Worcester GREENSOURCE 6 kW User manual

INSTALLATION MANUAL
GB/IE
GB/IE
HEA
WORCESTER GREENSOURCE
6 kW, 7 kW & 9.5 kW
HEAT PUMP WITH HOT WATER DISTRIBUTION UNIT
Please read carefully prior to
installation and user guide

Installation manual for the Worcester Greensource heat pump with hot water distribution unit
Worcester, 16.06.08
Part number: 8-716-115-330
Issue: a
Copyright © 2008
BUILDING REGULATIONS
This appliance must be installed and serviced only by a competent person in accordance with the current: IEE Regulations,
Building Regulation, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water
by-laws, Health & Safety Document 63S (The Electricity at Work Regulations 1989), IS 813 (Eire) and other local require-
ments.
The relevant Standards should be followed, including:
BS7074:1 : Code of practice for domestic and hot water supply
EN:12828 : Central heating for domestic premises
BS7593 : Treatment of water in domestic hot water central heating systems
BS EN 14511 : Requirements heat pumps for space heating and cooling
BS EN 378 : Safety and environmental requirements for heat pumps
The Health and Safety at Work Act 1974
The Management of Health and Safety at Work Regulations 1999
The Construction (Health, Safety and Welfare) Regulations 1996
The Construction (Design and Management) Regulations 1994
The Lifting Operations and Lifting Equipment Regulations 1998
Where no specific instruction is given, reference should be made to the relevant codes of Practice.
Potable water:
All seals, joints, compounds (including flux and solder) and components used as part of the secondary domestic water
system must be approved for use with potable water supplies.
This is to certify that the above ranges of products manufactured by Bosch Thermotechnology have been tested and found
to comply with –
the requirements of the (Water Fittings) Regulations 1999 for England and Wales, the Water Byelaws 2000, Scotland1. and the Water Regulations Northern Ireland.
the requirements of the UK Building Regulations:2.
The Building Regulations 1991 (England & Wales) Requirements G3, L1 and Regulation 7. The Building Standards
(Scotland) Regulations 1990. Regulation 10 (B2), 22 (J3.3a and J3.4), 27 and 28 (P2.6 and P3). The Building Regulations
(Northern Ireland) 2000.

3
Table of Contents
Contents
FOR THE INSTALLER ............................................................................................ 5
Important information to the installer .............................................................................6
Checklist.......................................................................................................................6
What the delivery includes .............................................................................................7
General.........................................................................................................................8
Transporting and storage............................................................................................................................................................... 8
Positioning the heat pump.............................................................................................................................................................. 8
Minimum and maximum working temperatures............................................................................................................................ 9
Different methods of heating control............................................................................................................................................... 9
Defrosting method .......................................................................................................................................................................... 9
Location of the temperature sensors.............................................................................................................................................. 10
CANbus........................................................................................................................................................................................ 11
Components identification............................................................................................................................................................ 12
Dimensions, clearance and plumbing connections..........................................................13
Greensource Air to water heat pump (outdoor)............................................................................................................................ 13
Hot water distribution unit........................................................................................................................................................... 13
Fit the filter valve......................................................................................................................................................................... 14
Connecting to the heating system ..................................................................................15
Fitting the unvented kit................................................................................................................................................................ 15
Use in hard water areas ............................................................................................................................................................... 15
Flushing the heating system.......................................................................................................................................................... 18
Connecting the heat pump, HWDU and heating system ................................................................................................................ 18
Pump diagram - Available pump head ......................................................................................................................................... 18
Principle method of operation....................................................................................................................................................... 19
Filling the heating system............................................................................................................................................................. 20
Connecting to the power supply ....................................................................................20
Sensors......................................................................................................................................................................................... 20
Isolation switch and residual current device................................................................................................................................. 21
Emergency operation.................................................................................................................................................................... 21
Wiring diagram Greensource heat pump...................................................................................................................................... 22
Wiring diagram Greensource HWDU........................................................................................................................................... 23
Terminal diagram Greensource heat pump - HWDU.................................................................................................................... 24
External connections Greensource heat pump............................................................................................................................... 25
External connections Greensource HWDU.................................................................................................................................... 26
Installer and service menu (I/S)...................................................................................27
Menu overview............................................................................................................28
Commissioning............................................................................................................31
Start the heat pump ..................................................................................................................................................................... 31
Start up ....................................................................................................................................................................................... 31
Other settings ............................................................................................................................................................................... 34
Important points to check after commissioning............................................................................................................................. 34
Timers........................................................................................................................35
Alarm functions...........................................................................................................36
Technical information ..................................................................................................39
Factory settings ............................................................................................................................................................................ 39
Technical information.................................................................................................................................................................. 42
Sound levels ................................................................................................................................................................................. 43
Sensor table.................................................................................................................................................................................. 43
Supplimentary technical information........................................................................................................................................... 44

4
PRODUCT CONTENTS LIST
Greensource Heat Pump.
Components included in delivery:
Rubber feet
Outdoor sensor T2 with cable
Room sensor T5
Valve with filter
Circlip pliers
Flexible connection hoses
Tundish (factory fitted)
Unvented cylinder kit:
DHW expansion vessel
Expansion Vessel Hose
Wall mounting kit for expansion vessel
High flow rate inlet control set
Blending valve
Tundish 15 mm x 22 mm
Filling loop and valve
Waste coupler
Literature pack:
User manuals
Installation manual
Guarantee card

5
This guide provides the heat pump installer with a description of how the heat
pump and the Hot water distribution unit (HWDU) are installed and commis-
sioned. The installation section consists of a plumbing part and an electrical
part. It also provides technical data such as measurements, wiring diagrams
and installer menus. We hope that you read through this guide carefully and
that you respect all notes and warning texts.
Note
It is important that as the installer you also read through the User guides for
our Greensource products. Here you will find the information necessary to get a
comprehensive understanding of the heating unit.
Contents:
Important information to the installer
Checklist
What the shipment includes
General
Dimensions, clearance and plumbing connections
Connecting the heat pump and HWDU to the heating system
Connecting the heat pump and HWDU to the power supply
External connections
Commissioning
Technical information
For the Installer

6
This manual gives you all the information necessary to install the heat pump
and HWDU. The guide is divided into several parts in the order in which
installation and commissioning must be carried out.
Before staring the installation:
The heat pump may be temporarily tilted with the compressor
downwards. It must never laid down or transported horizontally. (See
Transport and storage)
Check that the plumbing connections in the heat pump and the HWDU
are intact and have not shaken loose during transport.
Before the commissioning the heating system must be filled up and
completely vented.
Important information to the installer
Checklist
The following checklist will give you a general description of how the installation
should be carried out.
1. Position the heat pump on a solid base.
2. Install the incoming and outgoing pipes for the heat pump.
3. Install the drainage pipe for the heat pump.
4. Fit the filter valve.
5 Install the incoming and outgoing pipes for the HWDU.
6 Install the waste water hose for the HWDU.
7. Install the unvented kit and inlet control group external to the unit.
8. Connect the heat pump and HWDU.
9. Connect the heat pump and the HWDU to the heating system.
10. Install the outdoor sensor and room sensor.
11. Connect the CANbus wiring between the heat pump and the HWDU.
12. Fill and vent the heating system before commissioning.
13. Connect any residual current device.
14. Connect the heat pump and HWDU to the power supply.
15. Commission the heating installation by making all the necessary settings on the
control panel.
16. Check the heating installation after commissioning.
Warning
For reasons of safety the main power
supply must be disconnected before
working on the heat pump and
HWDU.
!
Note
Only qualified installers may carry
out the installation. The installer must
follow applicable rules and regula-
tions and recommendations from the
manufacturer.
Important information to the installer / Checklist

7
What the delivery includes
What the delivery includes
The following components are included in the delivery of the heat pump and HWDU:
Literature pack
User manual Greensource Heat pump
User manual Hot water distribution unit
Installation manual
Guarantee card
Outdoor sensor T2 (GT2) with cable
Quantity: 1
Rubber feet
Quantity: 4
Room sensor T5 (GT5) with cable:
Quantity: 1
Valve with filter
Quantity: 1
DHW expansion vessel
Quantity: 1
Expansion vessel hose
Quantity: 1
Filling loop with valve
Quantity: 1
Wall mounting kit for expansion vessel
Quantity: 1
High flow rate inlet control set
Quantity: 1
Acetal tundish
Quantity: 2
1 x factory fitted 22 mm x1"
1 x 15 mm x 22 mm
Circlip pliers
Quantity: 1
Blending valve
Quantity: 1
Flexible connection hose
Quantity: 2
Waste coupler
Quantity: 1

8
Positioning the heat pump
The heat pump is located outdoors. It contains a number of sensitive
parts. It is important that it stands on a flat and solid base, for example,
concrete or similar hard standing. A rubber mat may be fitted to
reduce possible noise transmission for uneven surfaces.
See more information under the heading Technical information/ Sound
levels.
The
HWDU is placed indoors. Pipe lengths should be kept to a
minimum between indoor and outdoor units. Class O insulation should
be used to insulate all pipes.
The heat pump produces condensation in normal operation and melted
ice during the defrosting process. It is therefore important to direct
waste water from the heat pump to a suitable drain.
Note that the discharge pipe must have a continual fall away from the
unit to a suitable drain. This will keep the discharge pipe free of frost
as air is drawn from inside the house.
The heat pump must be positioned so that air is not prevented from
passing through the evaporator. Minimum distance to a wall is 300
mm. Avoid positions which result in circulation of cold air because this
decreases the heat pump output.
Consideration should be given to siting the outdoor unit directly below
eaves and possible snow fall.
Any canopy or other cover must not be fitted closer than 2 m as this
will effect the heat pumps operation.
General
Transporting and storage
The heat pump should always be transported and stored in an upright
position. Otherwise the suspension fittings inside the compressor can be
damaged. If the heat pump must be tilted during entry to the installation
site, this should be done for as short a time as possible.
The HWDU must not be stored or transported at temperatures below 0ºC.
The heat pump must not be stored at temperatures below 0ºC.
Note
The amount of condensation water
can amount to 30-40 litres, during
days of high humidity. It is non acidic.
General

9
Maximum working temperatures
The heat pump can work with a maximum return temperature of approxi-
mately 59ºC. If the temperature rises above this value the heat pump will
stop for reasons of technical safety.
In the event of additional heat only, the maximum flow temperature is
limited to the factory setting 62ºC. This can be changed by the installer to
max 70ºC. If a value higher than 65ºC is set a mixing valve must be installed.
See Commissioning.
Minimum working temperatures
The heat pump stops if the outdoor temperatures falls below approx -20ºC.
All heat production then occurs in the HWDU by the additional electric
heater. The heat pump starts automatically when the outdoor temperature
climbs above approx -20ºC.
Different methods of heating control
The control unit uses different methods to control the heating installation.
These are: Control with an outdoor sensor and Control with an outdoor
sensor supplemented with a room sensor.
More information about the control methods can be found in the User
Guide.
General
Minimum and maximum working temperatures
Defrosting method
The principle of defrosting in the heat pump is known as hot gas defrost-
ing. During defrosting, the flow in the refrigerant circuit is reversed by
means of an electrically-controlled four-way valve. The compressed gas
from the compressor is fed into the top of the evaporator, causing the ice
on the outside to melt. During this process, the heating water is cooled
slightly. Hot gas is sprayed into the evaporator and sensor T11 ensures that
the process functions correctly. The time required for defrosting depends
on the amount of ice and the outdoor temperature.
This unit also operates as a fan defrost function, where hot air blows
upwards through the fan to prevent freezing.

10
General
3-way
valve
3-way
valve
Heating
system
Heating
system
T1 Flow sensor
T2 Outdoor sensor
T3 Hot water sensor
T5 Room sensor
T6 Sensor compressor temperature
T8 Sensor heat transfer fluid out
T9 Sensor heat transfer fluid in
T10 Sensor condenser temperature
T11 Sensor refrigerant temperature
evaporator
T12 Sensor air temperature evaporator
Location of the temperature sensors
Greensource Air to water heat pump Hot water distribution unit

11
General
The Rego 800 has different circuit boards which are connected by a
communications cable, CANbus. CAN is an abbreviation of Controller Area
Network and is a two wire system for communication between the micro-
processor based modules/circuit boards. These are connected in series.
The heat pump has one circuit board (IOB circuit board), other circuit
boards are in the HWDU.
Cable ELAQBY 2x2x0.4A is suitable cable for external laying (con-
nection between the circuit boards). The cable must be twisted pair and
screened. The screen must only be earthed at one end and to the chassis
(not to the circuit board). Maximum cable length is 20 m.
CANbus cables must not be laid alongside power cables. They may be laid
alongside sensor cables.
In the connection area of the heat pump and the HWDU the external
CANbus cable must be laid so that it does not come into contact high
current connections (230/400V).
The connection between the circuit boards is by four wires since the
12V-supply between the circuit boards must also be connected. The circuit
boards have markings for both the 12V and CANbus connections.
Warning
Do not mix up the 12V and CAN-
bus connections! If 12V (or other
incorrect voltage) is supplied to the
CANbus contacts the processors in the
CANbus are destroyed. Check, there-
fore, that the four cables are connected
to the contacts with the corresponding
marking on the circuit boards in the
HWDU and the heat pump.
Switch S1
The switch is used to mark the start and end of a CANbus loop. This means
that the display circuit board in the HWDU (marked CPU on the wiring
diagram) and the IOB circuit board in the heat pump must be terminated
using S1, which must be in position Term. If a residual power breaker is
used this circuit board must be terminated instead of the CPU circuit board
in the HWDU. Ensure that the correct circuit boards are terminated and
that all other switches are in the opposite position.
CANbus
Warning
The CANbus cable must be screened
and laid separately from the power
cable to prevent interference in the
CANbus communication.
Warning
Handle the circuit boards with great
care. They are sensitive to ESD (Elec-
trostatic discharge), which can cause
faults in electronic components.
Screen

12
General
Hot water distribution unit
Heat pump
Components identification
High pressure
switch
Service connection Compressor
Expansion valve
Four-way valve
Service connection
Non-return valve
Low pressure
switch
Drying filter
Sight glass
Condenser
Manual air vent
Three-way
valve Three-way valve
Pump for heating
system (G1)
Heat carrier
pump (G2)
Pressure gauge
(0.5 – 1.5 bar)
Mixing valve
Pipes to and from the
heat pump are con-
nected at the back

13
Dimensions, clearance and plumbing connections
Front
Left-hand side
1) Flow to HWDU.
Cable entry
Dimensions, clearance and plumbing connections
Back
Condensator
drain
640
1190
60
820 411
220
105
101 165 201
Greensource Air to water heat pump (outdoor)
Hot water distribution unit
Required installation space for the HWDU.
A free space of 600 mm is required in front of the HWDU. No clearance
required at the sides.
A minimum of 25 mm is required from the back of the unit to any
permanent fixture: i.e. outer wall or partition wall.
Min. space 1,240 mm
Wall Insu-
lated
wall
Front
Min. 25 mm
Min. 600 mm
HWDU
Required installation space for the heat pump.
Minimum distance from the pump to the wall is 300 mm.
Minimum distance in front of the pump 1000 mm, to the sides 500 mm.
If a roof is installed it must be positioned at least 1.5 m above the heat
pump to avoid the recirculation of cold air.
2) Return from HWDU
Note
The waste coupler must be fitted to
the condensator drain oulet.

14
Pipe connections
The following connections are made to the HWDU:
A 32 mm plastic pipe is taken from the waste water pipe to the floor drain.
The flow is connected to the inlet marked Forward flow.
The return is connected to the inlet marked Return flow. Cold water and
hot water are connected to inlets marked Cold water and Hot water.
The following connections are made to the heat pump:
A 32 mm plastic pipe is drawn from the drainage pipe to the floor drain.
Pipe dimensions
Flow/return
Clamping ring connection mm ø22
CW and HW
Clamping ring connection mm ø22
To/from connections
Clamping ring connection mm ø22 (in the HWDU)
Clamping ring connection mm ø28 (n the heat pump)
Waste water/drainage mm ø32 (in both)
HWDU front view
Hot water Cold water
View connection area HWDU
seen from behind
HWDU top view
Flow heating system
Return heating system
Fit the filter valve
The task of the particle filter is to filter out dirt before it can enter the
heat pump. Accordingly, the supplied filter valve should always be fitted
on the return pipe on the hot side, between the HWDU and the outdoor
heat pump. It should be fitted as close to the heat pump as possible and be
horizontal.
1) From the heat pump.
(Connect to 1) in the heat pump picture.
2) To the heat pump.
(Connect to 2) in the heat pump picture.
Dimensions, clearance and plumbing connections

15
Connecting to the heating system
Fitting the unvented kit
Parts to assemble:
The relief valve connections should
not be used for other purpose.
Note
Expansion vessel
Expansion vessel hose
Filling loop with valve
Wall mounting kit for expansion vessel
High flow rate inlet control set
Tundish - factory fitted
Tundish - 15mm x 22 mm supplied
separately
Connection:
Mount the expansion vessel with the wall mounting kit. Connect the
expansion vessel hose to the expansion vessel.
Connect the expansion vessel and inlet control set externally to the
appliance in line with G3 regulations. We recommend that this be positio-
ned above the HWDU.
The blending balve should be fitted between the cold and the DHW outlet
to the tap.
Blending valve
Use in hard water areas
Normally there is no need for water treatment to prevent scale formation.
In areas where temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale
prevention device. In such circumstances the advice of the local water authority should be sought.
Connecting to the heating system

16
Detailed discharge pipe installation requirements
The discharge pipework must be routed in accordance with part G3 of schedule 1 of the building Regulations.
The tundish should be vertical, located in the same space as the unvented hot water cylinder and be as close as possible
and within 500mm of the safety device e.g. the temperature relief valve. The discharge pipe from the tundish should be:
made of metal
at least one pipe size larger than the nominal outlet size of the safety device (larger sizes may be required if the
equivalent hydraulic resistance exceeds that of a straight pipe 9m long - refer to BS6700)
terminate in a safe place where there is no risk to persons in the vicinity of the discharge, and position safely from
electrical devices.
have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework
installed with a continuous fall
visible at both the tundish and the final point of discharge or where this is not possible or practically difficult there
should be clear visibility at one or the other of these locations
Connecting to the heating system

17
How to drain the hot water cylinder
1. Turn off the main water supply to the cylinder.
2. Open a hot water tap with a position as low as possible in the building,
in order to reduce the pressure.
3. Remove the pipe connection 1 - Mains cold water in and connect
one end of the hose pipe to the connection. Terminate the other end of
the hose to a drain or to outside. Ensure that the drain end of the hose
is at a lower level than the bottom of the cylinder. The greater the fall
on the hose, the higher the flow rate.
4. Disconnect connection 2 - Domestic hot water out.
5. Start the siphon effect by pumping or sucking at the drain end of the
hose.
6. Let the whole volume drain out.
Valve outlet size Size of discharge
pipework D1 Size of discharge pipework D2
Maximum length of
straight pipe
(no bends or elbows)
Deduct the figure below from the
maximum length for each bend or
elbow in the discharge pipe
22 mm Up to 9 m 0.8 m
G1/2 15 mm 28 mm Up to 18 m 1.0 m
35 mm Up to 27 m 1.4 m
28 mm Up to 9 m 1.0 m
<G3>/4 22 mm 35 mm Up to 18 m 1.4 m
42 mm Up to 27 m 1.7 m
35 mm Up to 9 m 1.4 m
G1 28 mm 42 mm Up to 18 m 1.7 m
54 mm Up to 27 m 2.3 m
How to flush the system & tank
To flush the tank use the above proposed setup, add a hose onto the hot
water outlet position number 2 (in the above diagram) and then flush the
hot water tank.
>0cm
1
2
Connecting to the heating system

18
Note
Only qualified installers may carry
out the installation. The installer must
follow applicable rules and regula-
tions and recommendations from the
manufacturer.
Connecting to the heating system
Flushing the heating system
It is important that all previously mentioned preparations have been carried out
before the heat pump is connected to the heating system. Also ensure the heating
system has been well flushed before the heat pump is installed. Flushing protects
the heat pump from contamination.
Faults in the heat pump can be caused by poor water quality in the radiators/
underfloor coils or that air is penetrating the system continuously. Oxygen causes
corrosion products in the form of magnetite and sediment, which is detrimental to
the heat pump components and reduces its working life.
Existing heating systems which require regular filling or where the heating water
is not clear when drained, requires cleansing and flushing before the installation
of a heat pump. Do not use any water treatment additives except agents for raising
the pH level.
Connecting the heat pump, HWDU and heating
system
Use the information in section Dimensions, clearances and plumbing connections to
connect the different parts of the heating installation.
In addition, to avoid vibration transfer between the heat pump and the pipe system
we recommend fitting flexible hoses at the inlet and outlet of the heat pump,
which are supplied.
Between the heat pump and the house we recommend 28 mm copper pipe for
lengths of less than 20 metres. The pipes must be insulated with a material,
such as class 0 Armaflex, which cannot absorb moisture. Venting valves must be
provided on the pipes. Short outdoor pipes reduce heat losses.
Diagram: Pump for heating system (G1)
Water flow [l/h and l/s]
Available pressure
Pos 1 Pos 2
Pos 3
Pump diagram - Available pump head

19
Greensource heat pump and HWDU
Principle method of operation
The principle method of operation is based on the vapour compression cycle with any additional heat being provided by
the built in electric heater. The control unit controls the heat pump using the outdoor sensor T2 and the flow sensor T1
according to the set heat curve. If the heat pump is unable to meet the heating requirements, the HWDU and the additional
electric heater starts automatically and together with the heat pump provides the required temperature. Hot water is priori-
tised and controlled by a sensor, T3 in the hot water cylinder. While the DHW is being heated in the hot water cylinder, the
CH production by the heat pump is stopped temporarily through a three-way valve. When the DHW temperature is satisfied
the heat pump continues the CH production.
Operation in extreme cold conditions:
At outdoor temperatures lower than approximately -20, the compressor in the heat pump is switched off and all heating and
hot water heating is via the built in electric heater.
Connecting to the heating system
E10 Radiator system
C11 Expansion vessel
C12 Primary water storage tank*
G1A Radiator pump
G1B Radiator pump
P11 Pressure gauge
Q10 Mixing valve
Q12 Isolating valve
Q13 Water outlet
E20 Heating system
E21 Heat pump
F21 Safety valve
G2 Heating system pump
G3 Fan
Q20 3-way valve
Q21 3-way valve
Q22 Air vent
V21 Filter heating system
E40 Tap water system
C41 Expansion vessel
E41 Hot water cylinder
V40 Hot water
W40 Cold water
F42 Temperature & pressure
relief valve
Q42 Isolation valve
Q43 Pressure reducing valve
Q44 Non return valve
Q45 Tundish
Sensors
T1 Heating system flow
sensor (indoor unit)
T2 Outdoor sensor
T3 DHW sensor
T5 Room sensor
T6 Hot gas sensor
T8 Heat pump flow sensor
(outdoor unit)
T9 Heat pump return sensor
(indoor unit)
T10 Condenser
T11 Evaporator temp.
T12 Air intake
* The drawing above shows the correct connection method for the heat pump where the flow rate around the heating system can fall below 70% of the
nominal flow (i.e. system with zone controls and thermostatic radiator valves). If the heating system has been designed to be fully open at all times then the use
of the primary water storage tank is not required

20
Connecting to the power supply
Check that cables and printed circuit boards are intact. High and low
current cables should be routed separately in order to avoid interference
and give false readings on the sensors.
Sensors
Outdoor sensor T2
Locate the outdoor sensor T2 on a North facing wall approximately 2 m
from ground level.
Room sensor T5
Position the indoor sensor T5 to a good reference location inside the
house, away from direct sunlight and heating appliances.
Warning
Handle the circuit boards with great
care. They are sensitive to ESD (Elec-
trostatic discharge), which can cause
faults in electronic components.
Connecting to the heating system
Filling the heating system
After flushing the heating system the hot water cylinder must be filled first
and then the heating system can be filled and pressurised.
The filling of the heating system is carried out via the supplied filling loop
sited externally to the unit.
It is recommneded that the DHW inner tank is filled and pressurised first.
Warning
The hot water cylinder must always be
filled and pressurised before the heat-
ing system is filled.
The installation must not, under any
circumstances, be switched on without
water.
Pressure gauge
(0.5 – 1.5 bar)