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
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Fig. 32 Shut-off valves, refrigerant circuit
[1] Shut-off valve on the liquid refrigerant pipe work
[2] Shut-off valve on the gas pipe work
[3] Schrader valve (under the service port)
[4] Section opening / closing
[5] Service port
[6] Do not use a spanner here
[7] Use two spanners here
[8] Insulation
[9] ¼ inch pipe
[10] ½ inch pipe
5.6.7 INSULATING THE REFRIGERANT SHUT-OFF VALVE
Insulate the refrigerant pipes, including the shut-off valve, following
connection to the external unit.
▶ Trim insulation material [3] so that it fits snug around the refrigerant
valves.
▶ Install the insulation [3] for the liquid refrigerant pipes (small,
2 holes) on the liquid side so that the holes fit the valve caps [1] and
cover the shut-off valve [2] entirely.
▶ Trim the insulating material for the liquid refrigerant pipe work and
make 2 holes for the locking caps.
▶ Fix to the pipe so that the holes surround the locking caps [1] and the
shut-off valve [2] is completely covered.
Fig. 33 Insulating material, shut-off valve and valve caps
[1] Locking caps
[2] Lock nut
[3] Insulating material (accessory drain kit EHP)
▶ Secure insulating material [1] with cable ties.
▶ Trim off the excess “tails” of the cable ties [2].
Fig. 34 Insulation with cable ties
[1] Insulating material (accessory drain kit EHP)
[2] Cable tie (accessory drain kit EHP)
▶ Trim and fix the insulating material [1] for the gaseous refrigerant
pipe work.
▶ Fix the insulation material [1] using cable ties [2].
▶ Trim off the excess “tails” of the cable ties [2].
5.6.8 EVACUATING AND DRYING THE REFRIGERANT CIRCUIT
Remove air from the refrigerant circuit by following recommended
procedure for vacuum drying. In the case of inadequate vacuum drying
air and water vapours remain in the refrigerant circuit. These may result
in an abnormal rise in positive pressure or in a drop in negative pressure
as well as to a loss of quality in the refrigerant oil through moisture. This
may have a negative effect on the compressor service life.
VACUUM DRYING
▶ Connect a high performance vacuum pump to the Schrader valve
( Fig. 32, [3]).
▶ With the vacuum pump build a pressure of 101 kPa(g) (5 Torr).
▶ Maintain this pressure for at least 1 hour.
– During this time check the vacuum pressure constantly at the
pressure gauge.
– If there is any moisture left in the pipe, complete evacuation is
sometimes not reached if the vacuum pump is applied for only a
short period.
▶ Close the distributor valve and then switch off the vacuum pump.
▶ Observe the pressure for one minute.
Should the pressure rise during that time (vacuum reduces), evacuate
and repeat the final test.
▶ Separate the vacuum pump from the refrigerant circuit.
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WARNING: Personal injury from rupturing refrigerant
pipes!
Air bubbles trapped in lines can result in pressure peaks
which can result in pipes bursting.
▶ Never allow air to remain in the lines.
The refrigerant circuit is pre-charged with 2.5 kg of
R410A refrigerant. Commissioning does not require
topping up with refrigerant.
Never use the refrigerant from the external unit to purge
air from the refrigerant lines.
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