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
MOUNTING AND INSTALLATION
6 720 803 687 (2012/11)20
4.3 UNPACKING THE HYBRID MANAGER
▶ Upon receipt, check that all packaging is in perfect condition.
▶ Remove packing straps and open the packaging at the top.
▶ Remove mounting plate and printed documents; keep safe for later
use.
▶ Remove outer packaging.
▶ Remove protective packaging.
▶ Dispose of packaging in an environmentally responsible manner.
▶ Carefully place the appliance on its back.
▶ Undo screws at the top and bottom of the appliance.
▶ Remove casing.
▶ Remove the screws on the transport bracket.
▶ Remove the transport bracket.
▶ Refit casing and screws.
4.4 CHECKING THE DELIVERY
▶ Check the delivery for completeness.
5 MOUNTING AND INSTALLATION
5.1 PREPARING FOR INSTALLATION
5.1.1 CLEANING PRIMARY SYSTEMS
BEFORE CLEANING THE SYSTEM:
▶ Ensure that the system and pipe work is in good working order.
▶ Where possible keep the existing boiler/circulating pump in place
when flushing the system.
FOLLOW THE GUIDANCE OF BS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
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 boiler is fired up.
▶ Run the boiler/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.
INHIBITOR
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system
is exposed to freezing conditions, to the heating system in accordance
with the DWTA code of practice and manufacturer‘s guidelines.
NOTICE: Damage to the hybrid manager and refrigerant
pipes may occur through incorrect handling.
▶ Treat refrigerant pipes and the hybrid manager with
care.
DANGER: Danger to life through electric shock!
▶ Before carrying out work on electrical components,
isolate them from the power supply (230 V AC) (fuse,
circuit breaker) and secure against unintentional
reconnection.
WARNING: Risk of injury and damage to appliance
through incorrect mounting and installation.
▶ The hybrid system and the components may only be
sited and installed by a competent person.
For commissioning:
The Power supply to the external unit must be “On”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. This is particularly important during colder
periods.The 12 hour period also compensates for any
unsettling of the lubricating oil within the compressor
which may have occurred during transportation.If this
12 hour time period cannot be met damage to the
outdoor unit may result.
Therefore, make the electrical connection as early as
needed ( chapter 5.7).
CAUTION:
ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
Worcester Bosch recommends the fitting of an in-line
system filter to the primary circuit which will assist with
maintaining system performance.
NOTICE:
Debris from the system can damage the hybrid manager
and reduce efficiency.
Failure to comply with the guidelines for the use of water
treatment with the appliance will invalidate the
appliance warranty.
NOTICE: Damage through high water flow:
The flow switch is damaged if the water flow is
excessively high.
▶ Flush the heating system with a water flow of 50l/
min.
NOTICE: ARTIFICIALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.
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.