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
FILLING THE REFRIGERANT CIRCUIT
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12.1 EVACUATING AND DRYING THE REFRIGERANT
CIRCUIT
Remove air from the refrigerant circuit by a the correct vacuum drying
process. 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.
12.2 VACUUM DRYING
▶ Connect a high performance vacuum pump to the Schrader valve
( Fig. 77, [1]).
▶ 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 the vacuum pump is only used for a short time, it may not be
possible to bring about a complete evacuation. In addition it may
result in moisture remaining in the pipe work.
▶ Switch off the vacuum pump and close the distributor valve.
▶ Observe the pressure for 15 minutes.
Should the pressure rise during that time (vacuum reduces), evacuate
and repeat the final test.
▶ Separate the vacuum pump from the refrigerant circuit.
12.3 OPENING THE SHUT-OFF VALVES OF THE EXTERNAL
UNIT
Open the shut-off valves on the liquid and gaseous refrigerant pipe work:
▶ Remove valve cap [2].
▶ With an Allen key (4 mm) turn the valve head [3] anti-clockwise as far
as it will go (approx. 10 turns).
Stop turning once the end-stop has been reached.
▶ Turn valve head [3] ½ one turn back (clockwise).
▶ Attach valve cap [2]. When doing this ensure that the inside remains
undamaged as this serves as a sealing face.
▶ Tighten valve cap [2] with a torque of between 20 and 25 Nm.
Failure to replace and tighten the caps may result in refrigerant
leakage.
Fig. 77 Shut-off valve on the liquid refrigerant pipe work
[1] Schrader valve
[2] Valve cap
[3] Valve head
[4] Pipe work to building
[5] Pipe work to the external unit
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 external unit 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.
NOTICE: Damage from closed shut-off valves!
Compressor and control valves will suffer damage if the
shut-off valves remain shut during the operation of the
external unit.
▶ Open shut-off valves for liquid and gaseous
refrigerant.
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