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)28
5.6.5 CONNECTING THE EXTERNAL UNIT
Never connect the refrigerant lines to the external unit until
• the refrigerant lines have been completely arranged
• the refrigerant lines have been connected to the hybrid manager.
▶ Connect the external unit to the refrigerant line after completing the
installation work, including the connection to the hybrid manager
(internal unit).
▶ Remove the service cover (1 screw).
▶ Close the external unit’s shut-off valve completely.
▶ Fit the flare nut (17 mm external diameter) to the liquid refrigerant
pipe.
▶ Fit the flare nut (26 mm external diameter) to the gaseous refrigerant
pipe.
▶ Flare the pipes for liquid and gaseous refrigerant ( Fig. 30 and
table 8).
Fig. 30 Flaring refrigerant pipes
▶ Apply a thin layer of refrigeration oil to pipe and joint seating surface
before tightening flare nut.
Fig. 31 Fitting refrigerant pipes
[1] Connection to the external unit
[2] Flared refrigerant pipe
[3] Conical nut
▶ Tighten conical nut [3] with a torque wrench. Observe the allowable
starting torque when doing so ( Table 9).
▶ There should be no contact with the outer case of the ODU.
▶ There should be no contact between the liquid and gas refrigerant
pipes.
5.6.6 CHECKING THE REFRIGERANT CIRCUIT FOR TIGHTNESS
After connecting the refrigerant pipes, check the connected pipes and
the hybrid manager for tightness.
▶ Connect the testing tools.
▶ Ensure that the shut-off valves on the pipe work for liquid [1]
( Fig. 32 and page 29). and gaseous refrigerant [2] ( Fig. 32
and page 29) are closed and do not open them.
▶ Feed nitrogen into the refrigerant lines via the shut-off valve's
Schrader valve on the gaseous refrigerant pipe work [2] and slowly
increase the pressure in the refrigerant circuit.
▶ Increase the pressure in stages:
– Step 1: build pressure to 0.5 MPa (5 bar(g)).
Wait 5 minutes.
Check pressure. A pressure drop indicates that there is a leak.
Identify the source, repair and check for tightness again.
– Step 2: build pressure to 1.5 MPa (15 bar(g)).
Wait 5 minutes.
Check pressure. A pressure drop indicates that there is a leak.
Identify the source, repair and check for tightness again.
– Step 3: Pressurise to 4.15 MPa (41.5 bar(g)).
Measure the ambient temperature and the pressure.
▶ After 24 hours, check ambient temperature and pressure again.
The refrigerant circuit has passed the tightness test if no pressure
drop can be identified.
▶ A pressure drop indicates that there is a leak. Identify the source,
repair and check for tightness again.
Use a gas leak detector or a soapy solution to check for gas leaks.
At the factory, the external unit has been filled with
sufficient R410A refrigerant for a line length (single
direction) of between 1 m and 30 m.
Pipe
External diameter
[inch]
Faring dimension
Ø A [mm]
Liquid refrigerant ¼ 8.9 – 9.1
Gaseous refrigerant ½ 16.2 – 16.6
Table 8 Swaging dimensions for refrigerant pipes
øA
R0.4~R0.8
90° 0.5°
45° 2°
6 720 646 970-24.2ITL
6 720 646 970-48.2ITL
1 2 3
Pipe work
External
diameter
[inch]
OD conical nut
[mm] Torque [Nm]
Liquid refrigerant ¼ 17 14 – 18
Gaseous refrigerant ½ 26 49 – 61
Table 9 Starting torque, external unit
The addition “(g)” identifies the stated value as pressure
differential relative to atmospheric pressure.
A minor change in pressure can be caused by the change
in temperature (approx. 0.01 MPa (0.1 bar(g)) per
1 °C). Take this into account in the evaluation.