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)26
5.5.1 PREPARING THE CONDENSATE DRAIN FOR THE EXTERNAL
UNIT
In addition to the condensate lines for the heat source, make provisions
for the condensate generated in the external unit.
Unlike boiler condensate, the condensate produced by the external unit
is not acidic and can soak away in chippings or be routed to a drain. The
diameter, slope and routing of the condensate pipe work must be
selected in such a way as to prevent blockage or freezing.
Preparing the condensate drain:
▶ Use a PVC rigid vinyl pipe (VP-32) or a vinyl hose with a minimum
internal diameter of 32 mm as condensate drain.
▶ Select the shortest possible pipe length.
▶ Keep condensate lines as vertical as possible with a minimum slope of
45 mm per metre to its outlet.
5.5.2 MOUNTING ON FOUNDATIONS
▶ Ensure that the foundations and installation surface meets
requirements ( chapter 5.2.7).
▶ Position and level the external unit.
▶ Mark out the holes to be drilled for the 4 anchor bolts.
▶ Move the external unit slightly to the side.
▶ Drill the holes for the 4 anchor bolts.
–Bolt size: M10
– Select a hole depth that allows the anchor bolts to be screwed into
the foundations to a depth of at least 70 mm.
▶ Level the external unit.
▶ Secure the feet of the external unit with four M 10 anchor bolts.
Fig. 28 Foundations for the external unit (2 plinth example shown)
[a] As long as possible, minimum 365 mm
[b] Minimum depth120 mm
[1] M 10 anchor bolt ( 70 mm)
5.5.3 MAKING A CONDENSATE DRAIN FOR THE EXTERNAL UNIT
The condensate generated in the external unit must be drained off free
from the risk of frost.
▶ Ensure that the on-site requirements for reliable condensate drainage
are met ( chapter 5.5.1).
The bottom of the external unit has 3 holes suitable for draining off
condensate.
Fig. 29 Fitting the condensate drain
[1] Condensate pipe
[2] Drain tap
[3] Blanking caps (accessory)
▶ Glue the drain tap [2] into a suitable hole.
▶ Glue blanking caps [3] onto the other holes that are not used. Apply
adhesive properly as it also acts as a sealant.
▶ Connect the condensate hose [1] to the drain tap.
▶ Apply weather-resistant insulation to the drain pipe.
▶ Route the condensate drain into a suitable drain pipe or a dry well.
▶ Protect against the risk of frost:
We recommend the use of the “electric trace heating for the
condensate drain of the external unit” (available as an accessory).
Accessory pack for outdoor unit contains:
• Blanking caps
• Pre-cut insulation (for lagging the service/installer connections)
• Cable ties (for securing lagging of service/installer connections)
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.
We recommend providing the pipe work with weather-
resistant insulation.
WARNING: Personal injury from unsuitable surfaces!
An external unit that has not been properly sited may fall
over and cause personal injury and property damage.
▶ Site the external unit on a stable, level substrate with
sufficient load-bearing capacity.
▶ Never site the external unit on wooden floors.
4x
6 720 646 970-19.2ITL
a
b
1
NOTICE: Frost damage!
Frost damage on the external unit will result if the
condensate fails to drain off.
▶ Either install a condensate drain or an optional
condensate pan fitted with a drain for the external
unit.
6 720 646 970-21.2ITL
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