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) 27
5.6 INSTALLING THE REFRIGERANT CIRCUIT
5.6.1 SAFETY
R410A is used exclusively as the refrigerant in the air to water heat
pump.
▶ Only qualified and authorised refrigeration engineers may work on the
refrigerant system.
▶ For the installation work, use tools and pipe components specifically
made for use with R410A refrigerant.
▶ Check for leaks in the refrigerant system. Escaping refrigerant coming
into contact with a naked flame will produce poisonous gases.
▶ Never release refrigerant to the atmosphere.
If refrigerant leaks and touches the skin, it can cause frostbite.
▶ In case of a refrigerant leak, never touch any part of the air to water
heat pump.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your skin or in your
eyes.
5.6.2 PREPARING FOR INSTALLATION
Tools required to handle R410A refrigerant:
• Pressure gauge kit
• Charge hose
•Gas leak detector
•Torque wrench
•Flaring tool
• Flaring gauge
• Vacuum pump adapter
• Electronic refrigerant charging scale
• Pipe press tool
PIPES AND PIPE JOINTS
▶ Ensure the insides of the pipes are clean and do not contain any
harmful contaminants such as sulphuric compounds, oxidants,
debris, or dust.
– Never store the refrigerant pipes to be used outdoors.
– Do not unseal the pipe ends until immediately before they are
brazed.
– 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.
▶ Use C1220 phosphorous copper for refrigerant pipe connections to
create seamless pipes from copper and copper alloys.
▶ Braze joints in refrigerant lines. Use phosphor bronze brazing rods
suitable for flux-free brazing.
▶ Apply small amounts of ester oil, ether oil or alkylbenzene as
refrigerant oil onto the flared sections of the refrigerant lines. Never
mix refrigerant oil with mineral oil.
▶ After cutting, immediately seal reusable lengths of refrigerant lines.
5.6.3 ROUTING REFRIGERANT LINES
▶ Ensure requirements have been met:
– A height differential between the installation site and the hybrid
manager is permissible. However, take the maximum pipe length of
30 m into account.
– The refrigerant line may have a maximum of 15 bends and a
maximum length of 30 metres one way.
▶ Start by connecting the refrigerant lines to the hybrid manager
(mounting plate).
▶ Bend pipes carefully to prevent breaking them. Bending radii between
100 mm and 150 mm are adequate.
▶ Generally braze refrigerant line joints.
▶ Wrap pipe work for liquid and gaseous refrigerant with commercially
available insulation (diffusion-proof, up to at least 100 °C, thickness
at least 20 mm).
▶ Use sealant to seal the ends of the thermal insulation around the pipe
connection sections to prevent water from entering the thermal
insulation.
5.6.4 CONNECTING THE HYBRID MANAGER
▶ Remove plug and braze the ¼ " diameter to the pipe work for liquid
refrigerant and the ½ " diameter to the pipe work for gaseous
refrigerant at the hybrid manager.
Compared to previously used refrigerants, the R410A
refrigerant operates at a pressure that is approx. 1.6-
times higher.
CAUTION: Property damage from incorrect installation!
▶ Use only those tools that are specifically intended for
handling R410A refrigerant.
WARNING: Risk of injury through escaping refrigerant!
Pipes that are not permissible or that are incorrectly
sized can burst.
▶ Use exclusively pipes with the specified wall
thickness.
Pipe
External diameter
[inch]
Wall thickness
[mm]
Liquid refrigerant ¼ 0.8
Gaseous refrigerant ½ 0.8
Table 7 Refrigerant pipe dimensions
Ensure that the lines are constantly shielded with
oxygen-free nitrogen (a little above atmospheric
pressure) whilst joints are being brazed to prevent
scaling and damage to the compressor.
The room volume must be at least 5.7 m³ if refrigerant
lines are routed through occupied rooms.
When brazing joints, ensure that the lines are constantly
shielded with oxygen-free nitrogen (a little above
atmospheric pressure). After brazing has been
completed, continue shielding the brazed area with
nitrogen until the temperature of the pipe work has
cooled down to below 200 °C.
When brazing joints, ensure that the lines are constantly
shielded with oxygen-free nitrogen (a little above
atmospheric pressure). After brazing has been
completed, continue shielding the brazed area with
nitrogen until the temperature of the pipe work has
cooled down to below 200 °C.