION DIAGRAM, HYDROCOMFORT UNIT WITH ELECTR. HEATER
1
2
3
5
4
6 720 806 629-10.1I
Fig. 46 Terminal connection diagram, Hydrocomfort unit with electr.
heater
[Solid line = factory connected]
[Dotted line = connected at installation]
[1]
Hydrocomfort module (main board)
[2]
outdoor unit
[3]
Safety switches (not included in standard delivery)
[4]
Fuse, outdoor unit
[5]
Fuse, Hydrocomfort unit
[E21.B11] External input 1
[E21.B12] External input 2
[E11.T1] Flow temperature sensor
[E10.T2] Outside temperature sensor
[E41.T3] Temperature sensor, domestic hot water
[E11.TT.T5] room temperature controller, heating system
[E11.TT.P1] room temperature controller, LED
[E21.E112] Heating cable
[E21.Q21] 3-way valve (accessory)
[E11.G1] Heating circuit pump, heating system
36
6 720 806 629 (2013/02)
ELECTRICAL CONNECTION
10.14 WIRING DIAGRAM, HYDROCOMFORT UNIT WITH ELECTR. HEATER
1
2
6 720 648 125-29.4I
Fig. 47 Wiring diagram, Hydrocomfort unit with electr. heater
[Solid line = factory connected]
[Dotted line = connected at installation]
[1]
Hydrocomfort module
[2]
Mains power supply
[E21.B11] External input 1
[E21.B12] External input 2
[E31.RM1.TM1-5]Dew point alarm (max 5 pcs.)
[E11.T1] Flow temperature sensor
[E10.T2] Outside temperature sensor
[E41.T3] Temperature sensor, domestic hot water
[E11.TT.T5] room temperature controller, heating system
[E11.TT.P1] room temperature controller, LED
[E21.T8] Heating water outlet
[E21.T9] Heating water inlet
[E71.E1.T71]Flow, CH
[E71.E1.F21]Alarm signal, electric booster heater
6 720 806 629 (2013/02)
[E21.E2.K11]Electric heater, stage 1
[E21.E2.K12]Electric heater, stage 2
[E21.Q21] 3-way valve (accessory)
[E11.G1] Heating circuit pump, heating system
[E21.G2] DHW circulation pump, heating water
[E21.E112] Heating cable
37
ELECTRICAL CONNECTION
10.15 SIGNAL CABLE, HYDROCOMFORT UNIT WITH ELECTR. HEATER
16
1
2
3
4
5
6
7
15
8
9
10
11
12
13
14
6 720 648 135-08.2I
Fig. 48 Signal cable, Hydrocomfort unit with electr. heater
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
38
Mains power supply
Interface board
Terminal S2, S3
Malfunctions
Compressor off/on
defrosting
Central heating
Compressor, stop
Central heating
Com 15+V
Stage/Capacitor
Stage/Capacitor
[13]
[14]
[15]
[16]
Stage/Capacitor
Display board
Main board
Pressure Switch
6 720 806 629 (2013/02)
TECHNICAL INFORMATION
11
TECHNICAL INFORMATION
11.1 SPECIFICATION - OUTDOOR UNIT
Unit
ODU 7.5s
ODU 10s
ODU 11s
ODU 12s
ODU 11t
ODU 12t
8 kW
11 kW
14 kW
16 kW
14 kW
16 kW
16.0
Operation, air/water
Rated output at A7/W351)
kW
8.7
11.9
14.0
16.0
14.0
Input power
kW
2.0
2.7
3.25
3.9
3.25
3.9
4.34
4.39
4.24
4.10
4.24
4.10
11.2
COP at A7/W351)
Rated output at A-7/W351)
kW
6.0
8.3
10.5
11.2
11.5
Input power
kW
2.4
3.5
4.5
4.5
5.1
4.5
2.45
2.40
2.34
2.47
2.26
2.47
COP at A-7/W351)
Electr. data
Mains power supply
230V, 1N AC 50Hz
400V, 3N AC 50Hz
Recommended automatic circuit breaker2)
A
25
32
32
32
10
16
Maximum current3)
A
19
26.5
26.5
28
9.5
13
Data, refrigeration connection
Connection type
Flare connection 3/8” & 5/8”
Refrigerant type4)
Refrigerant mass
R410A
kg
3.5
5.0
m3/h
1.008
1.404
1.764
2.016
1.764
2.016
P(kPa)
58
50
17
14
17
14
126
132
Nominal flow rate
Heating water
Pressure difference, water side
Air and noise data
Fan motor (DC inverter)
W
86
Nominal air flow rate
m3/h
3300
6600
60 + 60 (two fans)
7200
Sound pressure level at a distance of 1 m
dB(A)
48
51
52
Sound power level5)
dB(A)
66
68
68
General information
Compressor oil
FV 50S
Maximum heating water flow temperature,
outdoor unit only
°C
55
Maximum heating water flow temperature,
booster heating only
°C
80
Dimensions (WxDxH)
mm
950 x 360 x 943
Weight
kg
67
1050 x 360 x 1338
116
116
119
Table 8 outdoor unit
1) Rating according to EN 14511
2) No specific fuse rating or type is required. The starting current is low and will not exceed the operating current.
3) Starting current; depending on the type, a starting peak will not occur.
4) GWP100 = 1980
5) Sound power level in accordance with EN 9614-2
6 720 806 629 (2013/02)
39
TECHNICAL INFORMATION
HEATING OPERATION RANGE FOR THE OUTDOOR UNIT
T1( °C)
60
55
50
45
35
30
25
20
15
10
-30
-20
-10
0
10
20
30
40
T2 (°C)
6 720 648 125-85.2I
Fig. 49 ODU 7,5 - 12
[T1] Flow temperature
[T2] Outdoor temperature
11.2 SPECIFICATION, HYDROLIGHT UNIT WITH 2ND HEAT APPLIANCE
Electr. data
Recommended automatic circuit breaker
Mains power supply
Maximum power consumption
Hydraulic data
Maximum heating output, 2nd heat appliance
Connection type (central heating and booster
heater flow/return)
Maximum operating pressure
Expansion vessel
Internal pressure drop
Available external pressure
Circulation pump type
Refrigerant pipe data
Connection type
Dimensions and weight
Dimensions (WxDxH)
Weight
Hydrolight 8
Hydrolight 16
10 A
230V, 1N AC 50Hz
6A
10 A
230V, 1N AC 50Hz
6A
25 kW
1” male thread
25 kW
1” male thread
3 bar
N/A
8 kPa
38 kPa
Wilo-Star RS 25/6
3 bar
N/A
17 kPa
48 kPa
Wilo-Star Top-S 25/7
Flare connection 5/8” – 3/8”
Flare connection 5/8” – 3/8”
500 x 420 x 850 mm
49 kg
500 x 420 x 850 mm
52 kg
Table 9 Hydrolight unit with 2nd heat appliance
40
6 720 806 629 (2013/02)
TECHNICAL INFORMATION
11.3 SPECIFICATION - HYDROCOMFORT UNIT WITH
ELECTR. HEATER
Electr. data
Mains power supply
Recommended automatic circuit breaker
Maximum power consumption
Electric heater
Hydraulic data
Connection type (central heating and
electric heater flow/return)
Maximum operating pressure
Expansion vessel
Internal pressure drop
Available external pressure
Circulation pump type
Refrigerant pipe data
Connection type
Dimensions and weight
Dimensions (WxDxH)
Weight
Hydrocomfort 8
Hydrocomfort 8
Hydrocomfort 16
Hydrocomfort 16
230V 1N AC 50Hz
45 A
45 A
9 kW
400V 3N AC 50Hz
16 A
16 A
9 kW
230V 1N AC 50Hz
45 A
45 A
9 kW
400V 3N AC 50Hz
16 A
16 A
9 kW
1” male thread
3 bar
6L
8 kPa
38 kPa
Wilo-Star RS 25/6
8 kPa
38 kPa
Wilo-Star RS 25/6
17 kPa
17 kPa
49 kPa
49 kPa
Wilo-Star Top-S 25/7
Flare connection 5/8” – 3/8”
500x420x850 mm
51 kg
500x420x850 mm
51 kg
500x420x850 mm
54 kg
500x420x850 mm
54 kg
Table 10 Hydrocomfort unit with electr. heater
WARNING: The Hydrocomfort is delivered in 3-phase
version.
▶ To change the hydrocomfort to 1-phase version,
insert the jumpers in accordance with Chapter
10.1.2.
Wilo-StarRS 25/6
(H)
1~230 V, 50 Hz
(Q)
P
6720801699-04.1I
Fig. 51 Hydrolight/Hydrocomfort 16
6 720 801 699-03.1I
Fig. 50 Hydrolight/Hydrocomfort 8
6 720 806 629 (2013/02)
41
TECHNICAL INFORMATION
11.4 SYSTEM CONFIGURATIONS
11.4.1 SYSTEM CONFIGURATION EXPLANATIONS
E10
E10.T2
Outside temperature sensor
Table 11 E10
E11
E11.G1
E11.C111
E11. T1
E11.TT
Heating circuit without mixer
heating circuit pump (not in standard delivery)
Buffer tank (accessory)
Flow temperature sensor
room temperature controller (accessory)
Table 12 E11
E12
E12.G1
E12.Q11
E12.T1
E12.TT
Heating circuit with mixer (accessory)
heating circuit pump
Mixing valve
Flow temperature sensor
room temperature controller (accessory)
Table 13 E12
E21
E21.C101
E21.E2
E21.F101
E21.F111
E21.F112
E21.G2
E21.P101
E21.Q21
E21.TH2
E21.T8
E21.T9
E21.V101
Internal unit
Expansion vessel
Electric heater
Safety valve
Air vent valve (automatic)
Air vent valve (manual)
Heating water pump
Pressure gauge
3-way valve (accessory)
Temperature sensor, liquid refrigerant
Heating water temperature sensor, outlet
Heating water temperature sensor, inlet
Particle filter
E71
E71.E1.C101
E71.E1.F101
E71.E1.F111
E71.E1.G71
E71.E1.Q71
E71.E1.R101
E71.E1.T71
E71.E1.Q111
E71.E1.V40
E71.E1.W40
Electricity/oil/gas boiler
(2. heat appliance)
Expansion vessel
Safety valve
Automatic air vent valve
Circulation pump 2nd heat appliance
(optional  ch. 10.1.6)
Mixing valve
Non-return valve
Flow temperature sensor
Zone valve
(optional  ch. 10.1.5)
Domestic hot water
Cold water
Table 16 E71
E72
E72.E1
E72.E1.E72
E72.E1.C101
E72.E1.F101
E72.E1.F111
E72.E1.P101
E72.E1.TX1
E72.E1.TX2
Solar thermal system (not in standard
delivery)
Solar thermal collector
Pump station, solar
Expansion vessel
Safety valve
Automatic air vent valve
Pressure gauge
Sensor
Sensor
Table 17 E72
11.4.2 ADDITIONAL MIXED HEATING CIRCUIT
Table 14 E21
E41
E41.F101
E41.F111
E41.G6
E41.K41
E41.Q101
E41.R101
E41.R102
E41.T3
E41.V41
E41.W41
Table 15 E41
42
DHW cylinder (3rd party)
Safety valve
Air vent valve (automatic)
DHW circulation pump (accessory, secondary
circulation)
Thermostatic mixing valve (mains water)
isolation valve
Non-return valve
Ball check valve (spring-loaded)
Temperature sensor, domestic hot water
(accessory)
Domestic hot water
Cold water
1
6 720 806 629-20.1I
Fig. 52 Additional mixed heating circuit
[1]
Bypass
When a heating circuit with mixer is installed (E12), a bypass is required
if no buffer tank is installed. The bypass length must be at least ten times
that of the pipes inner dimension. The E11.T1 flow temperature sensor
has to be placed at the junction of the bypass.
6 720 806 629 (2013/02)
TECHNICAL INFORMATION
11.4.3 SYSTEM CONFIGURATIONS
1
2
6 720 648 135-18.2I
Fig. 53 Hydrocomfort with DHW cylinder and central heating
[1]
[2]
Hydrocomfort
Outdoor unit (ODU)
Indoor unit with internal electrical additional heat serving central heating
and hot water cylinder.
6 720 806 629 (2013/02)
The particle filter [E21.V101] is installed horizontally in
the return heating pipe to the Hydrolight/Hydrocomfort ,
43
TECHNICAL INFORMATION
1
2
6 720 648 135-19.2I
Fig. 54 Additional external heater with mixer
[1]
[2]
Hydrolight
Outdoor unit (ODU)
The particle filter [E21.V101] is installed horizontally in
the return heating pipe to the Hydrolight/Hydrocomfort ,
Indoor unit with external boiler additional heat serving central heating.
44
6 720 806 629 (2013/02)
TECHNICAL INFORMATION
1
E71.E1.G71
2
6 720 648 135-24.3I
Fig. 55 Additional external heater with mixer with DHW cylinder
[1] Hydrolight
[2] Outdoor unit (ODU)
[E71.E1.G71]Circulation pump for 2nd heat appliance, regulated by
the 2nd heat appliance ( Chapter 10.1.6)
The particle filter [E21.V101] is installed horizontally in
the return heating pipe to the Hydrolight/Hydrocomfort ,
Indoor unit with additional external heater serving central heating and
hot water cylinder.
6 720 806 629 (2013/02)
45
TECHNICAL INFORMATION
1
2
6 720 648 135-21.4I
Fig. 56 Indoor unit with external boiler additional heat serving central
heating through a buffer tank.
[1]
[2]
46
Hydrolight indoor unit.
Outdoor unit (ODU)
The particle filter [E21.V101] is installed horizontally in
the return heating pipe to the Hydrolight/Hydrocomfort ,
6 720 806 629 (2013/02)
TECHNICAL INFORMATION
6 720 135-20.5I
Fig. 57 External boiler additional heat serving central heating through a buffer tank. External Solar panels serving cylinder.
6 720 806 629 (2013/02)
47
TECHNICAL INFORMATION
The particle filter [E21.V101] is installed horizontally in
the return heating pipe to the Hydrolight/Hydrocomfort ,
11.4.5 TEMPERATURE SENSOR TEST VALUES
HYDROLIGHT/HYDROCOMFORT UNIT
Temperature sensor in, or connected to, the Hydrolight/Hydrocomfort
unit (T1, T2, T3, T5, T8, T9) has the measured value in accordance with
table 18.
In this setup example the solar panel will only be able to
produce domestic hot water (DHW).
The solar pump station E72.E1.E72 is controlled by its
own system and not by the heat pumps control panel.
For installation and settings refer to the installation
instructions of the solar pump station and its control.
FUNCTIONAL DESCRIPTION OF THE SOLAR SYSTEM
CONFIGURATION (FIG. 57)
• The Hydrolight unit is connected to an external additional boiler
(E71). This will supply additional heat and domestic hot water when
the heat pump alone is not sufficient.The domestic hot water
production is carried out in the solar cylinder with twin coils (E41).
• The heat pump and the additional boiler are controlled by the control
panel in the Hydrolight unit.
• The solar pump station (E72.E1.E72) is controlled by the solar
controller.
• The heating water pump (E21.G2) circulates the heating water from
the heat pump and/or the additional boiler to the buffer tank or the
DHW cylinder.
• The heating circuit pumps (E11.G1 and E12.G1) circulates the
heating water from the buffer tank to the unmixed (E11) and mixed
(E12) heating circuits.
• The solar pump station (E72.E1.E72) is fitted with a circulation pump
that circulates heating water from the solar thermal collectors
(E72.E1) to the DHW cylinder, if the temperature in the solar thermal
collectors are higher than the temperature in the cylinder.
If there is sufficient heat from the solar thermal collectors this will fully
cover the DHW demand. The heat pump and the additional boiler will
only provide central heating.
If the heat pump controller detects (by the E41.T3 sensor) that the
temperature in the DHW cylinder falls below the set point temperature
for the DHW production, the heat pump or the additional boiler will start
to produce domestic hot water.
11.4.4 FLOW OVER THE SYSTEM
An absolute prerequisite for the connection is that a
minimum flow of at least 70% of the nominal flow can be
maintained throughout the year.
If a bypass is used and an external circulation pump is
fitted, the flow over the heating system can be reduced
to 40% of the nominal flow of the heat pump. The bypass
length must be at least ten times that of the pipe's inner
dimension. Ensure that most of the thermostat valves
are fully open.
Otherwise a buffer tank must be installed.
48
°C
–40
–35
–30
–25
–20
–15
–10
–5
0
T...
154300
111700
81700
60400
45100
33950
25800
19770
15280
°C
5
10
15
20
25
30
35
40
45
T...
11900
9330
7370
5870
4700
3790
3070
2510
2055
°C
50
55
60
65
70
75
80
85
90
T...
1696
1405
1170
980
824
696
590
503
430
Table 18 Sensor values
The Hydrolight/Hydrocomfort unit also contains TH2 (temperature,
liquid line) which has the same characteristics as the low-temperature
sensor in the outdoor unit (table 20, fig. 58).
ODU
The temperature sensors in the outdoor unit have measurement values
and different operating ranges according to table 19.
TH4
TH3
TH6
TH7
TH32
TH8
Normal
160k  – 410k 
Abnormal
4.3k  – 9.6k 
Open-circuit or shortcircuit
39k  – 105k 
Table 19 The sensor values outdoor unit
LOW-TEMPERATURE SENSOR ODU
The temperature sensors TH3 (tube distributor, evaporator), TH6 and
TH7 (surroundings) and TH33 (between the expansion valve and
evaporator) show measured values in accordance with table 20 and the
diagram in fig. 58.
°C
0
10
20
k T...
15
9,6
6,3
k T...
5,2
4,3
3,0
°C
25
30
40
Table 20 The resistance values, low temperature sensor
6 720 806 629 (2013/02)
GENERAL SYSTEM INFORMATION
HIGH TEMPERATURE SENSOR ODU
R(kΩ)
The temperature sensors TH4 (hot gas) and TH32 (compressor
temperature) show measured values in accordance with table 22 and
the diagram in fig. 60.
50
k T...
250
160
104
70
48
°C
20
30
40
50
60
40
30
k T...
34
24
17,5
13,0
9,8
°C
70
80
90
100
110
Table 22 The resistance values, high temperature sensor
R(kΩ)
20
500
10
400
300
0
-20
-10
0
10
20
30
40
50
T(˚C)
6 720 614 486-19.1I
200
Fig. 58 Low-temperature sensor ODU
MEAN TEMPERATURE SENSOR ODU 7.5
Temperature sensor TH8 (heat sink) has measurement values according
to table 21 and diagram in fig 59.
k T...
180
50
17
°C
0
25
50
100
k T...
8
4
°C
70
90
0
25
50
75
100
120
T(˚C)
Table 21 The resistance values, medium temperature sensor
6 720 614 486-27.1I
Fig. 60 High temperature sensor ODU
R(kΩ)
200
12
GENERAL SYSTEM INFORMATION
The heating system consists of one or two circuits. The heating system is
installed according to operating mode, depending on access to and type
of additional heater.
150
12.1 HEATING CIRCUITS
• Circuit 1; control of the first circuit is regulated by the installed flow
sensor, in combination with installed room controller (accessory).
• Circuit 2 (mixed), accessory: circuit 2 is also regulated by the
controller if a Multi Box (accessory) is available. In this case, an
additional room temperature controller can be installed.
100
In heating mode, Circuit 2 cannot have a higher flow
temperature than circuit 1. This means that under floor
heating on circuit 1 cannot be combined with radiators
on circuit 2. Room temperature reduction for circuit 1
can affect circuit 2 in some modes.
50
12.2 HEATING CONTROLS
0
25
50
75
100
125
T(˚C)
It is only the room where the room controller is located
that can influence regulation of the temperature.
6 720 614 486-26.1I
Fig. 59 Mean temperature sensor ODU
6 720 806 629 (2013/02)
49
USER INTERFACE
• Outside temperature sensor and room temperature controller
(one room temperature controller can be used for each heating
circuit): if the system is to be controlled using an outside temperature
sensor and a room temperature controller, the outdoor sensor must
be located on the north facing external wall of the house.
The room temperature controller is connected to the Hydrolight/
Hydrocomfort unit and signals the current room temperature to the
control unit. This signal influences the flow temperature. The flow
temperature is reduced if the actual room temperature is higher than
the selected temperature.The room sensor must be located centrally
in the house.
12.3 CONTROL METHOD FOR COMPRESSOR
The outdoor unit makes use of variable compressor speeds (inverter
controlled) and adjusts to existing needs.
EXAMPLE: THE HEAT CURVE IS SET AT 55 °C AT –5 °C (NOT
FACTORY SETTING):
6 720 648 125-69.1I
Fig. 61
• Outside temperature higher than 10 °C: heat pump operation only.
• Outside temperature below 10 °C, but higher than – 5 °C: if required,
auxiliary operation together with the heat pump.
• Outside temperature below – 5 °C: auxiliary operation only.
If the required speed is greater or less than the current speed, after a
certain time the compressor will increase or decrease the speed
(depending on how far it is from its set point value).
12.7 MIXING VALVE CONTROL (MIXING VALVE FOR 2ND
HEAT APPLIANCE AND HEATING CIRCUIT WITH
MIXER)
Regardless of whether the required output is great (e.g. at initial startup) or small, the compressor will start at low speed and then increase in
speed step by step.
The controller uses PID control to control the integrated mixing valve and
can reach the flow either on the main circuit or at heating circuit 2. A
signal from the controller determines how much the mixing valve
opening needs to change. The signal is calculated at short intervals. In
order to calibrate the mixer, this is closed completely once every 24 hrs.
Depending on the mixer selected, this closing operation lasts between 3
and 5 minutes to make sure that this has been successfully carried out.
No warmth or cold is transferred to the system during this time.
Settings and additional information can be found in chapter 16.6.7.
12.4 TIME CONTROL OF CENTRAL HEATING
• Time control heating: enables you to increase or reduce the
temperature on different days of the week for custom times.
• Holiday: the control unit has a program for holiday mode, which
means that during the selected period the room temperature changes
to a lower or higher level.
• External input1 and External input 2 in the control unit can be used
for external control. A preselected function is performed when the
control unit senses an input signal.
12.5 OPERATION MODES
The outdoor unit stops automatically at outside
temperatures less than approx. – 20 °C. The heating and
DHW production is then provided by the electr. heater or
the 2nd heat appliance in the Hydrocomfort/Hydrolight
unit.
13
USER INTERFACE
All settings are made in the control panel and any alarms can be viewed.
The control unit can be controlled via the control panel in accordance
with the customer's requirements.
The user interface and controller are in the Hydrolight/Hydrocomfort
unit.
13.1 OVERVIEW OF THE USER INTERFACE
The heat pump is dimensioned for less than the house peak heating load,
and the additional heat sets in at the same time as the heat pump to meet
the demand, when the heat pump alone is not sufficient.
Alarm mode, extra domestic hot water and thermal disinfection also
activate the booster heater, even if the outdoor unit is switched off at low
outside temperatures. The heating can be independent of the selected
internal unit:
6 720 648 132-01.1I
• 3-stage electr. heater
• 2nd heat appliance (e.g. gas or oil boiler)
12.6 OPERATION CONTROL
The outdoor unit is designed for a flow temperature of up to 55 °C.
The controller blocks the additional heater at outside temperatures
higher than 10 °C (adjustable).
If at an outside temperature of more than –15 °C (adjustable) the
temperature in the flow line of the heating system needs to be higher
than 55 °C, the heating system switches over to CH mode exclusively
following a 30-minute delay. The outdoor unit is then switched off.
50
Fig. 62 Overview of the user interface
[1]
[2]
[3]
ON/OFF switch
Display
Rotary selector
6 720 806 629 (2013/02)
INSTALLATION AND SERVICE MENU (I/S)
13.3 MENU TABS
MENU DISPLAY
The menus are divided into four different tabs for different reasons.
•
•
•
•
Temperature - overview of heating settings
Blocking - blocking functions
Menu - the most popular menu items
Advanced menu - additional menu items.
6 720 648 148-47.1I
End users only see what is available in the customer levels.
Fig. 63
MENU DIAL
The menu dial is used to navigate between the menu windows and to
change the values of different settings. The menu dial is also used to
confirm selections.
14
INSTALLATION AND SERVICE MENU (I/S)
CAUTION: The installer and service menu
(I/S) is only for installers.
▶ Under no circumstances may the user access this
level.
POWER SWITCH
The power switch button is used to start and switch off the heating
installation.
13.2 CONTROL PANEL FUNCTION
Before you can access the I/S menus, the date and time
must be correctly set ( chapter 16.1).
The menu dial is used to navigate the menus.
▶ Turn the rotary selector anticlockwise to access the menus below or to
the left.
▶ Turn the menu button clockwise to access the menus above or to the
right.
▶ Once you have marked the required selection, press the rotary
selector to confirm.
The backlighting in the display goes out after ten minutes
if there has been no activity at the user interface.
At the top of each sub menu there are back arrows to return to the
previous menu.
Cooling is not an option in this unit.
▶ Press the rotary selector if the arrow is marked.
13.2.1 SYMBOL OVERVIEW
Symbols for different functions and components that are in operation
are displayed in the lower part of the menu window.
1
2
3
4
6 720 648 148-41.1I
Fig. 65
5
6
7
8
9
10
11
12
6 720 648 135-11.1I
Fig. 64 Overview of symbols
[1]
[2]
Compressor
Additional heater (electric heater with Hydrocomfort 8-16, 2nd
heat appliance with Hydrolight 8-16)
[3] External input
[4] DHW mode
[5] DHW peak
[6] Additional hot water
[7] Time control
[8] Heating Mode
[9] Malfunctions
[10] Holiday mode
[11] defrosting
[12] Info-Icon
6 720 806 629 (2013/02)
A 4-digit access code is required to open the installation and service
menu (I/S).
▶ Turn the dial to Advanced.
▶ Select Access level.
▶ Enter the four digit access code (the present date is given as two digits
for the month and two digits for the date, for example 0920) using the
menu dial and press the menu dial to confirm.
"Access = Service" appears in the display
▶ Navigate to Menu. Under Menu are now both customer functions and
I/S functions.
▶ Return to customer level by selecting Access level in Advanced and
enter 0000 as access code.
The control unit automatically returns to customer level approximately
120 minutes after the last adjustment.
51
MENU OVERVIEW
15
MENU OVERVIEW
Here you find the upper levels for all functions under Menu and
Advanced. All setting functions are also in the table Factory settings
(Chapter 19.1). Installer level (I/S) = [1], User level = [0].
Menu
Fast restart of heat pump
Start up
Language
Country
Setting the clock
Heat pump size
Operation mode
Room sensor with dew point
Additional heater options
At additional heating option electr. heater:
State total output
T1 maximum set point value
External input 1
External input 2
External input, heating system 2
External input 2, heating system 2
Set date
Set time
Not used in the UK
Activated if
change in temperature
Stop hot water loading
Stop heating production
Additional heat only
Limit electrical capacity to
External blocking
Safety thermostat
Stop additional heat hot water
Stop additional heat radiators
Activated if
change in temperature
Stop hot water loading
Stop heating production
Additional heat only
Limit electrical capacity to
External stop
Safety thermostat
Activated if
Change in temperature
Block cooling
External stop
Safety thermostat
Activated if
Change in temperature
Block cooling
External stop
Safety thermostat
Low energy circulation pump
Minimum outdoor temperature of heat curve
Accessory board function
Activate heating system 2
With activated mixer group:
E12.T1 maximum set point value
Connected extra sensors
T3 acknowledged
T5 acknowledged
Access level
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
With activated heating system 2:
E12.T5 acknowledged
Table 23 Menu
52
6 720 806 629 (2013/02)
MENU OVERVIEW
Menu
Manual operation
Operating option, additional heater
Correct sensor
Anti-jamming mode time
Alarm buzzer interval
Display
Screed drying
Manual operation
Manual operation time
3-way valve
G1 heating system pump
G2 Heat carrier pump
G2 Speed
Compressor
Cooling (non Function)
Electric water heater step 1
Electric water heater step 2
External additional heater
Mixing valve open
Mixing valve close
Mixing valve open, heating system 2
Mixing valve close, heating system 2
E12.G1 pump, heating system 2
Cooling season relay (non Function)
Heating cable
E41.G6 Hot water circulation pump
Additional heat only
Block additional heat
Correct T1
Correct T71
Correct T2
Correct T3
Correct T5
Correct T8
Correct T9
Correct E12.T1
Correct E12.T5
Contrast
Brightness
Activate
Access level
1
1
1
1
1
1
1
If screed drying is activated:
Current program step
Time remaining in current program step
Heat source
Program settings
Temperature increase/decrease
Temperature increase/decrease,
heating system 2
Temperature increase/decrease
settings
System pressure sensor connected (only in
Hydrocomfort)
Operation alternative G2
Only displayed if a room temperature sensor
is not installed.
Only displayed if a room temperature sensor
is not installed.
Only displayed if a room temperature sensor Limit value for V or H
is not installed.
Much colder/warmer, change
Colder/warmer, change
Limit value for V and H, heating system 2
Much colder/warmer, change
Colder/warmer, change
Change with cooling/heating, heating system 2
Room temperature setting
Only displayed if a room temperature sensor Setting the temperature
is installed (T5, TT).
Room temperature setting, heating Only displayed if a room temperature sensor Setting the temperature
system 2
is installed (E12T5, TT).
Extra hot water
Only displayed if DHW temperature sensor is Set run time of function
installed (T3)
1
1
0
0
1
1
1
1
1
0
0
0
Table 23 Menu
6 720 806 629 (2013/02)
53
MENU OVERVIEW
Blocking
Block additional heat
Block hot water
Block heating
Block heat,
heating system 2
Access level
0
0
0
0
Select Yes/No
Select Yes/No
Select Yes/No
Select Yes/No
Table 24 Blocking
Advanced menu
Heating/Cooling
Minimum outdoor temperature of heat curve
Heating system temperature
Room sensor settings
Time limited settings
Heating season
Heating, maximum operating time at hot water demand
Shut down protection, change over hot water to heating
Maximum speed compressor
Quick acceleration time
Quick brake time
Operation mode heating system 1
Heat curve
Hysteresis
--Quick acceleration
--Quick brake
--Quick stop
--integration time
--Rad brake temp increase
--Rad brake time
Room temperature setting
Outdoor temperature display in room sensor
Room sensor interval
Room sensor Influence
--Change factor
--Blocking time
Time control heating
--Day and time
--Change in temperature
1
0
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
Holiday
--Date
--Change in temperature
0
0
0
External input 1
--Activated if
--Change in temperature
--Installer settings
0
1
0
0
0
0
0
0
External input 2
--External in 2, active with
--Temperature change
--Installer settings
Heating season limit
Delay
Direct start limit
0
0
0
0
1
1
1
1
1
Table 25 Advanced menu
54
6 720 806 629 (2013/02)
MENU OVERVIEW
Advanced menu
Temperature heating system 2
(only if installed)
Hot water
Extra hot water
Hot water peak
Hot Water temperature
Temperatures
Time control hot water
Time control hot water circulation
Slowest speed at hot water production
Max speed during hot water production
Quick start of addition
Display of temperatures
Correct sensor
Inputs
Outputs
Demand
Timer display
Timers (timer
programs)
Operating times and Total operating time
consumptions
Short-term measurements
Heat curve
Room sensor settings
--Room temperature setting
--Room sensor influence
Time limited settings
---Time control heating
---Day and time
--Change in temperature
--Time control cooling day/time
--Holiday
---Date
---Change in temperature
--External input 1
--External input 2
Mixing valve settings
--Control unit reading
--P-constant
--I-time
--D-time
--Mixing valve running time
--Mixing valve limitation defrost mode
Number of hours
Stop temperature
Interval
Start time
In compressor mode
--T3 Start temperature
..T9 Stop temperature
Hot water, max operating time with heating demand
Readout of all sensors connected to the Hydrolight/
Hydrocomfort unit
Adjust all sensors connected to the Hydrolight/
Hydrocomfort unit
Readout of input signals
Readout of output signals
Actual status of heat pump
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
0
0
1
1
1
0
0
0
1
1
1
1
1
1
1
1
0
1
Table 25 Advanced menu
6 720 806 629 (2013/02)
55
MENU OVERVIEW
Advanced menu
Additional heat
settings
Start delay
Time control additional heat
Operating option
Electric additional heat settings
Mixing valve settings
Additional heat only
Block additional heat
Connection capacity
--State total output
--Compressor mode, output limitation
--Additional heat only, output limitation
Ramp time increase
Ramp time decrease
Locking of electricity supply when defrosting
Neutral zone
Mixing valve delay
1
1
1
1
1
Control unit reading
PID heat setting
--P-constant
--I-time
--D-time
PID hot water setting
--P-constant
--I-time
--D-time
Mixing valve running time
Locking of mixing valve during defrosting
Safety functions
Setting the clock
Alarm
Max outdoor temperature for additional heat
Connected electrical capacity (shows the current value)
Block heat pump at low outdoor temperature
Heating cable time after defrosting
1
1
1
1
Set date
Set time
Country
Alarm log
0
0
0
0
0
1
1
1
0
0
Alarm history
Info log
Alarm log
Delete alarm log?
Alarm history
Info log
Delete info log
Access level
Return to factory
settings
Deactivate alarm
buzzer
Program version
Shows installed program version for controller
Connected I/O cards Shows which I/O card is connected to the controller and
its version number.
0
0
1
Table 25 Advanced menu
Temperature
Temperature
Display current temperatures
Access level
0
Table 26 Temperatures
56
6 720 806 629 (2013/02)
COMMISSIONING
▶ Set date in the format Year-Month-Day.
16
COMMISSIONING
WARNING: The compressor must be warmed up before
starting for the first time.
▶ Switch on the power to the outdoor unit at least 2
hours prior to commissioning, up to 12 hours for
extreme climate conditions (below -15 °C ambient
temperature).
6 720 648 149-24.1I
Fig. 68
▶ Set time in the format Hour-Minute-Second.
In regions where the air has a high moisture content and
there is a danger of freezing (near lakes, rivers and the
sea), the SW 7-6 switch can be switched to "on". This
shortens the defrosting cycles.
6 720 648 149-23.1I
Before commissioning:
Fig. 69
▶ Open all radiators or underfloor heating systems.
▶ Fill the heating system.
▶ Bleed the heating system.
▶ Check the heating system for leaks.
When connecting a fan coil system the fans are to be started first and any
shut-off valves for the fan coils fully opened.
There is no automatic summer / winter clock change
over. This has to be done manually.
▶ Select the Heat pump size.
Cooling should not be selected on this unit. This function
is not supported for the UK market.
16.1 SWITCHING ON THE HEAT PUMP
6 720 648 135-02.1I
The heat pump may only be installed and started up by a competent
person.
▶ Switch the power supply to the heat pump on. Start the heat pump by
briefly pressing the ON/OFF switch on the user interface. The
available languages are displayed.
Fig. 70
▶ Select the Operating mode for which the heating system has been
configured.
6 720 648 148-56.1I
Fig. 71
6 720 648 125-42.1I
Always select Heating only as cooling is not an option in
this unit.
Fig. 66
▶ Select the required display language. The selected language is
automatically adopted as the factory setting and will not be changed
at Return to factory settings. To change the language, go to
Language under Start up.
▶ Then select the Country in which the heat pump is used. Options:
Germany, Great Britain, France, Sweden and Austria.
▶ Select the type of booster heating that is installed. Electric booster
heater, 3-stage with Hydrocomfort, booster heater with mixer with
Hydrolight.
6 720 648 148-45.1I
Fig. 72
6 720 648 135-01.1I
Fig. 67
▶ When selecting 3 step electric heater: select the heating output of
the booster heater.
▶ Set the current output of the incoming booster heater.
The electric additional heat built into the Hydrocomfort
module is 9 kW.
6 720 806 629 (2013/02)
57
COMMISSIONING
6 720 648 148-49.1I
6 720 648 135-14.1I
Fig. 76
Fig. 73
▶ Select E11.T1 Set point maximum, i.e. the max. permitted flow
temperature (H-value). The setting can be between 20°C and 80°C,
the factory setting is 45°C.
The T1 max. set value must set at 80°C when operating
with external auxiliary heaters.
▶ To activate manual mode, select Yes then Save under the Manual
operation menu item.
Three-way valves, circulation pumps, compressor, electric elements
and mixing valves can now be manually operated by selecting On and
then Save for each function.
The function must be deactivated afterwards by
selecting No on Manual operation.
16.3 HEATING SETTINGS
16.3.1 HEATING CURVE
The heat curve is only active in heating mode. For more
information on setting of the heat curve please consult
the user guide.
6 720 648 148-43.1I
Fig. 74
▶ State whether the heat transfer medium pump G2 is a Low energy
circulation pump.
Always select No.
▶ Select the Minimum outdoor temperature of heat curve, i.e. the
outside temperature below which the flow temperature no longer
increases as the outdoor temperature decreases. The value can be set
to between
–35°C and 0°C. Factory setting: –10°C.
The heating curve may need to be reset if the Minimum outdoor
temperature of heat curve is changed ( chapter 20.3).
The heat curve constitutes the basis for the control unit's control of the
temperature on the heating water to the circuit and indicates how high it
needs to be in relation to the outdoor temperature. The control unit
increases the temperature of the heating water when the outdoor
temperature drops. The temperature of the heating water out to the
circuit, i.e. the flow temperature is measured by sensor T1 for circuit 1
(full name E11.T1) and sensor T1 for circuit 2 (full name E12.T1).
Set appropriate V and H values.
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Heating system temperature (or Temperature heating
system 2 to set heating system 2)
▶ Select the Heat curve.
▶ Adjust to the desired value.
T1(˚C)
6 720 648 135-03.1I
Fig. 75
If the settings have been made as specified in chapter 16.1, the heat
pump will be ready for operation. To make further settings, or modify
existing settings, you will need to access the installation and service
menu. (chapter 14).
80
70
60
L
50
Settings that have already been made in accordance with chapter 16.1
can be modified under Menu in the user interface of the Hydrolight/
Hydrocomfort module.
40
16.2 MANUAL OPERATION
20
Before commissioning the heating installation, all functions can be
checked, by manually starting and stopping them. This can be found in
the Start up menu section.
10
20 15 10 5
H
V
30
0
-5 -10 -15 -20 -25 -30 -35
T2(˚C)
6 720 648 135-22.1I
Fig. 77 Heating curve
[T1] Flow temperature
[T2] Outside temperature
[1] Lowest outside temperature of heating curve. At low
temperatures the flow temperature remains unchanged.
58
6 720 806 629 (2013/02)
COMMISSIONING
Only the part of the heat curve with flow temperature up
to the highest permitted flow temperature (the H-value)
is shown in the window. Therefore, the heat curve is a
straight line in the window, and the point (L) is the value
at the right side of the window.
A heat curve is set for each circuit. If the room temperature is perceived
to be too high or too low in the circuit, it is preferable to adjust the curve.
The heat curve can be changed in several ways. The slope of the curve
can be changed by adjusting the flow temperature up or down in the left
and the right end points. The curve can also be affected every 5th
outdoor temperature degree.
• With the underfloor heating system, the end point on the right must be
set to no higher than 40 °C. Higher temperatures can damage the
pipes and floor.
• The end point on the right is normally 50 °C for radiators.
• The factory setting for the minimum outside temperature [1] is –
10 °C.
To change the value [1]:
– In I/S select Advanced.
– Select the Heating/Cooling.
– Select Minimum outdoor temperature of heat curve.
– Set the required value.
▶ Select Operating option
▶ Select Additional heat only.
▶ Select Yes and then Save. Heating and hot water is only supplied via
additional heating.
The function Block additional heat blocks the additional heat function,
but not during alarm mode, hot water peak, extra hot water or operation
with additional heat only.
Block additional heat normally this is not
recommended.
16.3.4 TEMPERATURE ADJUSTMENT EXTERNAL CH
When using a 2nd heat appliance (mixer with CH), this must be
configured so that the temperature it delivers is always higher than the
anticipated maximum temperature in the system, irrespective of the
outside temperature. The temperature set must however always be at
least 65 °C in order to be able to carry out thermal disinfection of the
DHW cylinder, or provide additional domestic hot water. Depending on
the supplier of the external booster heater, this may need to be set with
a heat curve. You can find further settings in the manual of the supplier
of the external heat source.
16.3.5 MIXING VALVE DELAY
The outdoor unit stops at outdoor temperatures lower
than approximately –20 °C. The heating installation then
goes over to additional heat mode only.
16.3.2 CONNECTION CAPACITY FOR HYDROCOMFORT
6 720 648 135-04.1I
Fig. 80
To achieve the required temperature, delayed opening of the mixer is
necessary.
To define the correct delay time:
6 720 648 148-48.3I
Fig. 78
▶ In I/S select Advanced
▶ Select Additional heat settings
▶ Select Electric additional heat settings
▶ Select Connection capacity
State total output: specify the connected total output of the electric
heater here. For a Hydrocomfort unit with 9 kW, enter 9 kW.
Compressor mode, output limitation: specify the output restriction for
the booster heater when the compressor is in operation here. The
factory setting is 2/3 the value set in State total output.
Additional heat only, output limitation: Setting permitted output
when the compressor is not in operation. The factory setting is the value
in State total output.
16.3.3 ADDITIONAL HEAT OPTIONS
▶ Measure the time between activation of the additional heater (in
manual mode), and deactivation of the additional heater because of
too high temperature in the boiler control.
▶ In I/S select Advanced
▶ Additional heat settings
▶ Mixing valve settings
▶ Select Mixing valve delay
▶ Enter the measured value as mixer delay
▶ Select Save
16.3.6 START DELAY ADDITIONAL HEATER
▶ Set what start delay should apply to the additional heat.
When the need for additional heat arises, a timer with set time is
started. When this time has passed the additional heat starts.
▶ In I/S select Advanced
▶ Select Additional heat settings
▶ Select Start delay
16.3.7 MAX OUTDOOR TEMPERATURE FOR ADDITIONAL HEAT
6 720 648 148-50.1I
Fig. 79
Blocking of compressor and fan start:
▶ In I/S select Advanced
▶ Select Additional heat settings
6 720 806 629 (2013/02)
▶ Set the highest outside temperature for the CH operation.
If the outside temperature exceeds the value set for more than 30
minutes, the booster heater will also be switched in above this
temperature in Alarm mode, Extra domestic hot water, Thermal
disinfection and during operation exclusively with additional heating.
CH mode will be activated again if the outside temperature falls below
the value set.
59
COMMISSIONING
16.3.8 BLOCK HEAT PUMP AT LOW OUTDOOR TEMPERATURE
OUTDOOR TEMPERATURE DISPLAY IN ROOM SENSOR YES/NO
With Yes the room controller displays the temperature in the house and
the temperature outdoors alternately.
16.4 DOMESTIC HOT WATER SETTINGS
▶ In I/S select Advanced
▶ Select Hot water
6 720 648 135-05.1I
Fig. 81
16.4.1 HOT WATER TEMPERATURE
▶ In I/S select Advanced
▶ Select Safety functions
▶ Select Block heat pump at low outdoor temperature
▶ Select Save
The DHW production is checked via sensor T3 (cylinder sensor) and T9
(return sensor in internal unit).
If this setting has is made, the booster heater takes over the heating and
DHW production as soon as the outside temperature has been below the
selected temperature for at least 30 mins.
16.3.9 EXTERNAL INPUT 1/ EXTERNAL INPUT 2
▶ In I/S select Advanced
▶ Select Heating/Cooling
▶ Select Tme limited settings
When External input 1/ External input 2 is activated, the control unit
performs the selected functions. When the external input is no longer
active, the control unit returns to normal mode.
During pre-configuration of the heat pump, select whether External
input 1 and External input 2 should be activated when the input is
closed or open ( chapter 16.1).
Select the menu item(s) to be executed if External input 1/ External
input 2 is activated:
▶ Change in temperature, set the amount of degrees that the flow line
temperature is to be changed.
▶ Stop heating production, stops heat production completely, frost
protection still active.
▶ Stop hot water loading, select Yes if hot water production with the
heat pump is to be blocked.
▶ Additional heat only, select Yes if the heat pump operation is to be
blocked.
▶ Limit electrical capacity to, select the maximum output that the
additional heater may have. This selection is used during tariff
control.
▶ External blocking is used if a fan convector is installed in the system
and indicates the status of the fan.
▶ Safety thermostat, switches the heat pump off and sends an alarm.
▶ Stop additional heat hot water, if Yes is selected, the electr. booster
heater is switched off.
▶ Stop additional heat radiators, if Yes is selected, the 2nd heat
appliance is stopped, i.e. only the compressor is used.
16.3.10 ROOM SENSOR SETTINGS (ROOM CONTROLLER)
▶ In I/S select Advanced
▶ Select Heating/Cooling
▶ Select Room sensor settings
ROOM SENSOR INFLUENCE
DHW charging starts if the temperature at sensor T3 falls below the set
value, and stops when the temperature exceeds the set value of
T3+0.5K and the set value of T9. If a greater degree of comfort is
required, the T9 stop temperature can be increased to the required
temperature. However, this has a significant impact on the effectiveness
of the heat pump.
Separate DHW heating by the 2nd heat appliance is only
possible if the highest anticipated temperature of the
2nd heat appliance does not exceed the maximum flow
temperature T1.
16.4.2 COMPRESSOR SPEED DURING DHW PRODUCTION
The compressor has been set at the factory to operate at stage 3 as
minimum and stage 7 as maximum when charging the DHW cylinder.
If the compressor stage is higher than 3 in heating mode, this stage is
also used for charging with domestic hot water. If a greater degree of
comfort and faster charging of the DHW cylinder is required, set the
value "Lowest speed when filling with domestic hot water" to the
required value.
If the factory setting is changed, this restricts the
efficiency of the heat pump and can lead to error
messages with several DHW cylinders.
16.4.3 HOT WATER PEAK (ANTI-LEGIONNELLA FUNCTION)
When the DHW peak program is activated, the DHW cylinder is heated
up to 65 °C with the assistance of the heat pump and booster heater. If
the temperature is too high for the heat pump, it is stopped and the
booster heater increases the temperature up to the stop temperature.
Hot water peak is not activated as a factory setting. If this function is
required, the interval in days and the time can be set under Advanced.
▶ In I/S select Advanced
▶ Select Hot water
▶ Select Hot water peak
If Activate under Interval is selected, Hot water peak is carried out
once and is subsequently inactive.
16.4.4 HOT WATER CIRCULATION
The time control for the DHW circulation pump is set under Advanced.
▶ In I/S select Advanced
▶ Select Hot water
▶ Select Time control hot water circulation
▶ Set the extent to which a room temperature deviation of 1 K (°C)
influences the set value for the flow temperature.
A switch-on and shutdown can be set for each day of the week.
Example: with a 2 K (°C) deviation from the set room temperature, the
set value of the flow temperature is changed by 4 K (°C) (2 K deviation *
factor 2 = 4 K). The greater the influence, the greater the effect of the
room controller, but also the potential fluctuation in temperature.
16.4.5 EXTRA HOT WATER
Additional amount of hot water is produced by temporarily increasing
the temperature of the hot water during the set number of hours to the
indicated stop temperature.
The heat pump starts the function directly and uses the compressor first
and then the additional heat source to increase the temperature. When
60
6 720 806 629 (2013/02)
COMMISSIONING
the desired number of hours have passed, the heat pump returns to
normal hot water mode.
DANGER: Risk of burn injuries.
▶ Use a mixing valve when the hot water temperature
exceeds 60 °C.
the external input is no longer active, the control unit returns to normal
mode.
Select pre-configuration of the heat pump if External input, heating
system 2 and External input 2, heating system 2 are to be activated
when the input is closed or open ( chapter 16.1).
▶ In I/S select Advanced
▶ Select Hot water
▶ Select Extra hot water
▶ Number of hours
▶ Set the time for which extra domestic hot water should be produced
▶ Select Stop temperature
▶ Set stop temperature for extra domestic hot water.
Select the menu item(s) to be executed if External input, heating system
2/ External input 2, heating system 2 is activated:
▶ Change in temperature, set the amount of degrees that the flow line
temperature is to be changed.
▶ Block cooling, select Yes if cooling is to be blocked.
▶ External stop, is used if a fan convector is installed in the system and
indicates the status of the fan.
▶ Safety thermostat switches the heating circuit pump and mixer off
and sends an alarm.
16.5 SETTINGS FOR HEATING CIRCUIT 2
16.5.6 ROOM SENSOR SETTINGS (ROOM CONTROLLER)
16.5.1 ACTIVATE MIXER GROUP
▶ In I/S select Menu
▶ Select Start up
▶ Select Accessory board function
If a mixer module is installed for heating circuit 2, this must be confirmed
in the menu. To do this, select Accessory board function.
▶ To confirm the accessories card, select Yes then Save.
16.5.2 HEATING CURVE
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Temperature heating system 2
▶ Select the Heat curve.
▶ Adjust to the desired value.
Perform the same settings made with heating system 1 (
chapter 16.3.1).
16.5.3 MAX LIMIT E12.T1 SET POINT VALUE
Maximum flow temperature for heating system (circuit) 2 can be
adjusted here.
▶ In I/S select Advanced
▶ Select Heating/Cooling
▶ Select Temperature heating system 2
▶ Select Room sensor settings
Perform the same settings made with heating system 1
( chapter 16.3.10).
16.6 OTHER SETTINGS
Following commissioning and pre-configuration in accordance with
chapter 16.1- 16.5, all the necessary settings have been made.
Furthermore, additional settings can be made if required. These are
listed in this chapter.
16.6.1 SYSTEM PRESSURE SENSOR CONNECTED
A system pressure transmitter is only available for Hydrocomfort. The
menu is not visible in Hydrolight.
▶ In I/S select Menu
▶ Select Start up
▶ Select System pressure sensor connected
Always select Yes.
This value is set to 45 °C on delivery. The value may need to be increased
if only radiators are used.
▶ In I/S select Menu
▶ Select Start up
▶ Select Max limit E12.T1 set point value
▶ Set the required value.
16.5.4 MIXER RUNTIME
If a mixed heating circuit with mixer is installed, the current runtime of
the mixer valve must be set. To do this, select Advanced.
▶ In I/S select Advanced
▶ Select Heating/Cooling
▶ Select Temperature heating system 2
▶ Select Mixing valve settings
▶ Select Mixing valve running time
Setting the runtime in seconds.
16.6.2 OPERATION ALTERNATIVE G2
▶ Setting the operating mode of the heat transfer medium pump G2 or
automatic start at compressor start.
In systems without bypass or without buffer cylinder, G2 must be
continuously in operation.
Setting continuous mode:
▶ In the installation and service menu select Menu.
▶ Select Start up.
▶ Select Operation alternative G2.
▶ Set the required value.
16.6.3 CONNECTED EXTRA SENSORS
If the DHW sensor T3 is installed, this is automatically confirmed.
If the room controller is installed, this is automatically confirmed.
16.5.5 EXTERNAL INPUT, HEATING SYSTEM 2/ EXTERNAL INPUT
2, HEATING SYSTEM 2
If the heating system (heating circuit) 2 is installed, the room controller
will also have automatically confirmed E12.T5.
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Temperature heating system 2
▶ Select the External input 1 or 2
All sensors can be deactivated if required.
▶ In I/S select Menu
▶ Select Start up
▶ Select Connected extra sensors
When External input, heating system 2/ External input 2, heating system
2 is activated, the control unit performs the selected functions. When
6 720 806 629 (2013/02)
61
COMMISSIONING
16.6.4 CORRECT SENSOR
All sensors can be corrected a maximum of 5 °C up or down. The value is
given directly in °C. Sensors should only be corrected in exceptional
cases.
▶ In I/S select Menu
▶ Select Start up
▶ Select Correct sensor
16.6.5 ANTI-JAMMING MODE TIME
At the set time each day the circulation pump G2 and 3-way valve VXV
are run for one minute each, provided that they have not been operated
during the previous twenty four hours. Factory setting = 2, which means
02:00. Min = 0, max = 23.
▶ In I/S select Menu
▶ Select Start up
▶ Select Anti-jamming mode time
The opposite applies if T1 falls below the heat curve by 5° instead, the
speed then increases (advances).
Setting the permissible temperature deviation:
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Heating system temperature.
▶ Select Hysteresis.
▶ Select Quick acceleration or Quick brake.
▶ Set the required value.
Select how long a deviation can last before the speed changes:
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Hysteresis.
▶ Select Rad brake temp increase or Rad brake time.
▶ Set the required value.
QUICK STOP
16.6.6 ALARM BUZZER, INTERVAL
If the alarm signal is not deactivated, it sounds at the specified interval in
the event of an alarm. Factory setting = 1 minute. Maximum = 10
minutes.
▶ In I/S select Menu
▶ Select Start up
▶ Select Alarm buzzer, interval
16.6.7 HYSTERESIS, HEATING
There is normally no reason to change the factory
setting. It is only in the event of large temperature
changes in the heating system or if the compressor
continuously changes speed between its outer positions
(0 - 7 steps), that adjustment is required.
Hysteresis determines when the heat pump’s compressor is to increase
and reduce the heating output in relation to the heat curve’s value. These
values are offset in relation to the heat curve to prevent the compressor
from starting and stopping continuously.
INTEGRATION TIME
The value Integration time is the normal regulation of hysteresis. The
integration time determines how quickly the compressor's speed is to be
regulated if the flow temperature (T1) deviates from the heat curve less
than that stated in the menu Quick acceleration or Quick brake.
A factory setting of 60 degree minutes (°min) means that if the deviation
is 1 °C it takes 60 minutes for the speed of the compressor to increase or
reduce by 1 stage. With a deviation of 2 °C it takes 30 minutes for the
speed of the compressor to change.
Setting the integration time:
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select Heating system temperature.
▶ Select Hysteresis.
▶ Select Integration time.
▶ Set the required value.
The value Quick stop determines how many degrees the flow
temperature (T1) can exceed the heat curve before the compressor
stops fully.
Setting the permissible temperature deviation:
▶ Go to Advanced on the I/S level.
▶ Select Heating/Cooling.
▶ Select the Heating system temperature.
▶ Select the Hysteresis.
▶ Select the Quick stop.
▶ Set the required value. Factory setting: 10 °C.
16.6.8 OPERATING TIMES AND CONSUMPTIONS
The total operating times of the controller, compressor and booster
heater are displayed here (active connection). Short-term
measurements can also be carried out for the compressor and booster
heater.
▶ Go to Advanced on the I/S level.
▶ Select Operating times and consumptions.
16.7 FAST RESTART OF HEAT PUMP
To bypass all timers when the heat pump starts:
▶ Select Menu
▶ Select Fast restart of heat pump
▶ Select Yes then Save.
The heat pump starts after 20 s if a central heating or domestic hot water
demand exists and all internal timers of the external unit have elapsed.
Internal timers cannot be influenced.
The internal timers in the outdoor unit can delay the start
more than 20s.
16.8 SCREED DRYING
Screed drying requires the installation of underfloor
heating coils under the floor tiles.
QUICK ACCELERATION AND QUICK BRAKE
The value determines how many degrees the flow temperature (T1) can
deviate from the heat curve before the compressor quickly changes
speed (heat output).
Factory setting is 5 °C (acceleration) 1 °C (brake), which means that if
the flow temperature T1 exceeds the set point value from the heat curve
by 1 °C the speed reduces by 1 step (brakes). The reduction occurs
gradually as long as the deviation is 1° or more during the set time Quick
brake.
62
Screed drying must take place with a continuous
electrical power supply. When screed drying is used, the
electric connection should therefore be made in the
standard way.
The screed drying function is used for the drying of screed in new-build
homes. The screed drying program has the highest priority, which
6 720 806 629 (2013/02)
TIMER (TIMER PROGRAMS)
means that all functions, apart from the safety functions and electric
heating only operation, are deactivated. When drying the screed, all
heating circuits are in operation.
17
TIMER (TIMER PROGRAMS)
The screed drying is carried out in three phases:
• Heating phase
• Phase with maximum temperature
• Cooling phase
Heating and cooling are performed stepwise; each step continues for at
least a day. The phase with maximum temperature is considered to be
one step. There are 9 steps with the factory values: Heating phase in 4
steps (25 °C, 30 °C, 35 °C, 40 °C), maximum temperature (45 °C for
four days), cooling phase in 4 steps (40 °C, 35 °C, 30 °C, 25 °C).
To activate the screed drying program ( chapter 16.8.1).
It is possible to cancel a running program. On completion of the program,
the heat pump returns to normal operation.
Following a power supply interruption or failure, the screed drying
program continues at the point where it was interrupted.
6 720 648 149-22.1I
Fig. 83
There is a number of timers in the control unit. The status for each of
these is shown in the menu Timers. Only functions that are active are
shown in the menu, the others are hidden until activated.
EXTRA HOT WATER
Displays the remaining time for requested extra hot water.
ADDITIONAL HEAT START
Displays the countdown of the timer for delay of additional heat.
16.8.1 SCREED DRYING
▶ In the installation and service menu select Menu.
▶ Select Start up.
▶ Select Screed drying.
▶ Select Activate.
▶ Enter Yes if screed drying is to be carried out.
Current program step and Remaining time for current step are
displayed. It is possible to change the program step.
MIXING VALVE CONTROL DELAY
Displays the time that the mixing valve function is delayed after the
additional heat timer has counted down.
ALARM MODE DELAY
Displays the remaining time until the additional heat is activated when an
alarm is triggered.
COMPRESSOR START
16.8.2 HEAT SOURCE FOR SCREED DRYING
Displays remaining time of compressor start delay
Select the heat source for the screed drying process in the user interface
of the Hydrolight/Hydrocomfort module.
HEATING, OPERATING TIME AT HOT WATER DEMAND
Displays the remaining time before the maximum time in heating mode
is reached if there is a simultaneous hot water requirement.
HOT WATER, OPERATING TIME AT HEATING SYSTEM DEMAND
Displays the remaining time before the maximum time for hot water
production is reached if there is a simultaneous heating requirement.
HEATING SEASON DELAY
6 720 648 135-06.1I
Fig. 82
Selecting the heat source for screed drying:
• Heat source 0: compressor and booster heater
• Heat source 1: compressor
• Heat source 2: booster heater
Displays the remaining time until the heating season is activated in the
heat pump.
DELAY IN DISCONNECTION OF HEATING SEASON
Indicates the remaining time before the heating period is deactivated in
the heat pump.
BLOCKING ROOM SENSOR INFLUENCE
16.8.3 PROGRAM SETTINGS FOR SCREED DRYING
The following changes can be made in the program settings menu:
•
•
•
•
•
•
Increase in flow temperature per heating stage
Number of days per heating stage
Maximum flow temperature
Number of days with maximum flow temperature
Flow temperature reduction per cooling stage
Number of days per cooling stage
6 720 806 629 (2013/02)
Displays the time remaining when the room controller is blocked.
HOT WATER PEAK INTERVAL
Displays the time remaining to the next hot water peak.
HEATING CABLE
Shows the time the heating cable is active following defrosting.
63
ERROR MANAGEMENT
18
ERROR MANAGEMENT
Alarms in the display window apply mainly to the Hydrolight/
Hydrocomfort module. Alarms that occur in the outdoor unit must be
checked with the diagnostic tool (accessory) ( chapter 18.10).
In the menu Alarm there is:
• Alarm log
• Alarm history
• Info log
If you press the rotary selector, Acknowledge is marked, the alarm
symbol disappears and the warning signal is suppressed. The heat pump
restarts if heat demand exists.
The alarm symbol ( [10] fig. 64) continues to be displayed and the ON
and fault indicators change from flashing red to constant red if the fault
is not remedied. Every alarm is stored in the alarm log. Active alarms are
indicated by the alarm symbol.
The alarm symbol appears for both alarms in the outdoor unit and for
alarms in the Hydrolight/Hydrocomfort module, if alarms have occurred
in both the units, two alarm symbols will appear.
18.4 DIMMED MENU DISPLAY
18.4.1 POSSIBLE CAUSE 1: FAULTY FUSE IN THE DOMESTIC
POWER SUPPLY.
6 720 648 135-07.1I
Fig. 84
After the fault has been remedied, the heat pump automatically restarts.
The customer level (K) gives access to alarm information in the Alarm
log.
Installer/Service level (I/S) gives access to:
•
•
•
•
▶ Check whether all domestic fuses are OK.
▶ If required, change/reset fuse/MCB.
Delete alarm log
Information regarding the Alarm history
Information regarding the Info log
Delete info log
18.4.2 PROBABLE CAUSE 2: THE MINIATURE CIRCUIT BREAKER IN
THE HYDROLIGHT/HYDROCOMFORT MODULE HAS
TRIPPED.
▶ Replace the fuse on the IOB A board.
18.5 ALL ALARMS, WARNINGS AND INFORMATION
WINDOWS
18.1 ALARM HISTORY
ALARM INFORMATION
Alarms are stored in chronological order. Turn the menu dial to read off
all information about the most recent alarm, continuing to turn will show
the previous alarm.
An alarm can occur temporarily due to various reasons. However, there
is never a risk involved in resetting an alarm. All the alarms that can
appear in the menu display are described in this section. The
descriptions give an idea about the nature of the alarm and what can be
done to rectify it.
The alarm log shows alarms and warnings that have occurred.
18.6 ALARM WINDOW
18.6.1 FAILURE / SHORT CIRCUIT ON SENSOR
6 720 648 148-54.1I
Fig. 85
Alarm information consists of a heading and then detailed information
about the time, temperatures of all sensors and status for each output at
the alarm point.
18.2 ALARM LOG AND INFO LOG
In the Alarm log and the Info log, all alarms and warnings that have
occurred are stored in chronological order.
▶ Delete the Alarm log and the Info log after commissioning is
complete.
6 720 648 149-27.1I
Fig. 87
All sensors connected to the heating installation can give an alarm in the
event of a fault. In the example, it is sensor T3, hot water, which has
given an alarm. All sensors give alarms in the same way.
Possible cause 1: occasional fault:
▶ No action required.
Possible cause 2: fault at temperature sensor or incorrect
connection:
18.3 EXAMPLE OF AN ALARM:
When an alarm is triggered, an alarm window is displayed and a warning
signal sounds. The alarm window displays the alarm causes and the time
and date that the alarm occurred.
▶ Check the sensor connection.
▶ Check the sensor ( chapter 11.4.5).
18.6.2 MAX FLOW TEMPERATURE, HEATING SYSTEMOR MAX
FLOW TEMPERATURE, HEATING SYSTEM 2
An alarm is triggered if the flow temperature exceeds the set value by 6
K, i.e. E11.T1 Set point maximum + 6 K, in order to protect the
underfloor heating system.
6 720 648 148-56.1I
Fig. 86
Possible cause 1; value in E11.T1 Set point maximum incorrectly set
▶ Check E11.T1 Set point maximum. Adjust if necessary.
Possible cause 2; flow rate fault
▶ Check the filter and thermostatic valve.
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6 720 806 629 (2013/02)
ERROR MANAGEMENT
Possible cause 3; maximum flow temperature incorrectly set
▶ With separate domestic hot water heating, the anticipated
temperature of the additional heater must not exceed the maximum
flow temperature T1. The settings can be modified at the external
booster heater or at T1.
▶ Check termination settings in the room controller.
▶ Check the power supply on CAN-BUS. The voltage should be 12V DC.
▶ Replace the faulty room controller.
18.6.7 ERROR IN MULTI FUNCTION BOARD
Fault in the multi function board or corresponding communication.
18.6.3 T8 HIGH FLOW TEMPERATURE OR T71 HIGH FLOW
TEMPERATURE
6 720 649 018-03.1I
▶ Check the LED on the circuit board, it should flash green.
▶ Check the termination switches S1, they should be in the terminated
position.
▶ Check the CAN-BUS connections to the room controller.
▶ Check the power supply on CAN-BUS. The voltage should be 12V DC.
▶ Replace the faulty room controller.
18.6.8 FAULT ON ADDITIONAL HEATER
Fig. 88
Alarm from booster heater.
There are two sensors, T8 and T71, in the Hydrolight/Hydrocomfort
module, which for safety reasons stop the heat pump if the temperature
of the flow rises above the set value.
▶ Check status in the booster heating.
▶ 230 V must be present at the alarm input for the 2nd heat appliance
( chapter 10.1.3).
Possible cause 1: insufficient flow rate in heat pump:
18.6.9 FREEZE PROTECTION EXCHANGER T9 ACTIVATED
▶ Check that the heat carrier pump has not stopped.
▶ Check that all the valves are open. The thermostat valves in heating
systems should be fully open and in floor heating systems at least half
of the coils should be fully open.
▶ If the heat carrier pump speed (G2) is not self-adjusting: Increase the
speed of the heat carrier pump. Note that the speed of the circulation
pump for the heating system must also be increased, as it must be
greater than the speed of the heat carrier pump.
▶ Select the Acknowledge.
The purpose of the alarm is to prevent the condenser from freezing at
low temperatures. Possible causes:
Possible cause 2: filter blocked
▶ Check the filter.
▶ Clean the filter if necessary (chapter 22.1).
▶ Select the Acknowledge.
18.6.4 ERROR IN MAIN BOARD, HEATING SYSTEM
Fault in the IOB A board in the Hydrolight/Hydrocomfort, or in
communication with it.
▶ Check the LED on the circuit board, it should flash green.
▶ Check termination switch S1 ( fig. 38). This should be in the nonterminated position.
▶ Check the CAN-BUS connections to the IOB-B board.
▶ Check the strap on the IOB-B board according to the wiring diagram
( fig 38).
▶ Check the power supply on CAN-BUS. The voltage should be 12V DC.
▶ Replace the faulty IOB board.
18.6.5 ERROR IN ACCESSORY BOARD
Fault in the accessories board (IOB-B) in the Hydrolight/Hydrocomfort
module or corresponding communication.
▶ Check the LED on the circuit board, it should flash green.
▶ Check the termination switch S1 ( fig 38), it should be in the not
terminated position.
▶ Check the CAN-BUS connections to the IOB-B board.
▶ Check the strap on the IOB-B board according to the wiring diagram
( fig 38).
▶ Check the power supply on CAN-BUS. The voltage should be 12V DC.
▶ Replace the faulty IOB board.
▶ With defrosting: is there still enough water in the system?
18.6.10 ALARM HEAT PUMP
The outdoor unit has developed a fault.
▶ Check the signal cable connection in the outdoor unit and in the
Hydrolight/Hydrocomfort module. Connection S2 of the outdoor unit
must be connected to connection S2 of the Hydrolight/Hydrocomfort
module. The same applies for S3.
▶ Check fault code using diagnostic tool (accessory).
▶ Check mains voltage to external unit.
▶ If the power supply to the Hydrolight/Hydrocomfort module or the
outdoor unit was briefly interrupted, switch off the power supply to
both units roughly at the same time then wait at least one minute
before switching the power back on. Wait to see if the alarm
disappears.
18.6.11 LOW MAINS VOLTAGE
If the mains voltage falls below 170 V, the information symbol in the
display lights up. If the voltage falls below 170 V for more than one hour,
the alarm is activated.
▶ Check mains voltage.
18.6.12 SCREED DRYING SET POINT VALUE FOR HEATING NOT
REACHED
The alarm is activated if the temperature at the current stage in the
screed drying program is not reached within the set time.
18.6.13 OVERLOADED TRANSFORMER
If the voltage at the secondary side of the transformer falls below 9V, and
the voltage at the primary side is OK, an alarm is triggered and all outputs
are enabled. The alarm must be acknowledged manually.
▶ Check the voltage on the secondary side.
▶ Fault in the transformer. Replace main board.
18.6.6 ERROR IN ROOM SENSOR BOARD OR ERROR IN E12.T5
ROOM SENSOR BOARD
Fault in the CAN-BUS connected room controller or communication to it.
▶ Check the termination switches S1, they should be in the terminated
position.
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65
ERROR MANAGEMENT
18.7.3 HIGH TEMPERATURE DIFFERENCE HEAT TRANSFER FLUID
18.6.14 FAULT ON ELECTRIC ELEMENT
6 720 649 018-04.1I
6 720 648 148-56.1I
Fig. 89
Fig. 91
Possible cause 1: overheating protection of the power supply has
tripped:
This warning window is displayed when the temperature difference
between sensors T8 and T9 becomes too high (> 13 K).
▶ Check that the heat carrier pump has not stopped.
▶ Reset overheating protection of power supply. A reset button is
located in the switch box of the Hydrolight/Hydrocomfort module.
▶ Select the Acknowledge.
Possible cause 1: insufficient flow rate in heat pump:
18.6.15 NO PRESSURE IN SYSTEM
If the system pressure is less than 0.5 bar, this trips the pressure switch
which switches off the power supply and triggers the alarm No pressure
in system. To remedy the fault:
▶ Check that the expansion vessel and safety valve are designed to
operate with the pressure in the system.
▶ Slowly increase the pressure in the heating system by filling water via
the filling cock.
▶ Acknowledge the alarm manually by pressing the rotary selector in the
user interface of the Hydrolight/Hydrocomfort module ([3],
fig. 62).
▶ Check that the heat carrier pump has not stopped.
▶ Check that all the valves are open. The thermostat valves in heating
systems should be fully open and in floor heating systems at least half
of the coils should be fully open.
▶ If the heat carrier pump speed (G2) is not self-adjusting: Increase the
speed of the heat carrier pump. Note that the speed of the circulation
pump for the heating system must also be increased, as it must be
greater than the speed of the heat carrier pump.
▶ Select Acknowledge.
Possible cause 2: filter blocked:
▶ Check the filter.
▶ Clean the filter if necessary (chapter 22.1).
▶ Select Acknowledge.
18.7.4 TOO SHORT CHANGEOVER TIME FOR FLOOR HEATING
In the info log is stored Too short changeover time for floor heating
18.7 WARNING MESSAGE
18.7.1 IS THE HEAT PUMP FUSED FOR THIS OUTPUT?
The warning is activated to ensure that the system is designed to handle
the load produced.
In the info log is stored Check fuse.
▶ Check that the outdoor unit and the Hydrolight/Hydrocomfort unit are
connected to the correct fuse size.
The warning appears if the value Delay before is set to a shorter time
than 7hours or the value Delay after is set shorter than 7 hours, which
is not recommended during underfloor heating.
18.8 INFORMATION WINDOW
18.8.1 LOW MAINS VOLTAGE
18.7.2 MAXIMUM WORKING TEMPERATURE HEAT PUMP
If the mains voltage falls below 170 V, the information symbol in the
display lights up. If the mains voltage is below 170 V for one hour, an
alarm is triggered.
In the info log is stored Maximum working temperature heat pump.
▶ Check mains voltage.
18.9 INFO SYMBOL
6 720 649 018-05.1I
Fig. 90
The temperature sensor T9 located in the Hydrolight/Hydrocomfort unit
stops the heat pump for safety reasons as soon as the temperature of the
return water exceeds a certain limit (>56 °C).
Probable cause 1; The heat setting is set so high that the heating
system’s return temperature is too high:
▶ Reduce the heat setting.
Possible cause 2: valves at the underfloor heating system or
radiators are closed:
▶ Open the valves.
Possible cause 3: the flow rate of the heat pump is higher than the
flow rate in the heating system:
▶ Check the speed of the heating circuit pump and flow rate as specified
in chapter 20.3.
For a number of events that occur when the heat pump is in operation an
icon appears in the display without an alarm being triggered. Although
these events do not require immediate action, they are saved in the
information report.
Once the text in the information report has been read the icon vanishes
from the display.
18.9.1 TOO HOT FOR HEAT PUMP OPERATION
If the temperature exceeds 46 °C for 30 minutes, the Info icon is
activated. The booster heater takes over operation of the system.
Confirmation is given if the temperature once again falls below 46 °C.
18.9.2 TOO COLD FOR HEAT PUMP OPERATION
If the outdoor temperature falls below the set value in Block heat pump
at low outdoor temperature (factory value = – 15 °C) the heat pump
stops. The warning is activated and the heating installation switches to
operating with only additional heat.
18.9.3 MAXIMUM FLOW TEMPERATURE, HEAT PUMP
The temperature in the system has reached the maximum temperature
for the heat pump.
Possible cause 1: heating curve set too high
▶ Adjust the heating curve ( chapter 16.5.2).
66
6 720 806 629 (2013/02)
ERROR MANAGEMENT
Possible cause 2; bivalence point set incorrectly Block heat pump at
low outdoor temperature .
SW2
▶ Adjust bivalance point ( 16.3.8).
Possible cause 3; flow rate fault
▶ Check filters and valves
6 720 614 486-35.1I
18.9.4 MAXIMUM FLOW TEMPERATURE, ADDITIONAL HEAT
Fig. 93 SW2
The CH flow has now reached its max. temperature.
[1]
[0]
Possible cause 1: heating curve set too high
▶ Adjust the heating curve ( chapter 16.5.2).
Possible cause 2; bivalence point set incorrectly Block heat pump at
low outdoor temperature .
▶ Consult the installer if this occurs more than once.
ON
OUT
Please refer to the service manual for the heat pump for a list of codes to
be used in the SW2 to check the functions of the heat pump, as well as
suggestions to deal with possible faults.
The service manual is delivered with the diagnostic tool.
Possible cause 3; flow rate fault
▶ Check filters and valves
18.9.5 MAXIMUM WORKING TEMPERATURE ADDITIONAL HEAT
The CH return has reached the max. permissible temperature.
Possible cause 1: heating curve set too high
▶ Adjust the heating curve ( chapter 16.5.2).
Possible cause 2; bivalence point set incorrectly Block heat pump at
low outdoor temperature .
▶ Adjust bivalance point ( 16.3.8).
18.9.6 TOO LOW FLOW TEMPERATUREOR TOO LOW FLOW
TEMPERATURE, HEATING SYSTEM 2
If the temperature of the flow falls below the set point value longer than
15 minutes, the heat pump shuts down and the warning is activated.
18.9.7 TOO HIGH RETURN TEMP
The warning appears if the return line to the heat pump (T9) becomes
too hot.
▶ Check the 4-way valve in the event of repeated warnings.
18.10 CHECKING THE HEAT PUMP USING THE DIAGNOSTIC
TOOL (ACCESSORY).
SW9 SW7
SW8 SW5
SW4
SW1 SW6
1
6 720 644 816-34.1I
Fig. 92
[1]
Connecting the diagnostic tool
18.10.1 CHECKING THE HEAT PUMP
The function of the heat pump can be checked by making adjustments in
the diagnostic tool (accessory).
6 720 806 629 (2013/02)
67
ERROR MANAGEMENT
18.10.2 REFRIGERANT CIRCUIT DIAGRAM
10
9
TH6
1
TH7
TH3
2
TH4
TH32
TH33
3
5
6
7
8
4
6 720 644 816-59.1I
Fig. 94 Refrigerant circuit, ODU 7.5
[1] 4-way valve
[2] High pressure switch 63H
[3] Compressor
[4] Expansion valve A
[5] Liquid separator
[6] Expansion valve B
[7] Shut-off valve
[8] Refrigerant liquid pipe
[9] Refrigerant gas pipe
[10] Service output
[TH32]Temperature sensor, compressor
[TH33]Temperature sensor, surroundings
[TH3] Temperature sensor, evaporator
[TH4] Temperature sensor, hot gas
[TH6] Temperature sensor, condenser
[TH7] Temperature sensor, surroundings
68
6 720 806 629 (2013/02)
ERROR MANAGEMENT
1
TH6
TH7
10
9
TH3
2
TH4
TH32
TH33
3
5
6
7
8
4
6 720 644 816-60.1I
Fig. 95 Refrigerant circuit, ODU 10
[1] 4-way valve
[2] High pressure switch 63H
[3] Compressor
[4] Expansion valve A
[5] Liquid separator
[6] Expansion valve B
[7] Shut-off valve
[8] Refrigerant liquid pipe
[9] Refrigerant gas pipe
[10] Service output
[TH32]Temperature sensor, compressor
[TH33]Temperature sensor, surroundings
[TH3] Temperature sensor, evaporator
[TH4] Temperature sensor, hot gas
[TH6] Temperature sensor, condenser
[TH7] Temperature sensor, surroundings
6 720 806 629 (2013/02)
69
ERROR MANAGEMENT
1
TH6
11
10
TH7
TH3
2
TH4
TH32
TH33
3
5
4
8
7
9
6
6 720 644 816-61.1I
Fig. 96 Refrigerant circuit, ODU 12
[1] 4-way valve
[2] High pressure switch 63H
[3] Compressor
[4] Expansion valve A
[5] Liquid separator
[6] Expansion valve C
[7] Expansion valve B
[8] Shut-off valve
[9] Refrigerant liquid pipe
[10] Refrigerant gas pipe
[11] Service output
[TH32]Temperature sensor, compressor
[TH33]Temperature sensor, surroundings
[TH3] Temperature sensor, evaporator
[TH4] Temperature sensor, hot gas
[TH6] Temperature sensor, condenser
[TH7] Temperature sensor, surroundings
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FACTORY SETTINGS
19
FACTORY SETTINGS
19.1 FACTORY SETTINGS
The tables show the values that have been preset at the factory (factory
settings). These values can be modified by the user [0] via user levels
Menu and Advanced.
The installer can access the items in the installation and service menu (I/
S =1) listed in the following table after changing the access level under
Menu or Advanced menu.
Menu
Level
Fast restart of heat pump
1
Start up
_”_\Setting the clock
_”_\_”_\Set date
1
_”_\_”_\Set time
1
_”_\T1 maximum set point value
1
_”_\External input
_”_\_”_\Activated if
1
_”_\_”_\Change in temperature
1
_”_\_”_\Stop hot water loading
1
_”_\_”_\Stop heating production
1
_”_\_”_\Additional heat only
1
_”_\_”_\Limit electrical capacity to
1
_”_\_”_\External blocking
1
_”_\_”_\Safety thermostat
1
_”_\_”_\Stop additional heat hot water
1
_”_\_”_\Stop additional heat radiators
1
_”_\Lowest outdoor temperature
1
_”_\Accessory board function
1
_”_\Max limit E12.T1 Set point value
1
_”_\Connected extra sensors
_”_\_”_\ T3 acknowledged
1
_”_\_”_\T5 acknowledged (T5)
1
_”_\Manual operation
1
_”_\Operating mode, additional heater
_”_\_”_\Additional heat only
1
_”_\_”_\Block additional heat
1
_”_\Correct sensor
1
_”_\Anti-jamming mode time
1
_”_\Alarm buzzer interval
1
_”_\Display
_”_\_”_\Contrast
0
_”_\_”_\Brightness
0
_”_\System pressure sensor connected
1
_”_\Operation alternative G2
1
Room temperature setting (T5)
0
Room temperature setting, heating system 2
0
Extra hot water
0
Table 27 Menu
F value
No
yy-mm-dd
hh:mm:ss
45 °C
Closed
0 °C
No
No
No
3/3
No
No
No
No
-10 °C
No
45 °C
Yes
Yes
No
No
No
0
02:00
1 min
27
100
Yes
Continuous
20°C
20°C
0h
Advanced menu
Heating/cooling
_”_\Minimum outdoor temperature of heat
curve
_”_Heating system temperature
_”_\_”_\Heat curve
Level
F value
1
–10 °C
0
V=20.0 °C
H=35.0 °C
_”_\_”_\Hysteresis
_”_\_”_\_”_\Quick acceleration
_”_\_”_\_”_\Quick brake
_”_\_”_\_”_\Quick stop
_”_\_”_\_”_\Integration time
_”_\_”_\_”_\Rad brake temp increase
_”_\_”_\_”_\Rad brake time
_”_\Room sensor setting
_”_\_”_\Room temperature setting
_”_\_”_\Room sensor interval
_”_\_”_\Room sensor influence
_”_\_”_\_”_\Change factor
_”_\_”_\Blocking time
_”_\Time limited settings
_”_\_”_\Time control heating
_”_\_”_\_”_\Day and time
_”_\_”_\_”_\Change in temperature
_”_\_”_\Holiday
_”_\_”_\_”_\Date
_”_\_”_\_”_\Change in temperature
_”_\_”_\External input
_”_\_”_\_”_\Activated if
_”_\_”_\_”_\Change in temperature
_”_\Heating season
_”_\_”_\Heating season limit
_”_\_”_\Delay
_”_\_”_\Direct start limit
_”_\Heating, maximum operating time at hot
water demand
_”_\Shut down protection, change over hot
water to heating
_”_\Maximum speed compressor
_”_\Quick acceleration time
_”_\Quick brake time
1
1
1
1
1
1
5.0 °C
1.0 °C
10.0 °C
60°min
1.0 °C
0 min
0
0
20 °C
3K
0
0
2.0
4 hrs
0
0
Off
–10 °C
0
0
Off
-10 °C
1
0
Closed
0 °C
0
0
0
0
18 °C
4 hrs
10 °C
20 min
1
300 s
1
1
1
7
15 min
5 min
Level
F value
Table 28 Advanced menu
Advanced menu
_”_\Temperature heating system 2
_”_\_”_\Heat curve
0
V=20.0 °C
H=35.0 °C
_”_\_”_\Room sensor settings
_”_\_”_\_”_\Room temperature setting
_”_\_”_\_”_\Room sensor influence
_”_\_”_\_”_\_”_\Change factor
_”_\_”_\_”_\_”_\Blocking time
_”_\_”_\Time limited settings
_”_\_”_\_”_\Time control heating
_”_\_”_\_”_\_”_\Day and time
_”_\_”_\_”_\_”_\Change in temperature
0
20 °C
0
0
5,0
4 hrs
0
0
Off
-10 °C
Table 29 Advanced menu
6 720 806 629 (2013/02)
71
FACTORY SETTINGS
Advanced menu
_”_\_”_\_”_\Holiday
_”_\_”_\_”_\_”_\Date
_”_\_”_\_”_\_”_\Change in temperature
_”_\_”_\_“_\External input
_”_\_”_\_”_\Active if
_”_\_”_\_”_\Change in temperature
_”_\_”_\Mixing valve settings
_”_\_”_\_”_\Control unit reading
_”_\_”_\_”_\P-constant
_”_\_”_\_”_\I-time
_”_\_”_\_”_\D-time
_”_\_”_\_”_\Mixing valve running time
_”_\_”_\_”_\Mixing valve limitation defrost
mode
Level
F value
0
0
Off
-10 °C
1
0
Closed
0 °C
1
1
1
1
1
1
1
300s
0.0s
300s
5 min
Table 29 Advanced menu
Advanced menu
Hot water (T3)
_”_\Extra hot water
_”_\_”_\Number of hours
_”_\_”_\Stop temperature
_”_\Hot water peak
_”_\_”_\Interval
_”_\_”_\Start time
_”_\Hot water temperature
_”_\_”_\In compressor mode
_”_\_”_\_”_\T3 Start temperature
_”_\_”_\_”_\T9 Stop temperature
_”_\_”_\Hot water, max operating time at
heating demand
_”_\Time control hot water
_”_\Slowest speed at hot water production
_“_\Max speed during hot water production
_“_\Quick start of addition
Level
F value
0
0
0
65 °C
0
0
0 day
03:00
1
1
1
0
46 °C
47 °C
30 min
0
1
1
1
Off
3
7
0 °C
Level
F value
1
1
1
1
0,0 °C
Advanced menu
Additional heat settings
_”_\Start delay
_”_\Time control additional heat
_”_\Operating option
_”_\_”_\Additional heat only
_”_\_”_\Block additional heat
_”_\Electric additional heat settings
_”_\_”_\Connection capacity
_”_\_”_\_”_\State total output
_”_\_”_\_”_\Compressor mode, output
limitation
_”_\_”_\_”_\Additional heat only, output
limitation
_”_\_”_\Stop temperature T3
_”_\_”_\Ramp time increase
_”_\_”_\Ramp time decrease
_”_\_”_\Locking of electricity supply when
defrosting
_”_\_”_\Neutral zone
_”_\Mixing valve settings
_”_\_”_\Mixing valve delay
_”_\_”_\_”_\PID heat setting
_”_\_”_\_”_\_”_\P constant
_”_\_”_\_”_\_”_\I time
_”_\_”_\_”_\_”_\D time
_”_\_”_\_”_\PID hot water setting
_”_\_”_\_”_\_”_\P constant
_”_\_”_\_”_\_”_\I time
_”_\_”_\_”_\_”_\D time
Mixing valve’s run time
Locking of mixing valve during defrosting
_”_\_”_\Max outdoor temperature for
additional heat
Level
F value
1
1
60 min
Off
1
1
No
No
1
1
9.0 kW
2/3
1
3/3
1
1
1
1
60 °C
20 min
10 min
5 min
1
5 °C
1
20 min
1
1
1
2.0
300 s
0
1
1
1
1
1
1
4.0
300 s
0
120 s
5 min
10 °C
Level
Fact. setting
1
– 15 °C
1
15 min
0
0
JJ-MM-TT
hh:mm:ss
1
No
1
0, 1
0, 1
0
No
K(0)
B
No
Table 32 Advanced menu
Table 30 Advanced menu
Advanced menu
Temperatures
_”_\Correct sensor
_”_\Inputs
_”_\Outputs
_”_\Demand
Timers
Table 31 Advanced menu
Extended menu
Safety functions
_”_\Block heat pump at low outdoor
temperature
_”_\Heating cable time
Setting the clock
Setting the date
Setting the time
Alarm
_”_\Alarm log
_”_\_”_\Delete alarm log
_”_\Alarm history
_”_\Info log
_”_\_”_\Delete info log
Access level
Return to factory settings
Deactivate alarm buzzer
Table 33 Extended menu
72
6 720 806 629 (2013/02)
FUNCTIONAL CHECK
▶ Decrease the speed on the corresponding circulation pump (G2).
20
FUNCTIONAL CHECK
20.1 REFRIGERANT CIRCUIT
Work on the refrigerant circuit must only be carried out
by a competent person.
DANGER: Discharge of poisonous gases!
The refrigerant circuit contains materials that can form
poisonous gases if released or if in the presence of a
naked flame. Even low concentrations of these gases
can lead to respiratory arrest.
▶ Leave the room immediately if the refrigerant circuit
is leaking and ventilate thoroughly.
20.2 SETTING THE OPERATING PRESSURE OF THE
HEATING SYSTEM
CAUTION: The heat pump can be damaged.
▶ Fill with water only when the heat pump is cold.
Indication on pressure gauge
1 bar
Minimum system pressure (when cold)
2.5 bar
Maximum filling pressure at max. temperature of the
heating water: may not be exceeded (safety valve
opens).
Table 34 Operating pressure
▶ Fill up until required pressure is reached, depending on the height of
the property.
Fill the hose with water before topping up. This prevents
air being introduced into the system.
▶ If there is a pressure drop: check the expansion vessel and heating
system for leaks.
If the temperature differential is too great:
▶ Increase the speed on the corresponding circulation pump (G2) to
obtain a greater flow.
21
ENVIRONMENTAL PROTECTION
Environmental protection is a fundamental corporate strategy of the
Bosch Group.
The quality of our products, their economy and environmental safety are
all of equal importance to us and all environmental protection legislation
and regulations are strictly observed.
We use the best possible technology and materials for protecting the
environment taking account of economic considerations.
PACKAGING
We are dedicated in adhering to country specific disposal standards as
they relate to packaging to ensure optimum recycling.
All packaging materials are environmentally friendly and can be
recycled.
OLD APPLIANCES
Old appliances contain materials that must be recycled.
The relevant assemblies are easy to separate, and all plastics are
identified. In this manner the individual components are easily sorted
and added into the recycling and disposal systems.
22
MAINTENANCE
DANGER: Risk of electric shock!
▶ Switch off the main power supply before starting work
on the electrical part.
We recommend that a function check be performed regularly by an
competent person.
▶ Only use genuine spare parts!
▶ Refer to the spare parts list when ordering spare parts.
▶ Always renew seals and O-rings removed during servicing or repair
work.
During service, the activities described below should be conducted.
20.3 OPERATING TEMPERATURES
Show alarms
The information in this chapter is only relevant for operation at a
constant speed (G2), i.e. not self-regulating.
▶ Check alarm log.
For the installation to perform at its best, it is important to check the flow
over the condenser in the indoor unit and the heating system. Check
after a 10 minute run time and at max compressor speed = step 7
(manual operation, heating).
▶ Carry out a function check ( page 73).
The flow is adjusted by heat carrier pump G2 so that the temperature
difference over the condenser is between 5 and 10 °C.
FUNCTIONAL CHECK
ELECTRICAL CABLE ROUTING
▶ Check the electrical cable routing with regard to mechanical damage
and replace defective cables.
These are the optimum settings for heat pumps. It is important to be
aware of which heating system is installed.
Checking the temperature differential:
▶ Read off sensor T8 (heat transfer fluid out) and T9 (heat transfer fluid
in) in heating mode. T8 must have a temperature greater than T9.
▶ Calculate the difference by taking T8 – T9.
When commissioning is carried out at a low outdoor temperature (below
0 °C) the temperature difference should be between 5 and 7 °C.
When commissioning is carried out at outdoor temperatures above
15 °C) the temperature difference should be between 8 and 10 °C.
If the temperature differential is too low:
6 720 806 629 (2013/02)
73
THE GUARANTEE
22.1 PARTICLE FILTER
In some regions disposal of washing-up liquid in a gravel
bed is not permitted. If the condensate pipe from the
heat pump discharges into a gravel bed:
▶ Remove the service flap.
▶ Remove flexible condensate pipe from the drain pipe
before carrying out the cleaning.
▶ Collect washing-up liquid in a suitable vessel.
▶ Connect the condensate pipe after cleaning.
▶ Fit the service flap.
The filter prevents particles and dirt from entering the interior of the
capacitor/exchanger. Over time, the filter can become blocked and must
be cleaned.
The particle filter is installed in the return heating pipe to
the Hydrolight/Hydrocomfort ( [E21.V101], chapter
11.4.3).
23
1
2
3
6 720 614 050-34.1D
Fig. 97
[1]
[2]
[3]
THE GUARANTEE
The Greensource Air to Water split heat pump has a 2 year guarantee
against faulty material or manufacture subject to Terms and conditions.
To read the full Terms and Conditions please visit us online at
www.worcester-bosch.co.uk/guarantee. The Guarantee Registration
form is available on this same page and can be completed and submitted
electronically. Alternatively please telephone one of our Guarantee
Registration advisors on 0844 892 2552. Your statutory rights are not
affected by the manufacturers guarantee.
Filter
Circlip
Plug
Cleaning the filter:
▶ Switch off the heat pump with the ON/OFF switch.
▶ Close the valve and remove the plug.
▶ Remove the circlip that holds the filter in the valve, using the pliers
provided.
▶ Take the filter out of the valve and rinse it with water.
▶ Reinstall the filter, circlip and plug.
▶ Open the valve and start the heat pump via the ON/OFF switch.
22.2 EVAPORATOR
If a layer of dust or dirt has accumulated on the surface of the evaporator
or aluminium fins, you must remove this.
WARNING: The thin aluminium fins are fragile and can
be damaged if careless. Never wipe the delicate fins with
a cloth.
▶ Hard objects may not be used.
▶ Use protective gloves to protect your hands from
cuts.
▶ Do not use a too powerful water jet.
Damage to system by cleaning agents and care products!
▶ Do not use cleaning agents and care products that are
abrasive or contain acid or chlorine.
Clean the evaporator:
▶ Switch off heat pump at ON/OFF switch.
▶ Spray washing-up liquid onto the evaporator fins.
▶ Rinse off coating and washing-up liquid with water.
74
6 720 806 629 (2013/02)
COMMISSIONING REPORT
24
COMMISSIONING REPORT
Commissioning date:
Customer address:
Surname, first name:
Street, house number:
Town:
Telephone:
Specialist contractor:
Surname, first name:
Street:
Town:
Telephone:
Appliance data:
Appliance type:
Part no.:
Serial number:
FD no.:
Installation test steps
System components:
room controller CAN-BUS
2nd heat appliance, oil/gas
Art/Type:
Solar integration
Buffer tank
Type / volume ( L ):
DHW cylinder
Type / volume ( L ):
Other components
Which?
Minimum clearances, external unit:
Is the external unit set up on a stable level subsurface?
Minimum clearance to wall ? …… mm
Minimum clearance from sides ? …… mm
Minimum clearance from roofing ? …… mm
Minimum clearance in front of heat pump ? …… mm
Has the external unit been set up in such a manner that snow or water cannot
slip or drip onto it?
Condensate drain, external unit
Is the condensate drain equipped with a heating cable ?
Is it possible to prevent the drain from freezing by means of the condensate
drain connection ?
Connecting pipes to the external unit
Length of connection pipe, number of elbows
Has refrigerant been topped up because the max. length of 30m has been
exceeded?
How much?
Who installed/supplied the connection pipe?
Who established the connection (flanging)?
Basic leak test performed?
Vacuum (value at which outside temperature?)
Fine leak test performed?
Minimum clearances, internal unit:
Minimum clearance from walls ? …… mm
Minimum clearance in front of internal unit ? …… mm
Central heating:
Pre-charge pressure in expansion vessel determined ? …….. bar
Was the heating system flushed prior to installation ?
Confirmation / values
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes
 Yes
 Yes
 Yes
 Yes
 Yes
|
|
|
|
|
|






No
No
No
No
No
No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
Table 35 Commissioning report
6 720 806 629 (2013/02)
75
COMMISSIONING REPORT
Heating system filled via the determined pre-charge pressure of the expansion
vessel to …….. bar ?
Internal unit sufficiently bled
Tightness test carried out for all connections inside and outside the internal unit
Cleanliness of filter in the heating circuit at the internal unit checked ?
Electrical connection:
Are the low-voltage cables installed at least 100mm away from 230 V /400 V
carrying cables, or has a screened cable been used for the CAN - BUS
communication ? Screening applied on one side ?
Have the connections in the CAN-BUS been established correctly ?
Is an output limiter connected ?
Is the outdoor sensor T2 positioned correctly north-east ?
Power supply:
Phase sequence or rotational direction L1, L2, L3 , N and PE in the internal and
external unit OK ?
Power supply in accordance with installation instructions? Can external and
internal unit be switched off at the same time?
Fuse protection of heat pump and booster heater, triggering characteristic?
Manual operation ( Chapter 16.2):
Function test of individual assemblies (pumps, changeover valves, fan,
compressor, etc.) carried out ?
Comments :
Temperature values in advanced menu checked and documented?
T1
T2
T3
T5
T8
T9
CH settings (Chapter 16.3.3):
Start delay
Time control additional heat
Block CH
Electr. booster heater settings, connected load
Maximum temperature of booster heater
Power consumption (shows the current value)
Safety functions (Chapter 16.3.8):
Block heat pump at low outside temperature
Has commissioning been completed successfully ?
Additional measures by installer necessary ?
Comments :
Signature of heat pump specialist :
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
 Yes |  No
________ °C
________ °C
________ °C
________ °C
________ °C
________ °C
 Yes |  No
________ °C
 Yes |  No
 Yes |  No
Signature of customer or installer :
Table 35 Commissioning report
76
6 720 806 629 (2013/02)
INSPECTION AND MAINTENANCE REPORTS
25
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
Maintenance report for air to water heat pumps
Customer/system user:
Surname, first name:
Street, house number:
Postcode:
Telephone/fax:
System manufacturer / Installer :
Order number:
Appliance type (external unit/internal unit):
Serial number:
Program version, Rego :
System components:
Details of system user :
Work carried out:
Part no.:
room controller CAN-BUS.....
Temp. limiter:................
Buffer cylinder :................ litres
Cylinder by other manufacturer yes/no :....
litres/type
DHW cylinder :.. litres
Cylinder by other manufacturer yes/no:.....
litres/type
Other:
FD (date of manufacture):
Commissioning date:
2nd heat appliance, oil/gas : 
Solar integration :.................... 
Read out saved alarm logs and warnings .........................
Error messages logged and heat pump checked on basis of alarms............................................
Log runtimes in the Operating times and consumption menu ( F )
( compressor and CH ) : .......................................................
Operating time for domestic hot water heating
h
Number of compressor starts
Number of compressor starts in heating mode
Number of compressor starts in DHW mode
Read out sensor values in Temperatures menu
and compare with table of values ..................................................................
Comments :
Electrical connections ( 230 VAC / 400 VAC )
External/internal unit checked to ensure secure seating ..............................................
Interior of external/internal unit checked using
leak detector for refrigerant ........................................................
Internal unit checked for discharge of liquid (heating water ) ..........
Fins on evaporator cleaned .............................................................
remarks:
Filter in heating pipe cleaned : ...................................................................
Safety valve checked : ..............................................................................
Function of circulation pumps , changeover valve , 3-way mixer
checked : ......................................................................................
Menu Service level ( I / S ) - Start - manual operation
Pre-charge pressure on heating side in diaphragm expansion vessel checked : .......bar
System filled on heating side to : ..........................................................bar
Table 36 Inspection and maintenance reports
6 720 806 629 (2013/02)
77
INSPECTION AND MAINTENANCE REPORTS
Maintenance report for air to water heat pumps
Parameter settings changed :
Heat:...................................................................
remarks:
DHW settings changed :.............
remarks:
CH settings changed :...........................
remarks:
Safety settings changed ................
remarks:
Reset to factory settings :............
remarks:
Temperature of heat transfer medium during Off (T8 ) ................................... °C
On (T9 ) ................................... °C
operation :
Temperature spread determined ...........K at ........... °C Outside temperature
Cold transfer medium during operation:
Air temperature / On ................ °C
Other comments :
Measures :
Date and signature, system user
Date and signature, Service
Table 36 Inspection and maintenance reports
78
6 720 806 629 (2013/02)
BENCHMARK LOG BOOK
26
BENCHMARK LOG BOOK
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.
Company Name & Address
Commissioning Date
[1]
Telephone No.
Building Regulations Notification Number
(if applicable)
CONTROLS - SYSTEM AND HEAT PUMP
[2]
Tick the appropriate boxes if applicable
1. Time & Temperature
Control to Heating
Room Thermostat &
Programmer/Timer
Programmable
Roomstat
2. Time & Temperature
Control to Hot Water
Load/Weather
Compensation
Optimum Start
Control
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
6. Heat Pump Safety Interlock
[3]
Fitted
Not Required
Built In
Provided
7. Outdoor Sensor
Fitted
Not Required
8. Automatic Bypass System
Fitted
Not Required
9. Buffer Vessel Fitted
Yes
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?
litres
Yes
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
°C
DOMESTIC HOT WATER MODE
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
Unvented
Yes
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
6 720 641 467-81.1I
Fig. 98
6 720 806 629 (2013/02)
79
BENCHMARK LOG BOOK
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
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6 720 641 467-82.1I
Fig. 99
80
6 720 806 629 (2013/02)
NOTES
6 720 806 629 (2013/02)
81
NOTES
82
6 720 806 629 (2013/02)
NOTES
6 720 806 629 (2013/02)
83
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
6 720 806 629
TECHNICAL SUPPORT:
0844 892 3366
APPOINTMENTS:
0844 892 3000
SPARES:
01905 752571
LITERATURE:
0844 892 9800
TRAINING:
01905 752526
SALES:
01905 752640
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