Technical data

TABLE OF CONTENTS
6 720 803 687 (2012/11)2
TABLE OF CONTENTS
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 About the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Tools, materials and miscellaneous parts . . . . . . . . . . . . 6
2.7 General information on energy use and heat production 6
2.8 Function description of the hybrid manager . . . . . . . . . . 7
2.9 Handling circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.10 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Combi boiler with serial buffer tank, bypass valve and
unmixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 System boiler with serial buffer tank, bypass valve and
unmixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.13 Combi boiler with serial buffer tank, bypass valve,
unmixed heating circuit and independently controlled
mixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.14 System boiler with serial buffer tank, bypass valve,
unmixed heating circuit and independently controlled
mixed heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.15 Overview of components . . . . . . . . . . . . . . . . . . . . . . . 13
2.15.1 Greenstar Plus hybrid manager (internal unit) . . . . . . 13
2.15.2 Greenstar Plus hybrid external unit . . . . . . . . . . . . . . . 14
2.16 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.16.1 hybrid manager (internal unit) . . . . . . . . . . . . . . . . . . . 16
2.16.2 external unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.17 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.1 Hybrid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.2 Hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17.3 External unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Standards, regulations and guidelines . . . . . . . . . . . . . 19
3.1.1 General regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Lifting and carrying the external unit . . . . . . . . . . . . . . 19
4.2 Unpacking the external unit . . . . . . . . . . . . . . . . . . . . . 19
4.3 Unpacking the hybrid manager . . . . . . . . . . . . . . . . . . 20
4.4 Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 System component configuration . . . . . . . . . . . . . . . . 21
5.2.1 General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.2 Buffer tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.3 Bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.4 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.5 Thermostatic radiator valves . . . . . . . . . . . . . . . . . . . . 21
5.2.6 Hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.7 External unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Pre-installing pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Preparing the hybrid manager connection . . . . . . . . . . 24
5.3.2 Fitting the bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.3 Mounting the FW200 programming unit . . . . . . . . . . . . 24
5.4 Mounting the hybrid manager . . . . . . . . . . . . . . . . . . . . 24
5.5 Installing the external unit . . . . . . . . . . . . . . . . . . . . . . . 25
5.5.1 Preparing the condensate drain for the external unit . . 26
5.5.2 Mounting on foundations . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5.3 Making a condensate drain for the external unit . . . . . . 26
5.6 Installing the refrigerant circuit . . . . . . . . . . . . . . . . . . . 27
5.6.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6.2 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6.3 Routing refrigerant lines . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6.4 Connecting the hybrid manager . . . . . . . . . . . . . . . . . . . 27
5.6.5 Connecting the external unit . . . . . . . . . . . . . . . . . . . . . 28
5.6.6 Checking the refrigerant circuit for tightness . . . . . . . . 28
5.6.7 Insulating the refrigerant shut-off valve . . . . . . . . . . . . . 29
5.6.8 Evacuating and drying the refrigerant circuit . . . . . . . . 29
5.7 Making the electrical connection . . . . . . . . . . . . . . . . . . 30
5.7.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7.2 General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7.3 Connecting the external unit . . . . . . . . . . . . . . . . . . . . . 30
5.8 Installing the outside temperature sensor . . . . . . . . . . . 31
5.8.1 Select the installation location . . . . . . . . . . . . . . . . . . . . 31
5.8.2 Connecting the outside temperature sensor . . . . . . . . . 32
5.9 Setting the DIP switches of the external unit . . . . . . . . . 32
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.2 Commissioning requirements . . . . . . . . . . . . . . . . . . . . 32
6.2 Commissioning the system for the first time . . . . . . . . . 33
6.2.1 Providing the external unit with a power supply ahead of
commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.2 providing the external unit with a power supply during
commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.3 Connecting the CANBUS cable to the hybrid manager unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.4 Making the power supply connection . . . . . . . . . . . . . . 33
6.2.5 Switching on the hybrid system . . . . . . . . . . . . . . . . . . . 33
6.2.6 Connecting the programming unit to the hybrid control
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2.7 Connecting the heat source to the hybrid manager . . . 34
6.2.8 Communication error from External unit on initial power
ON of External Unit and Hybrid Manager . . . . . . . . . . . 34
6.2.9 Adjusting the Hybrid manager circulating pump in the
hybrid manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.10 System with series buffer tank . . . . . . . . . . . . . . . . . . . . 35
6.2.11 Venting the hybrid manager . . . . . . . . . . . . . . . . . . . . . . 38
6.2.12 Setting the bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.13 Setting parameters for optimising energy use and costs of
the hybrid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.14 Explanation of the parameters for energy and cost
optimization of the hybrid system (control strategy) . 39
6.2.15 Control Strategy: Option CO2 Optimised and
co2 :cost mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41