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
COMMISSIONING
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If the External Unit is powered ON first, its controller tries to establish
the communication with the Hybrid Manager but until the Hybrid
Manager is powered ON, the communication cannot be established.
If this status continues for a period of time, the External Unit judges this
status as a ‘communication error’ and this error can not be reset until the
External Unit is powered OFF once.
The same thing can happen when the Hybrid Manager is powered on first
and the External Unit can not be powered on within a certain period of
time.
In order to avoid this ‘false’ communication error, SW8-3 is available on
the External Unit controller circuit board. If switch SW8-3 is set to ON,
the Hybrid Manager/External Unit communication error is ignored and
the External Unit keeps waiting until the Hybrid Manager is powered ON
and responds to the External Unit.
In other words, even though it could take a long time from when the
External Unit is powered ON until the Hybrid Manager is powered ON,
the communication error is never detected as far as SW8-3 is set ON.
If SW8-3 is NOT set ON, the Hybrid Manager/External Unit
communication error will be detected in 3 minutes at the earliest case.
If you are sure that both the Hybrid Manager and the External unit
can be powered on within 3 minutes, you do not need to set SW8-3
ON.
If the communication error is caused not only by this power supply issue
but by electrical noise etc, the error can be detected by the indoor board
side even if SW8-3 is ON and the error code can be displayed on the
FW200.
6.2.9 ADJUSTING THE HYBRID MANAGER CIRCULATING PUMP
IN THE HYBRID MANAGER
The Hybrid manager circulating pump in the hybrid manager is set
subject to the system configuration.
ADJUSTING THE HYBRID MANAGER CIRCULATING PUMP CURVE
The Hybrid manager circulating pump can be set up in different ways:
• I Constant pressure curve, speed stage I
• II Constant pressure curve, speed stage II
• III Constant pressure curve, speed stage III.
▶ Select and set the speed stage in line with the procedures described
in section 6.2.9
▶ Press arrow button [1] on the Hybrid manager circulating pump to
select the required stage.
Fig. 47 Setting the speed stage at the HE pump
6.2.10 SYSTEM WITH SERIES BUFFER TANK
Does the installation have a single or a multi heating circuit with a serial
buffer tank? As shown in Fig. 7 8, 9 and 10.
1. The pump in the accessory box should be set on Constant Speed III,II
or I.
The pump should be set on the lowest setting which matches P the
Total System Pressure Drop.
2. The Available Pump Head, see figure 49 (Available head), must
overcome A the Heating Circuit Resistance and B the resistance of any
Additional Pipe work between the Accessory Box and the heating
system
3. What is the maximum condensing boiler heat output Q for the heating
system in kW?
4. What is T the required design Delta T (Flow temperature - Return
temperature) across the system?
5. What is V the required system flow rate to achieve T the design Delta
T at the maximum CH heating output Q?
V = 14.3 x Q /T
6. What is the pressure drop of the heating circuit at flow rate F [l/min]
in mbar?
7. What is the equivalent length of additional 22mm pipe work between
the Accessory Box and the heating system in metres?
8. What is B the pressure drop of the equivalent length of additional pipe
work in mbar? - refer to figure 48, Pressure drop/Flow rate
9. Calculate P the Total System Pressure Drop that the pump needs to
overcome, P = A + B
10.From Available Hydraulic Pump Head Chart, refer to figure 49, select
the closest pump setting which provides P the Total pressure at F the
system flow rate.
11.If none of the pump curves match the requirement it may be
necessary to reduced B the equivalent length of additional pipe work
Constant pressure curve, speed stage III is the standard
setting. Pump must be used in fixed speed mode only.
6 720 646 970-106.1ITL
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Set the Hybrid manager circulating pump to the lowest
speed stage possible subject to system pressure drop.
We recommend speed stage II or III.
NOTICE: The typical design Delta T is 20K
NOTICE: The equivalent length of pipe work includes all
additional pipe work bends (an elbow is equivalent to
1m length of pipe work)