Technical data
Table Of Contents
- Table of contents
- 1 Key to symbols and safety instructions
- 1.1 Explanation of symbols
- 1.2 Safety instructions
- 2 About the appliance
- 2.1 Designated use
- 2.2 EU Declaration of Conformity
- 2.3 Data plate
- 2.4 Standard delivery
- 2.5 Accessories
- 2.6 Tools, materials and miscellaneous parts
- 2.7 General information on energy use and heat production
- 2.8 Function description of the hybrid manager
- 2.9 Handling circuit boards
- 2.10 Refrigerant circuit
- 2.11 Combi boiler with serial buffer tank, bypass valve and unmixed heating circuit
- 2.12 System boiler with serial buffer tank, bypass valve and unmixed heating circuit
- 2.13 Combi boiler with serial buffer tank, bypass valve, unmixed heating circuit and independently controlled mixed heating circuit
- 2.14 System boiler with serial buffer tank, bypass valve, unmixed heating circuit and independently controlled mixed heating circuit
- 2.15 Overview of components
- 2.16 Dimensions
- 2.17 Technical Data
- 3 Regulations
- 4 Transport
- 5 Mounting and installation
- 5.1 Preparing for installation
- 5.2 System component configuration
- 5.3 Pre-installing pipes
- 5.4 Mounting the hybrid manager
- 5.5 Installing the external unit
- 5.6 Installing the refrigerant circuit
- 5.7 Making the electrical connection
- 5.8 Installing the outside temperature sensor
- 5.9 Setting the DIP switches of the external unit
- 6 Commissioning
- 6.1 Before commissioning
- 6.2 Commissioning the system for the first time
- 6.2.1 Providing the external unit with a power supply ahead of commissioning
- 6.2.2 providing the external unit with a power supply during commissioning
- 6.2.3 Connecting the CANBUS cable to the hybrid manager unit
- 6.2.4 Making the power supply connection
- 6.2.5 Switching on the hybrid system
- 6.2.6 Connecting the programming unit to the hybrid control module
- 6.2.7 Connecting the heat source to the hybrid manager
- 6.2.8 Communication error from External unit on initial power ON of External Unit and Hybrid Manager
- 6.2.9 Adjusting the Hybrid manager circulating pump in the hybrid manager
- 6.2.10 System with series buffer tank
- 6.2.11 Venting the hybrid manager
- 6.2.12 Setting the bypass valve
- 6.2.13 Setting parameters for optimising energy use and costs of the hybrid system
- 6.2.14 Explanation of the parameters for energy and cost optimization of the hybrid system (control strategy)
- 6.2.15 Control Strategy: Option CO2 Optimised and co2 :cost mix
- 6.2.16 Control Strategy: Co2 optimised (environmental factors)
- 6.2.17 Control Strategy: CO2: Cost mix
- 6.2.18 Control Strategy: Option changeover temperature
- 6.2.19 Control Strategy: Cost optimised
- 6.2.20 Control strategy: hydraulic connection
- 6.2.21 Control strategy: Delay time for boiler heating
- 6.2.22 Control strategy: Temperature diff for boiler switch ON
- 6.2.23 Setting parameters at the hybrid control module
- 6.2.24 Commissioning of the air to water heat pump at outside temperatures outside the standard operating range
- 6.2.25 Informing the customer and handing over the technical documents
- 7 Operation
- 8 Environmental protection/disposal
- 9 Inspection and maintenance
- 10 Faults
- 10.1 Faults that are not displayed
- 10.2 Displayed faults
- Overview of internal hybrid fault indicators locations
- 10.2.1 Fault displays on the hybrid control module
- 10.2.2 Check temperature sensor of hybrid manager
- 10.2.3 Faults of the FW200 programming unit
- 10.2.4 Fault display on the FW 200 weather-compensated controller at user level
- 10.2.5 Fault display on the rear of the hybrid manager
- 10.2.6 External unit faults
- 10.2.7 Check components
- 10.2.8 DC fan motors/check PCB
- 10.2.9 Check external unit temperature sensor
- 10.2.10 Check linear expansion valves (LEV)
- 11 Replace components
- 11.1 Pumping refrigerant back into the external unit
- 11.2 Removing the casing from the external unit
- 11.3 Replacing the fan motor
- 11.4 Replacing the PCB housing
- 11.5 Replacing PCBs
- 11.6 Replacing faulty temperature sensors TH3, TH6 or TH33
- 11.7 Replacing outside temperature sensor TH7
- 11.8 Replacing temperature sensors TH4 and TH32
- 11.9 Fitting and removing the linear expansion valve
- 11.10 Removing the transformer (ACL)
- 12 Filling the refrigerant circuit
- 13 Appendix
- 13.1 Cost weighting electricity price — gas price
- 13.2 System wiring (heatronic III boiler connections) with a bypass valve and one unmixed heating circuit
- 13.3 System wiring (CUS boiler connections) with a bypass valve and one unmixed heating circuit
- 13.4 Wiring to PCB in the external unit (heat pump)
- 13.5 Controller circuit board in external unit
- 13.6 Alternative pipe work lengths and T
- 14 General details
- 15 Assembly and installation report for the installer
- 16 Commissioning report for the commissioning engineer
REGULATIONS
6 720 803 687 (2012/11) 19
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
Observe the following guidelines and regulations:
• Local regulations and requirements by the relevant power supply
utility and the associated special connection requirements
• BS EN 378 Safety and environmental requirements for heat pumps
• BS EN 14511 Requirements heat pumps for space heating and
cooling
• BS EN 14276-2:2007 Pressure equipment for refrigerating systems
and heat pumps. Piping. General requirements
• BS EN 14324:2004 Brazing. Guidance on the application of brazed
joints
• BS EN 12735-1:2010 Copper and copper alloys. Seamless, round
copper tubes for air conditioning and refrigeration. Tubes for piping
system
• European Parliament Regulation (EC) 842/2006 on Certain
Fluorinated Greenhouse Gases
• Gas Safety Regulations 1998 (Installation and use)
• Building Regulations
• Building Regulations Northern Ireland)
• Building Regulations (Scotland) (Consolidation)
• IGE Gas Installation in Timber Frame Buildings
• Law no. 46 of 5/3/1990 - Regulations for the safety of installation
• Standard UNI-CIG 7129 - gas installations for domestic use supplied
from the mains network
• Standard UNI 11071 - Gas installation for domestic use controlled be
condensing and similar appliances
• Any other local requirement
– The Health and Safety at Work Act 1974
– The Management of Health and Safety at Work Regulations 1999
– The Construction (Health, Safety and Welfare) Regulations 1996
– The Construction (Design and Management) Regulations 1994
– The Lifting Operations and Lifting Equipment Regulations 1998
Where no specific instruction is given, reference should be made to the
relevant codes of Practice.
Potable water: All seals, joints, compounds (including flux and solder)
and components used as part of the secondary domestic water system
must be approved for use with potable water supplies.
This is to certify that the above ranges of products manufactured by
Bosch Thermotechnology have been tested and found to comply with:
• The requirements of the (Water Fittings) Regulations 1999 for
England and Wales, the Water Byelaws 2000, Scotland and the Water
Regulations Northern Ireland.
• The requirements of the UK Building Regulations:
– The Building Regulations 1991 (England & Wales) Requirements
G3, L1 and Regulation 7.
– The Building Standards (Scotland) Regulations 1990. Regulation
10 (B2), 22 (J3.3a and J3.4), 27 and 28 (P2.6 and P3).
– The Building Regulations (Northern Ireland) 2000.
The relevant Standards to be followed include:
• BS 1306 Specification for copper and copper alloy pressure piping
systems
• BS 5440:1 Flues and ventilation for gas appliances of rated heating
not exceeding 70kW (net): Flues
• BS 5440:2 Flues and ventilation for gas appliances of rated heating
not exceeding 70kW (net): Air Supply
• BS 6798 Installation of gas fired boilers of rated input up to 70kW
(net)
• BS 7074:1 Code of practice for domestic and hot water supply
• BS 6891 Installation of low pressure gas pipe work up to 28 mm (R1)
• BS 5546 Installation of gas hot water supplies for domestic purposes
• EN:12828 Central heating for domestic premises 3 Product
Description
• BS 7593 Treatment of water in domestic hot water central heating
system
4 TRANSPORT
During handling, also observe the following:
▶ Never lift packages by the shipping straps.
▶ Wear safety gloves as sharp edges can result in cuts.
4.1 LIFTING AND CARRYING THE EXTERNAL UNIT
Handling by trained personnel:
▶ Only remove packaging at the time of the final installation.
▶ At least two people should lift and carry the external unit.
▶ Only move the external unit upright.
▶ Never carry the external unit by the packing straps.
▶ During handling and unpacking, wear safety gloves to prevent injuries
on your hands through sharp-edged appliance components.
▶ Dispose of packaging materials appropriately.
4.2 UNPACKING THE EXTERNAL UNIT
▶ Undo straps carefully.
▶ Remove the outer carton by pulling it vertically upwards.
▶ Remove the padding from the front and sides.
▶ Remove the plastic cover and protective cover from the top of the
external unit and keep safe.
▶ Provide at least two people for lifting the external unit from the bottom
plate.
▶ Ensure that this does not damage the external unit.
▶ Dispose of packaging in an environmentally responsible manner.
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.
WARNING: Risk of injury through improper handling.
▶ Use a means of transport suitable for handling
appliances (e.g. sack truck with strap, stair climbing
or step trolley).
▶ When handling appliances, secure them against a fall.
▶ Let only trained personnel undertake the handling.
WARNING: Risk of injury through incorrect lifting and
carrying!
The external unit weighs in excess of 20 kg.
▶ Never lift or carry the external unit on your own.
WARNING: Risk of injury through sharp-edged tools.
▶ Handle tools carefully.
▶ Ensure that the outer carton is not damaged when
removing the straps.