INSTALLATION AND MAINTENANCE INSTRUCTIONS HYBRID SYSTEM WITH AIR TO WATER HEAT PUMP GREENSTAR PLUS HYBRID FOR COMBINATION WITH WORCESTER APPLIANCES THAT HAVE A CENTRAL HEATING OUTPUT UP TO 28kW 6720803687-00.
TABLE OF CONTENTS TABLE OF CONTENTS 1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 4 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 About the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 EU Declaration of Conformity . . . .
TABLE OF CONTENTS 6.2.16 Control Strategy: Co2 optimised (environmental factors) 41 6.2.17 Control Strategy: CO2: Cost mix . . . . . . . . . . . . . . . . . 42 6.2.18 Control Strategy: Option changeover temperature . . . 42 6.2.19 Control Strategy: Cost optimised . . . . . . . . . . . . . . . . . 42 6.2.20 Control strategy: hydraulic connection . . . . . . . . . . . . 42 6.2.21 Control strategy: Delay time for boiler heating . . . . . . 43 6.2.22 Control strategy: Temperature diff for boiler switch ON . .
KEY TO SYMBOLS AND SAFETY INSTRUCTIONS 1 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS 1.1 EXPLANATION OF SYMBOLS WARNING SYMBOLS Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background. DANGER POSED BY EXPLOSIVE AND EASILY FLAMMABLE MATERIALS ▶ Never use, store or place highly flammable materials (paper, clothing, thinners, paints etc.) near the external unit.
ABOUT THE APPLIANCE 2.1 ABOUT THE APPLIANCE A DESIGNATED USE The appliance may only be installed in sealed unvented hot water central heating systems to EN 12828. Any other use is considered improper. Any damage that may result is excluded from liability. The commercial and industrial use of the appliance for generating process heat is not permitted. • Use the appliance exclusively for the stated purpose whilst adhering to the specification and environmental conditions ( chapter 2.17).
ABOUT THE APPLIANCE 2.4 STANDARD DELIVERY • • • • System components are supplied ready assembled. Drain plug kit (including pre cut insulation for service connections) Condensation catch pan Trace heating element to prevent freezing of water in the catch pan Refrigerant pipe ¼ " and ½ " OD 2.6 TOOLS, MATERIALS AND MISCELLANEOUS PARTS Servicing the Hybrid Manager module requires standard tools as used by heating system installers and those for gas and water installations. 2.
ABOUT THE APPLIANCE 2.8 FUNCTION DESCRIPTION OF THE HYBRID MANAGER The hybrid control module monitors the external unit, the condensing boiler and the FW200 programming unit. Subject to outside temperature, heating water flow and return temperature and the primary flow temperature, the hybrid control module determines what proportion of the total energy to be expended should be covered by the condensing boiler and the external unit respectively.
ABOUT THE APPLIANCE 2.10 REFRIGERANT CIRCUIT 14 7 15 1 16 2 3 13 4 5 17 18 A B 18 19 6 20 21 12 11 7 10 9 8 7 6 720 646 970-04.3ITL Fig.
ABOUT THE APPLIANCE 2.11 COMBI BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE AND UNMIXED HEATING CIRCUIT 1 2 3 5 4 5 F R 6 F 9 7 6720803687-01.1Wo 10 8 Fig.
ABOUT THE APPLIANCE 2.12 SYSTEM BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE AND UNMIXED HEATING CIRCUIT 1 12 2 4 5 3 5 F R 6 F 9 7 6720803687-02.1Wo 10 8 Fig.
ABOUT THE APPLIANCE 2.13 COMBI BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE, UNMIXED HEATING CIRCUIT AND INDEPENDENTLY CONTROLLED MIXED HEATING CIRCUIT 1 2 3 5 4 11 F R A A A A №4 10 20 15 25 10 30 №4 20 15 25 10 30 №1 №3 №3 6 F 20 15 25 10 30 №2 №2 20 15 25 10 30 №1 9 7 6720803687-03.1Wo 8 Fig.
ABOUT THE APPLIANCE 2.14 SYSTEM BOILER WITH SERIAL BUFFER TANK, BYPASS VALVE, UNMIXED HEATING CIRCUIT AND INDEPENDENTLY CONTROLLED MIXED HEATING CIRCUIT 1 12 2 5 4 3 11 F R A A A A №4 10 20 15 25 10 30 №4 20 15 25 10 30 №1 №3 №3 6 F 20 15 25 10 30 №2 №2 20 15 25 10 30 №1 9 7 6720803687-04.1Wo 8 Fig.
ABOUT THE APPLIANCE 2.15 OVERVIEW OF COMPONENTS 2.15.1 GREENSTAR PLUS HYBRID MANAGER (INTERNAL UNIT) 18 17 16 15 14 13 1 2 3 4 5 6 12 7 10 8 9 6720646970-05.4Wo 11 Fig.
ABOUT THE APPLIANCE 2.15.2 GREENSTAR PLUS HYBRID EXTERNAL UNIT 1 2 3 4 6 7 5 10 9 8 6 720 646 970-49.3ITL Fig.
ABOUT THE APPLIANCE 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 29 19 20 21 22 28 27 26 25 24 23 6 720 646 970-58.6ITL Fig.
ABOUT THE APPLIANCE 2.16 DIMENSIONS 2.16.1 HYBRID MANAGER (INTERNAL UNIT) 360 32 95 30 500 448 85 53 22 363 390 6720803687-23.1Wo Fig.
ABOUT THE APPLIANCE 2.16.2 EXTERNAL UNIT 365 300 330 152 155 43.6 400 347.5 40 23 10 155 90 300 600 18 32.5 45.4 150 69 183 287.5 500 800 6720803687-29.1Wo Fig.
ABOUT THE APPLIANCE 2.17 TECHNICAL DATA 2.17.1 HYBRID SYSTEM Description Max. heating output 1) Power supply Refrigerant R410A Pipe for liquid refrigerant, external diameter Pipe for gaseous refrigerant, external diameter Minimum water flow rate in the air to water heat pump circuit Unit kW V/Hz/PH kg inch inch l/min Value 25.14 230/50/1~ 2.5 ¼ ½ 6.0 Table 2 Specification for hybrid system 1) At 20 K (T) between the heating system flow and return relative to a pressure drop of 200 mbar.
REGULATIONS – The Building Regulations (Northern Ireland) 2000. 3 REGULATIONS 3.1 STANDARDS, REGULATIONS AND GUIDELINES The product is in compliance with the following EC directives: • Low Voltage Directive 2006/95/ EC • Electromagnetic Compatibility Directive 2004/108/EC. 3.1.1 GENERAL REGULATIONS Concerning the installation and operation of the hybrid system, observe the country-specific standards and directives. Observe the details on the data plate of the components of the hybrid system.
MOUNTING AND INSTALLATION 4.3 UNPACKING THE HYBRID MANAGER Worcester Bosch recommends the fitting of an in-line system filter to the primary circuit which will assist with maintaining system performance. NOTICE: Damage to the hybrid manager and refrigerant pipes may occur through incorrect handling. ▶ Treat refrigerant pipes and the hybrid manager with care. ▶ Upon receipt, check that all packaging is in perfect condition. ▶ Remove packing straps and open the packaging at the top.
MOUNTING AND INSTALLATION WATER TREATMENT PRODUCTS Suitable water treatment products can be obtained from the following manufacturers: FERNOX SENTNEL 0870 601 5000 or www.fernox.com 0800 389 4670 or www.sentinel-solutions.net Table 5 • Fit the bypass valve as near as possible to the heating system and as far away as possible from the buffer vessel. 5.2.4 EXPANSION VESSEL Install an additional expansion vessel on the heating system return between the bypass valve and the hybrid manager.
MOUNTING AND INSTALLATION AMBIENT CONDITIONS AND SITE LOCATION. The ambient conditions and site location significantly influence the external unit's output and service life. Unfavourable ambient conditions or site location can result in a significant reduction in output and even possible appliance damage. • Never site the external unit where it is exposed to vapour, volatile oils (incl. machine oil) or sulphurous gas. • In areas with a high salt content (e.g.
MOUNTING AND INSTALLATION MINIMUM CLEARANCES e f 1 d a1 a 2 a1 e 4 f d1 a c b 3 a2 c b 5 6 6 720 646 970-12.2ITL Fig. 19 Minimum clearances for specific installation situations Pos. 1 2 Obstacle • Rear • Rear • Above 3 • Rear • Sides • Connection side Clearance [mm] • a 150 • a1 300 • e 1000 • f 500 • a1 300 • b 200 • d 200 Pos.
MOUNTING AND INSTALLATION 5.3 PRE-INSTALLING PIPES 5.3.2 FITTING THE BYPASS VALVE Regarding the arrangement and position of the bypass valve, observe the information in section 5.2.3. Contamination in the system can result in damage to the air to water heat pump and reduce the output. 5.3.1 PREPARING THE HYBRID MANAGER CONNECTION ▶ Installing on-site pipe work. For this, observe the information on system component configuration ( chapter 5.2).
MOUNTING AND INSTALLATION ▶ Reposition the hybrid control module. CASING REMOVAL 1. Undo the outer case screws [1]. 2. Lift off the case. 1 1. 1. 1 6720803687-33.1Wo 2. 6 720 646 970-17.3ITL Fig. 26 Reposition the hybrid control module 1. Screw both top screws for the hybrid manager almost all the way into the wall, but do not tighten them fully. Fig. 23 Casing removal ▶ Raise the hybrid manager and hook it onto both screws. [1] 2. Connect pipe work.
MOUNTING AND INSTALLATION 5.5.1 PREPARING THE CONDENSATE DRAIN FOR THE EXTERNAL UNIT 5.5.3 MAKING A CONDENSATE DRAIN FOR THE EXTERNAL UNIT NOTICE: Frost damage! Frost damage on the external unit will result if the condensate fails to drain off. NOTICE: Damage from moisture! Spilled condensate can be a nuisance as well as a hazard if it leaks onto a walkway and freezes. ▶ Never permit condensate to drain across walkways; instead, route them to a suitable drainage point.
MOUNTING AND INSTALLATION 5.6 INSTALLING THE REFRIGERANT CIRCUIT 5.6.1 SAFETY R410A is used exclusively as the refrigerant in the air to water heat pump. Compared to previously used refrigerants, the R410A refrigerant operates at a pressure that is approx. 1.6times higher. – Apply the utmost care when routing refrigerant lines. Dust, foreign bodies and moisture inside the refrigerant lines can be detrimental to oil quality or result in compressor failure.
MOUNTING AND INSTALLATION 5.6.5 CONNECTING THE EXTERNAL UNIT Never connect the refrigerant lines to the external unit until • the refrigerant lines have been completely arranged • the refrigerant lines have been connected to the hybrid manager. At the factory, the external unit has been filled with sufficient R410A refrigerant for a line length (single direction) of between 1 m and 30 m.
MOUNTING AND INSTALLATION ▶ Trim off the excess “tails” of the cable ties [2]. 9 1 4 2 2 10 6 7 3 5 Fig. 34 Insulation with cable ties 6 720 646 970-27.3Wo [1] [2] Fig. 32 Shut-off valves, refrigerant circuit [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] 6720803687-32.
MOUNTING AND INSTALLATION OPENING THE SHUT-OFF VALVES NOTICE: Material loss from closed shut-off valves. Compressor and control valves will suffer damage if the shut-off valves remain shut during the operation of the external unit. ▶ Open shut-off valves for liquid and gaseous refrigerant. Opening the shut-off valves on the liquid and gaseous refrigerant pipe work ( Fig. 35): ▶ Remove valve cap [2]. ▶ With an Allen key (4 mm) turn the valve spindle [3] anti-clockwise as far as it will go (approx.
MOUNTING AND INSTALLATION PREREQUISITES Prior to connecting the external unit, ensure that the on-site conditions have been met. • A 16A circuit breaker with type D characteristic and 300mA fault current circuit breaker for AC and DC current at the main distribution board. • An external isolator switch with at least 3.0 mm contact separation across all poles has been installed near the external unit.
COMMISSIONING 6.1 WALL MOUNTING ▶ Drill 2 holes and mount the outside temperature sensor. 6.1.1 SAFETY 2. 6 720 610 967-10.2J 1. Fig. 39 Installing the outside temperature sensor [a] Clearance between drilled holes: 62 mm 5.8.2 CONNECTING THE OUTSIDE TEMPERATURE SENSOR Refer to the gas boiler installation literature with regards to the wiring connection of the out door sensor to the gas boiler. ▶ We recommend the use of screened cables, run inside conduits, e.g. LIY CY (TP).
COMMISSIONING 6.2 COMMISSIONING THE SYSTEM FOR THE FIRST TIME ▶ Undo three screws and remove the small cover for the internal connections at the back. NOTICE: Damage when starting the compressor in the external unit from cold! ▶ For commissioning: The Power supply to the external unit must be “Live”for at least 12 hours before starting operation. This is to ensure that the compressor is warmed up sufficiently to avoid any liquid refrigerant from entering the compressor.
COMMISSIONING ▶ Route the cable through the cable guide behind the insulation. 6.2.6 CONNECTING THE PROGRAMMING UNIT TO THE HYBRID CONTROL MODULE Use only one FW200 programming unit per hybrid system. Connect this to the hybrid control module. Mount the FW200 programming unit separately on a wall, if the unit has been previously fitted in the front of the boiler unit, it must be removed and fitted externally as stated. 3 2 1 CONNECTIONS INSIDE THE HYBRID MANAGER 2 3 BUS 6720646970-107.
COMMISSIONING If the External Unit is powered ON first, its controller tries to establish the communication with the Hybrid Manager but until the Hybrid Manager is powered ON, the communication cannot be established. If this status continues for a period of time, the External Unit judges this status as a ‘communication error’ and this error can not be reset until the External Unit is powered OFF once.
COMMISSIONING 8.5 8 7.5 mbar/metre 7 6.5 6 5.5 5 4.5 4 3.5 3 2.5 2 2 1.5 1 0.5 0 0 1 2 3 4 5 6 7 8 9 1 10 11 12 13 14 litres/min 15 16 17 18 19 20 21 22 23 6720646970-130.1Wo Fig.
COMMISSIONING 600 550 500 mbar 450 400 III 350 300 250 3 II 200 150 100 I 50 0 0 1 2 3 4 5 6 7 4 8 9 10 11 12 13 litres/minute 14 15 16 17 18 19 20 6720803687-07.1Wo Fig.
COMMISSIONING 6.2.11 VENTING THE HYBRID MANAGER 6.2.12 SETTING THE BYPASS VALVE NOTICE: Damage through pump running dry! ▶ Regularly check the water level and top up heating system with water, if required. Once the bypass valve is set it is recommended to lock the valve setting in place. Set the bypass valve subject to the selected pump curve: We recommend the installation of a manual air vent valve near the heating water return of the hybrid manager to enable the hybrid manager to be vented.
COMMISSIONING 6.2.14 EXPLANATION OF THE PARAMETERS FOR ENERGY AND COST OPTIMIZATION OF THE HYBRID SYSTEM (CONTROL STRATEGY) These parameters can be set either via the FW 200 weather compensated controller or via the hybrid control module. These values are transferred and overwritten respectively. The following section will describe how to make the settings using the FW 200 weather-compensated controller. For information on making settings on the hybrid control module, see chapter 6.2.23.
COMMISSIONING INSTALLER SETTINGS: HYBRID MENU The parameters for the selected control strategy of the hybrid system are set in the room controller or the Hybrid Manager. Knowledge of the following operations should be conveyed to the user at hand over: • Basic principles of operation • Commissioning • General settings for the heating system Operation Display Normal view of FW200 when running in auto 12 h 9 ▶ Open the flap (by pulling the recessed grip on the front).
COMMISSIONING 6.2.15 CONTROL STRATEGY: OPTION CO2 OPTIMISED AND CO2 :COST MIX Operation is dependent on a number of factors all of which must be discussed and agreed to with the customer. Operation Display ▶ HYBRID SETTINGS> Control strategy > ( Table 13) ▶ Select Control strategy from the menu ▶ Confirm the selected menu item ▶ Adjust chosen option, for example, CO2 : optimised (description of options page 39).
COMMISSIONING 6.2.17 CONTROL STRATEGY: CO2: COST MIX For this control strategy the Energy: Price ratio and the environmental factors for both fossil fuel and electricity must be set. Operation Display ▶ HYBRID SETTINGS> Control strategy > ( Table 13) If CO2 :cost mix is selected the controller will then display the following menu items. 9 12 h 15 HYBRID SETTINGS Energy :price ratio • Energy: price ratio • Environmental factor fossil fuel • Environmental factor electrical energy 6 3.
COMMISSIONING 6.2.21 CONTROL STRATEGY: DELAY TIME FOR BOILER HEATING Set time delay. The delay time of the boiler starting if (requested system flow set temperature - requested heat pump flow set temperature) is equal to or less than the set Delta T.
COMMISSIONING 6.2.23 SETTING PARAMETERS AT THE HYBRID CONTROL MODULE 5 6 4 3 2 1 6 720 646 970-36.2ITL Fig. 51 Control module of the hybrid manager [1] [2] [3] [4] [5] [6] Fuse, 5 AT, ceramic, filled with sand Spare fuse Service key connection Rotary selector: turn to scroll, push to select Display Back button Display [5] shows the current status/display code or parameter list. This can be recognised by the letters on the right hand side of the display.
COMMISSIONING Display code A7 Standard setting 10 Input range 7 - 10 — — — — 1 C2 Dual mode changeover °C threshold 6 1 = Environmental factors 2 = Costs 3 = Changeover threshold 4 = Environment and costs -20 - 20 C3 Cost weighting — electricity price — gas price. Environmental factors - kWh/ gas. kWh 3.3 0 - 19.9 1.1 0-5 C5 Environmental factors - kWh/ electricity. kWh 2.6 0-5 5b Return to the standard setting.
OPERATION 6.2.24 COMMISSIONING OF THE AIR TO WATER HEAT PUMP AT OUTSIDE TEMPERATURES OUTSIDE THE STANDARD OPERATING RANGE The air to water heat pump must only be commissioned if the entire system, including condensing boiler, is connected and ready for operation. At outside temperatures in excess of 21 °C or below -9 °C, the air to water heat pump will not start in standard mode, as there is no heat demand [for the heat pump] in this temperature ranges.
ENVIRONMENTAL PROTECTION/DISPOSAL 7.3 RESTARTING THE HYBRID SYSTEM AFTER AN INTERRUPTION IN OPERATION NOTICE: Damage to the external unit from low compressor operating temperature! The Power supply to the external unit must be “Live” for at least 12 hours before any heating demand. This is to ensure that the compressor is warmed up sufficiently to avoid any liquid refrigerant from entering the compressor. This is particularly important during colder periods.
INSPECTION AND MAINTENANCE All inspection and maintenance activities must be carried out in such a way that personal safety is ensured and damage to property is avoided. This includes the following: ▶ Shut off the gas supply prior to any work on the heat source. ▶ Isolate the system from the power supply. For commissioning: The Power supply to the external unit must be “Live” for at least 12 hours before starting operation.
INSPECTION AND MAINTENANCE 9.4 MAINTAINING THE HYBRID MANAGER 9.4.1 VISUAL INSPECTION OF THE HYBRID MANAGER ▶ With the hybrid manager running, pay attention to any unusual noise. ▶ Check the insulation of the refrigerant lines in the hybrid manager for damage and repair if required. ▶ Check the hybrid manager and pipe work for possible damage. ▶ If the hybrid manager is located inside a compartment or cupboard, ensure that the specified minimum service clearances are maintained.
INSPECTION AND MAINTENANCE ▶ Remove top insulation panel. ▶ Remove the filter and clean using fresh water. 6 720 646 970-38.2ITL 1 Fig. 55 Removing the top insulation panel ▶ Remove bottom insulation panel. 6 720 646 970-41.2ITL Fig. 58 Removing the filter [1] Filter cover ▶ Replace the filter and re-assemble the unit following the above in reverse. 9.4.
INSPECTION AND MAINTENANCE 9.5 SERVICING THE EXTERNAL UNIT DANGER: Risk to life due to escaping refrigerant. Escaping refrigerant can result in asphyxiation and frost bite in the case of contact at its exit point. ▶ When refrigerant escapes, never touch any components of the air to water heat pump and ensure adequate fresh air ventilation. ▶ Avoid skin or eye contact with refrigerant. ▶ Seek medical attention if you get refrigerant on your skin or in your eyes.
INSPECTION AND MAINTENANCE 9.5.5 OVERVIEW OF DIP SWITCHES IN THE EXTERNAL UNIT The table offers an overview of the DIP switches on the PCB of the external unit that are relevant for the hybrid system. These DIP switches are correctly set at the factory. Their setting does not need to be changed by customers. Switch position Type DIP switch Name SW1 No.
INSPECTION AND MAINTENANCE 9.6 INSPECTION AND MAINTENANCE REPORTS The inspection and maintenance reports are also designed as templates and may be photocopied. ▶ Sign and date the completed inspection work.
FAULTS 10 FAULTS 10.1 FAULTS THAT ARE NOT DISPLAYED 10.1.1 GENERAL FAULTS Appliance faults Flow noises Remedy ▶ Set the pump rate or pump parameter field correctly and match it to the maximum output. ▶ Vent the hybrid manager ( chapter 6.2.11, page 38). ▶ Set the pump rate or pump parameter field correctly and match it to the maximum output. Heat-up takes too long Table 27 Faults that are not shown on the display 10.1.
FAULTS 10.2 DISPLAYED FAULTS OVERVIEW OF INTERNAL HYBRID FAULT INDICATORS LOCATIONS DANGER: Danger to life through electric shock! ▶ Prior to working on the electrical section, isolate the power supply (230 V AC) (fuse for the external unit, hybrid manager and heat source) and secure against unintentional reconnection. 1 WARNING: Risk of injury and damage through incorrect troubleshooting. ▶ Have troubleshooting carried out only by a competent person.
FAULTS 1 2 3 4 Position 1 5 Symbol Explanation ON/OFF (hybrid control module) Communication with the programming unit 2 3 Fault 4 Demand to the air to water heat pump Boiler communication and boiler demand Display Back button Rotary selector Service key 5 6 7 8 9 — — — — Table 29 Key to Fig.
FAULTS 10.2.3 FAULTS OF THE FW200 PROGRAMMING UNIT Operating and fault indications of the hybrid manager are displayed on the FW200 programming unit and on the hybrid manager control module. The following information given in the service instructions of the FW200 programming unit is prerequisite. • Principles of operation • Troubleshooting INDICATORS ON THE HYBRID SYSTEM ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Fault No.
FAULTS LED fault Fault No.1) Status2) FW 200 ON A8 B ON A8 B ON CC B ON d1 L ON d1 L OFF B ON E2 L ON E2 L ON EF L ON HP L ON HP L On EF L Steps Description No communication with EMS heat appliance Cause Communication cannot be established between the hybrid control module (internal unit) and the boiler Check the contacts, cables and connections between the hybrid control module and the boiler.
FAULTS 10.2.5 FAULT DISPLAY ON THE REAR OF THE HYBRID MANAGER Indication of operating states by LED signals at the interface to the external unit: Status Standard operation Fault, communication with the hybrid manager LED2 LED3 Table 35 Operating code at the interface to the external unit ( = LED illuminates, = LED does not illuminate, = LED flashes) 1 2 6 720 646 970-63.1ITL Fig.
FAULTS 10.2.6 EXTERNAL UNIT FAULTS EXTERNAL UNIT LED DISPLAY DANGER: Risk to life through accumulated charges. With the power supply switched off, electronic components may still hold an electric charge that is maintained after switching off and isolation from the power supply. Contact with such components can result in severe or fatal injuries. 2 1 ▶ Once the green LED on the PCB of the external unit has extinguished, wait at least a further 10 minutes.
FAULTS Fault Indication on the PCB of the external unit Description Code LED (green) flashes LED (red) flashes 1x 2x High pressure switch 63H F5 2x 1x Control cable wiring fault between internal and external unit — phases reversed, no contact Eb Time limit exceeded for start of operation. EC 2x Signalling error between the internal and external units (reception error) recognised by the E6 internal unit.
FAULTS Code Description No indication — Cause Possible solution / check No supply voltage applied to terminal block TB1. ▶ Check mains isolator • The mains isolator upstream is switched off ▶ Check and correct connection, wiring, phases and contacts at TB1. • Poor connection/contacts or terminal loose • Open phase (L, L1 or N). No voltage applied to power supply input on power ▶ Check and correct connection, wiring, phases and contacts circuit board. at TB1.
FAULTS Code Description Cause EC Time limit exceeded for start of operation Poor connection/contacts or terminal loose at the ▶ Check and repair contacts, cables and control cable control cable connections or wiring error. connections for all appliances. U1 Possible solution / check Control cables incorrectly sized. The system has not initialised correctly after 4 minutes have elapsed since start of operation. The fault display “EC” is shown. Noise in the control cables.
FAULTS Code Description Cause Possible solution / check U2 (1) Hot gas temperature too high Temperature increase in compressor due to insufficient refrigerant. ▶ Check inlet overheating. Faulty ball valve (not completely open). ▶ Check if all ball valves are completely open. Faulty temperature sensor TH4, TH5. ▶ Switch the supply voltage off and on again. Faulty external unit PCB ▶ Check if fault code “U3” is shown. If yes, see “Possible solution / check” for “U3”.
FAULTS Code Description Cause U2 (3) Compressor temperature too high See U2 (2), but replace temperature sensors TH4, See U2 (2) 5 and 6 with temperature sensor TH32 Possible solution / check Faulty if temperature sensor TH32 exceeds 125 °C or 110 °C for 5 minutes. U3 Open / short circuit on hot gas temperature sensor TH4 or compressor temperature sensor TH32 Poor connection/contacts or terminal loose at the ▶ Check and repair plug and contacts of the temperature cables and plugs on the PCB.
FAULTS Code Description Cause U7 Overheating faulty due to insufficient hot gas temperature Poor connection/contacts or terminal loose at the ▶ Check and repair contacts, cables and connections for cables and plugs of hot gas temperature sensor temperature sensor TH4. TH4 on the PCB. Fault display “U7” is shown when superheating of -15 °C lasted longer than 3 minutes, with the LEV almost closed (lowest pulse rate) and 10 minutes have passed since the compressor started.
FAULTS Code Description Ud Overheating protection (overload Temperature sensor TH3 faulty. protection, fan motor fault) UF UH Cause Possible solution / check ▶ Check temperature sensor, replace faulty temperature sensor. If the line temperature (TH3) exceeds 70 °C, fault display “Ud” is shown. Circuit board faulty. ▶ Check PCB, replace if faulty. Protective equipment against compressor overcurrent: compressor blocked Shut-off valves closed. ▶ Open shut-off valves.
FAULTS Code Description Cause Possible solution / check UL Low pressure fault Shut-off valves closed. ▶ Open shut-off valves. Fault “UL” is shown if the following conditions are met for 3 minutes in 10 following compressor start in heating mode. Insufficient refrigerant or leak. ▶ Check amount of refrigerant and additional charge. Faulty linear expansion valve (LEV). ▶ Check linear expansion valve (LEV).
FAULTS Code Description Cause E9 Communication error between internal and external unit — transmission error Poor connection/contacts or terminal loose on the ▶ Check and correct wiring for all control cables between control cables, cable break. internal and external unit. Possible solution / check Faulty transmitter/receiver circuit on external unit. ▶ Switch the supply voltage off and on again (reset system). Noise in the voltage system.
FAULTS 10.2.7 CHECK COMPONENTS Component Temperature sensor: • • • • • • • Liquid line TH3 Hot gas TH4 Evaporator TH6 Fresh air TH7 Heat deflector TH8 Compressor shell TH32 Outdoor pipes TH33 4-way valve Compressor motor MC Points and criteria to check ▶ Check the temperature sensor resistance (sensor temperature range from 10 °C to 30 °C). TH3, TH6, TH7, TH33: Illustration — • Standard: 4.3 k – 9.
FAULTS 10.2.8 DC FAN MOTORS/CHECK PCB Start Check fuse: Checking fuse F5 on the PCB Fuse blown? Yes Replace PCB and fan motor. No Check wiring and contacts at motor plugs CNF1, CNF2 Contacts loose? Plug pulled? Yes Correct wiring.
FAULTS 10.2.
FAULTS Reference curve B Temperature sensor R50 = 17 k 2 % constant B = 4150 k 2 % (kΩ ) 1 1 Rt = 17 exp 4150 --------------------- – ----------- 273 + t 323 Value range 0 °C 25 °C 50 °C 70 °C 90 °C 180 k 50 k 17 k 8k 4k (°C) Table 44 Reference curve B 6 720 803 687 (2012/11) 73
FAULTS Reference curve C Temperature sensor R120 = 7.465 k 2 % constant B = 4057 k 2 % 500 1 1 Rt = 7 465 exp 4057 --------------------- – ----------- 273 + t 393 400 250 k 160 k 104 k 70 k 48 k 34 k 24 k 17.5 k 13.0 k 9.8 k 300 (kΩ ) Value range 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 200 100 0 25 50 75 (°C) 100 120 Table 45 Reference curve C 10.2.
FAULTS CONTROL SIGNAL SWITCHING PATTERN The extent to which the linear expansion valve opens depends on the number of pulses that are supplied by the PCB drive circuit to the LEV drive.
REPLACE COMPONENTS 11 ▶ Undo two screws and remove the small cover for the internal connections at the back. REPLACE COMPONENTS 11.1 PUMPING REFRIGERANT BACK INTO THE EXTERNAL UNIT DANGER: Risk to life due to escaping refrigerant! Escaping refrigerant can result in asphyxiation and frost bite in the case of contact at its exit point. ▶ When refrigerant escapes, never touch any components of the air to water heat pump and ensure adequate fresh air ventilation.
REPLACE COMPONENTS PREPARING THE EXTERNAL UNIT Only start refrigerant collection after the external unit has not operated for a period of 5 minutes or longer. ▶ Connect a pressure gauge to the service port [3] (Fig. 32, page 29) to check the pressure in the refrigerant system whilst pumping the refrigerant back to the external unit. ▶ Remove caps from the shut-off valve on the pipe work for liquid and gaseous refrigerant ( Fig. 32, page 29).
REPLACE COMPONENTS 11.3 REPLACING THE FAN MOTOR CAUTION: Damage through electrostatic discharge! ▶ Never touch a PCB without an earthed wristband. ▶ Removing the top section of the casing ▶ Remove front casing panel. ▶ Remove nut (M 6, left-hand thread). ▶ Remove impeller. 1 3 ▶ Pull plug CNF1 off the PCB inside the electronics casing ( Fig. 81, page 87). ▶ Undo fixing for connecting cable on motor bracket. ▶ Remove 4 screws (M 4 x 18) and remove the fan motor.
REPLACE COMPONENTS 11.4 REPLACING THE PCB HOUSING CAUTION: Damage through electrostatic discharge! ▶ Never touch a PCB if you are not wearing an earthed wristband. ▶ Remove service cover ( Fig. 73, page 77). ▶ Remove top casing panel. ▶ Remove front casing panel. ▶ Pull BUS cable plug to the hybrid manager at the terminal strip (TB1). ▶ Pull the following plugs at the PCB ( Fig. 74, page 78 and Fig. 81, page 87).
FILLING THE REFRIGERANT CIRCUIT 11.9 FITTING AND REMOVING THE LINEAR EXPANSION VALVE The linear expansion valve LEV ( Fig. 74, Page 78) comprises two components, i.e. the valve body and the electric drive. The electric drive can be replaced separately from the valve body. When fitting or removing the electric drive always ensure that you hold the valve body tightly to prevent damage to the refrigerant lines. Never wind the control and power cables around the valve body.
FILLING THE REFRIGERANT CIRCUIT 12.1 EVACUATING AND DRYING THE REFRIGERANT CIRCUIT 12.3 OPENING THE SHUT-OFF VALVES OF THE EXTERNAL UNIT WARNING: Personal injury from rupturing refrigerant pipes! Air bubbles trapped in lines can result in pressure peaks which can result in pipes bursting. NOTICE: Damage from closed shut-off valves! Compressor and control valves will suffer damage if the shut-off valves remain shut during the operation of the external unit. ▶ Never allow air to remain in the lines.
APPENDIX 13 APPENDIX 13.1 COST WEIGHTING ELECTRICITY PRICE — GAS PRICE Gas price [P/kWh] 30.0-30.9 29.0-29.9 28.0-28.9 27.0-27.9 26.0-26.9 25.0-25.9 24.0-24.9 23.0-23.9 22.0-22.9 21.0-21.9 20.0-20.9 19.0-19.9 18.0-18.9 17.0-17.9 16.0-16.9 15.0-15.9 14.0-14.9 13.0-13.9 12.0-12.9 11.0-11.9 10.0-10.9 Electricity price [P/kWh] 3.0-3.9 2.8 3.0 3.3 3.5 3.8 4.1 4.3 4.6 4.9 5.1 5.4 5.7 5.9 6.2 6.4 6.7 7.7 7.2 7.5 7.8 8.8 4.0-4.9 2.1 2.3 2.5 2.7 3.0 3.2 3.4 3.
APPENDIX 13.
APPENDIX 13.
APPENDIX 13.4 WIRING TO PCB IN THE EXTERNAL UNIT (HEAT PUMP) Fig.
APPENDIX Symbol TB1 MC MF1, MF2 21S4 63H 63L SV TH3 TH4 TH6 TH7 TH8 LEV-A, LEV-B DCL1, DCL2 ACL 52C RS ACTM CE P.
APPENDIX 13.5 CONTROLLER CIRCUIT BOARD IN EXTERNAL UNIT Fig.
APPENDIX No.
APPENDIX 13.6 ALTERNATIVE PIPE WORK LENGTHS AND T Additional pipe length [m] 20 10 6 0 20 10 6 0 Maximum flow rate [l/min] 15.3 16.3 16.8 17.6 15.3 16.3 16.8 17.6 Heating output [kW] 21.86 23.29 24.00 25.14 23.96 25.03 25.80 27.03 T [K] 20 20 20 20 21.5 21.5 21.5 21.
GENERAL DETAILS 14 GENERAL DETAILS CLIENT / HEATING CONTRACTOR Name: Commission number: Street / House number: Postcode / Town: Telephone: Fax: Mobile: Email: COMMISSIONING Initial comm Repeat comm Comm terminated SYSTEM LOCATION Name: Street: Postcode: Town: HEATING INSTALLATION Name: Street: Postcode: Town: ELECTRICAL INSTALLATION Name: Street: Postcode: Town: Table 52 General details APPLIANCE AND ACCESSORY (to be completed by installer) The following was/were installed
GENERAL DETAILS APPLIANCE AND ACCESSORY (to be completed by installer) Control system Hybrid control module Bypass valve Table 53 Installed appliance and accessory 6 720 803 687 (2012/11) 91
ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER 15 ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER The assembly and installation report is designed as a confirmation that the assembly and installation have been carried out correctly by a competent person.
ASSEMBLY AND INSTALLATION REPORT FOR THE INSTALLER • Pipework length of heating system • Total pipework pressure drop • Installation room volume (min. 5.
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER 16 COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER The commissioning report will be completed and signed by the commissioning engineer. Action Refrigerant lines connected, insulated and tightness of the refrigerant circuit checked. Power supply established and BUS cable connected to the external unit. DIP switches of the external unit set and checked.
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER Commissioning and handover of the heat pump by the commissioning engineer: Commissioning completed successfully. Commissioning terminated; follow-up date required. User instructed. Commissioning completed, faults noted under "Comments" must be removed.1) Faults removed on the: Client signature: 1 ) The faults recorded in the commissioning report must be actioned with out delay.
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER 96 6 720 803 687 (2012/11)
COMMISSIONING REPORT FOR THE COMMISSIONING ENGINEER 6 720 803 687 (2012/11) 97
AIR TO WATER HEAT PUMP COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the heat pump and associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing controls. Service 1 Date: Service 2 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No.
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.
