Worcester Greensource 9,5 User manual

UK/IE
INSTALLATION MANUAL
AIR TO WATER HEAT PUMP WITH DOMESTIC HOT WATER DISTRIBUTION UNIT
GREENSOURCE
6 720 641 467-00.1I
6 KW, 7 KW AND 9.5 KW
6 720 641 467(2010/01)
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TABLE OF CONTENTS
6 720 641 467 (2010/01)
2
TABLE OF CONTENTS
1 Explanation of symbols and safety information 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . 3
2 Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Building regulations . . . . . . . . . . . . . . . . . . . . . . 5
4 Included in the delivery . . . . . . . . . . . . . . . . . . . 6
4.1 Greensource 6, 7 & 9.5 with
internal unit HWDU-151 . . . . . . . . . . . . . . . 6
5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Transport and storage . . . . . . . . . . . . . . . . 7
5.2 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Minimum and maximum
operating temperatures . . . . . . . . . . . . . . . 7
5.4 Weather compensation control . . . . . . . . . 7
5.5 Defrosting method . . . . . . . . . . . . . . . . . . 7
5.6 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.7 Locations of the temperature sensors . . . 8
5.8 CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.9 Handling circuit boards . . . . . . . . . . . . . . 10
5.10 Appliance layout . . . . . . . . . . . . . . . . . . . 11
6 Dimensions, clearance and pipe connections . 12
6.1 Heat pump . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Internal unit . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Fitting the filter valve . . . . . . . . . . . . . . . 14
7 Heating system connection . . . . . . . . . . . . . . . 15
7.1 Fitting the unvented kit . . . . . . . . . . . . . . 15
7.2 Use in hard water areas . . . . . . . . . . . . . 15
7.3 Detailed G3 discharge pipe
installation requirements . . . . . . . . . . . . . 15
7.4 Tundish (HWDU) . . . . . . . . . . . . . . . . . . . 16
7.5 How to drain the hot water cylinder . . . . 17
7.6 How to flush the system & tank . . . . . . . 17
7.7 Flushing the heating system . . . . . . . . . . 17
7.8 Connecting the heat pump
to the heating system . . . . . . . . . . . . . . . . 18
7.9 Connection principle of the internal unit 19
7.10 Filling the heating system . . . . . . . . . . . . 20
8 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Accessory . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Emergency operation . . . . . . . . . . . . . . . 21
8.3 Heat pump . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4 Internal unit HWDU-151 . . . . . . . . . . . . . 24
9 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1 Control panel display . . . . . . . . . . . . . . . . 27
9.2 Control panel function . . . . . . . . . . . . . . . 27
9.3 Menu levels . . . . . . . . . . . . . . . . . . . . . . . 28
10 Installation and service menu (I/S) . . . . . . . . . 29
11 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . 30
12 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.1 Switching on the heat pump . . . . . . . . . . 33
12.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.3 Other settings . . . . . . . . . . . . . . . . . . . . . 35
12.4 Post commision checking . . . . . . . . . . . . 37
13 Timer functions . . . . . . . . . . . . . . . . . . . . . . . . . 38
14 Alarm functions and displays . . . . . . . . . . . . . . 39
14.1 Alarm history . . . . . . . . . . . . . . . . . . . . . . 39
14.2 Warning log . . . . . . . . . . . . . . . . . . . . . . . 39
14.3 Example of an alarm: . . . . . . . . . . . . . . . . 39
14.4 Dimmed menu display . . . . . . . . . . . . . . . 39
14.5 Emergency operation . . . . . . . . . . . . . . . . 39
14.6 Overheating protection . . . . . . . . . . . . . . 40
14.7 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.8 All alarms and warning windows . . . . . . . 40
14.9 Alarm window . . . . . . . . . . . . . . . . . . . . . 41
14.10 Warning window . . . . . . . . . . . . . . . . . . . 43
14.11 Information from the heat pump . . . . . . . 44
15 Technical information . . . . . . . . . . . . . . . . . . . . 46
15.1 Factory settings . . . . . . . . . . . . . . . . . . . . 46
15.2 Technical Data . . . . . . . . . . . . . . . . . . . . . 49
15.3 Sound pressure level . . . . . . . . . . . . . . . . 50
15.4 Temperature sensor resistance values . . 50
15.5 Supplementary technical information . . . 51
16 Commissioning report . . . . . . . . . . . . . . . . . . . . 52
17 Benchmark log book . . . . . . . . . . . . . . . . . . . . . 53
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EXPLANATION OF SYMBOLS AND SAFETY INFORMATION
6 720 641 467 (2010/01) 3
1 EXPLANATION OF SYMBOLS AND SAFETY INFORMATION
1.1 EXPLANATION OF SYMBOLS
WARNING SYMBOLS
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
•NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.
•CAUTION indicates possible injury.
•WARNING indicates possible severe injury.
•DANGER indicates possible risk to life.
IMPORTANT INFORMATION
ADDITIONAL SYMBOLS
1.2 SAFETY PRECAUTIONS
GENERAL
BRead the guide carefully and keep it to hand for future
use.
INSTALLATION AND COMMISSIONING
Installation and commissioning may only be carried out
by a qualified installer.
RISK OF DAMAGE DUE TO OPERATOR ERROR
Operator errors can result in injury and damage to
property.
BThis heat pump must only be operated by a
responsible adult who has been instructed in,
understands and is aware of the heat pump's
operating conditions and effects.
SERVICE AND MAINTENANCE
BOnly qualified personnel may carry out repairs.
Incorrect repairs can lead to serious risks to the user,
and may invalidate your warranty.
BOnly use original Bosch spare parts.
BService and maintenance must be carried out annually
by an suitably qualified service representative.
Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.
Electrical hazards are identified by a
lightning symbol surrounded by a warning
triangle.
Notes contain important information in
cases where there is no risk of personal
injury or material losses and are identified
by the symbol shown on the left. They are
bordered by horizontal lines above and
below the text.
Symbol Meaning
Ba step in an action sequence
Æa reference to a related part in the docu-
ment or to other related documents
•a list entry
–a list entry (second level)
Tab. 1
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BENCHMARK
6 720 641 467 (2010/01)
4
2 BENCHMARK
Benchmark places responsibilities on both
manufacturers and installers. The purpose is to ensure
that customers are provided with the correct equipment
for their needs, that it is installed, commissioned and
serviced in accordance with the manufacturer's
instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate
compliance with Building Regulations and should be
provided to the customer for future reference.
Installers are required to carry out installation,
commissioning and servicing work in accordance with
the Benchmark Code of Practice which is available from
the Heating and Hotwater Industry Council who manage
and promote the scheme. Visit
www.centralheating.co.uk for more information.
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BUILDING REGULATIONS
6 720 641 467 (2010/01) 5
3 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 requirements.
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,
Scotland and the Water Regulations Northern Ireland.
•the requirements of the UK Building Regulations:
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.
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INCLUDED IN THE DELIVERY
6 720 641 467 (2010/01)
6
4 INCLUDED IN THE DELIVERY
4.1 GREENSOURCE 6, 7 & 9.5 WITH INTERNAL UNIT HWDU-151
Fig. 1
With heat pump:
1Valve with filter
2Circlip pliers
3Rubber feet
4Outdoor sensor T2 with cable (with HWDU)
5Literature pack
6Room sensor T5 with cable (with HWDU)
7Flexible connection hose
With unvented air to water kit:
8Blending valve
9DHW expansion vessel
10 High flow rate inlet control set
11 Expansion vessel hose
12 Acetal tundish
13 Wall mounting kit for expansion vessel
14 Waste coupler
15 Filling loop with valve
6 720 641 467-79.1I
4
56
3
2
8
10
1
7
9
12
11
14
13
15
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GENERAL
6 720 641 467 (2010/01) 7
5GENERAL
5.1 TRANSPORT AND STORAGE
The heat pump should always be transported and stored
in an upright position. However, the heat pump may be
tilted temporarily, but must not be laid down on its back
or sides.
5.2 SETTING UP
•The heat pump must be installed outside the building
on a level, hard standing area.
•The installer should take the sound level of the heat
pump into consideration when siting
(Æchapter 15.3).
•The hdwu must be installed inside the property.
Pipework between the heat pump and the internal
unit should be kept as short as possible. All pipe work
between the outdoor and indoor unit must be well
insulated using class 0 insulation or better.
•Condensate drain water from the heat pump should
be led to a suitable drain area and the pipe work
insulated using class O insulation.
The pipe work must fall and terminate above the
drain.
•The drain pipe can also be routed into a foul water
drain outside.
•The heat pump must be installed with the specified
clearances for airflow.
•The heat pump must not be positioned so that the
recirculation of cold air can occur.
•Consideration should be given to siting the outdoor
unit directly below eaves and possible snow fall onto
the fan.
•Removing transport stay.
Fig. 2 Transport stay
5.3 MINIMUM AND MAXIMUM
OPERATING TEMPERATURES
Maximum operating return temperature: The heat
pump can operate with a maximum return temperature
of approx. 59 °C. For safety reasons the heat pump
stops as soon as this temperature is exceeded.
Maximum operating temperature heat only: The
maximum operating flow temperature is factory set to
62 °C. This can be changed by the installer to a
maximum of 70 °C. It is recommend that the factory
supplied blending valve be fitted in line with G3
regulations.
Minimum operating temperature: The heat pump stops
when the outside temperature is below - 20 °C. Only the
internal unit will then generate heat. The heat pump
restarts automatically when the outside temperature
rises again.
5.4 WEATHER COMPENSATION
CONTROL
The control unit regulates heat generation for the
heating either exclusively via the outside temperature
sensor (weather-compensated control) or via a
combination of outside temperature sensor and room
temperature sensor (room temperature-dependent
control).
For more detailed information regarding the control unit,
see the heat pump operating instructions.
5.5 DEFROSTING METHOD
The principle of defrosting in the heat pump is known as
hot gas defrosting. During defrosting, the flow in the
refrigerant circuit is reversed by means of an electrically-
controlled four-way valve.
The hot gas melts the ice on the evaporator fins. As this
happens, the heating water cools down a little. The
defrost duration depends on the thickness of the ice and
the current outside temperature. This process is
controlled by the T2, T11 and T12 temperature sensors.
An additional function enables defrosting of the fan.
Warm air is drawn through the fan and thereby prevents
it from freezing up again.
Only qualified installers may carry out the
installation. The installer must follow
applicable rules and regulations and
recommendations from the manufacturer.
6 720 616 817-26.1I
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GENERAL
6 720 641 467 (2010/01)
8
5.6 CHECKLIST
5.6.1 GREENSOURCE 6-9.5 WITH INTERNAL UNIT
HWDU-151
1. Position the heat pump on a level and stable base.
2. Connect the flow and return pipes to the heat pump.
3. Fit the valve with filter.
4. Fit the drain pipe to the heat pump.
5. Fit the corresponding flow and return pipes to the
internal unit.
6. Connect the relief valve discharge pipe.
7. Connect the HWDU unit to the heating system or
buffer cylinder.
8. Fit the outside temperature sensor and, the room
temperature sensor.
9. Connect the CAN-BUS cable to the hwdu unit and the
heat pump.
10. Fill and vent the heating system.
11. Connect the power supply RCD and isolation
switches to both indoor and outdoor units.
12. Switch on the system. Make all required settings at
the control panel.
13. Check the heating installation after commissioning
and insulate all external pipe work.
5.7 LOCATIONS OF THE TEMPERATURE
SENSORS
5.7.1 GREENSOURCE 6-9.5 WITH INTERNAL UNIT
HWDU-151
Fig. 3 Greensource 6-9.5 - internal unit HWDU-151
T1 Flow temperature sensor
T2 Outside temperature sensor
T3 Cylinder temperature sensor
T5 Room temperature sensor
T6 Hot gas temperature sensor
T8 Heating water temperature sensor, flow out
T9 Heating water temperature sensor, return in
T10 Condenser temperature sensor
T11 Refrigerant temperature sensor, evaporator
T12 Air temperature sensor, evaporator
Each heat pump installation is unique. The
following checklist will give you a general
description of how the installation should
be carried out.
6 720 616 817-03.1I
T5
T3
T1
T2
T9
T10
T8
T6
T11
T12
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GENERAL
6 720 641 467 (2010/01) 9
5.8 CAN-BUS
The various circuit boards in the heat pump and hwdu
are connected by a CAN-BUS communications cable.
CAN (Controller Area Network) is a two-wire system for
communication between microprocessor based
modules/circuit boards, which are connected in series.
The Greensource outdoor unit holds the PCB - IOB
board, all other pcbs are located in the indoor HWDU.
A suitable cable for the external connection is a CAT 5
E FTP 2x2x0.5A. The cable must be multi-core and
screened. The screen may only be earthed at one end
and only at the casing.
The cable may be up to 20 m long.
CAN-BUS cable must not be laid alongside power supply
cables. Minimum distance 100 mm between cables.
They may be laid alongside sensor cables.
Ensure that the external CAN- BUS cables when routed
into the hwdu are not in connect with the mains cable.
The connection between the circuit boards is by four
wires, because the 12V-supply between the circuit
boards must also be connected. The circuit boards have
markings for both the 12V and CAN-BUS connections.
Fig. 4
Switch S1 highlights the beginning and end of the CAN-
BUS cable. This means that the CPU board in the internal
unit and the IOB board in the heat pump must be
terminated by S1. For this, set S1 to Term.
CAUTION: Interference.
BThe CAN-BUS cable must be screened
and laid separately from the power cable.
CAUTION: Do not mix up the 12V and CAN-
BUS connections!
The processors are destroyed if 12V is
connected to the CAN-BUS.
BCheck that the four cables are connected
to the contacts with the corresponding
marking on the circuit board.
6 720 0614 056-03.1D
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GENERAL
6 720 641 467 (2010/01)
10
5.9 HANDLING CIRCUIT BOARDS
Circuit boards with control electronics are sensitive to
discharges of static electricity (ESD – ElectroStatic
Discharge) when handled. To prevent damaging the
components, special care is therefore required when
handled.
Fig. 5 Bracelet
Damage is usually hidden due to the nature of the failure,
and a circuit board can operate impeccably during
commissioning but show signs of problems later.
Charged objects may only be problematic if they are in
close proximity to the electronics. Keep a distance of at
least one metre from expanded polystyrene, protective
plastic and other packaging, synthetic material (e.g.
fleeces) and similar before starting work.
Anti-static protection facilities (e.g. mats, wrist bands
etc) should always be used if available. If not available,
the following handling precautions must be observed ;
touch the boiler earth immediately prior to removing the
part from the packaging. Handle the PCB only at the
edges. Touch earth on a regular basis whilst the board is
being fitted and connected. Do not touch any electronic
components.
A condition for good ESD protection is a ground-
connected bracelet when handling electronics. This
bracelet should be put on before opening the screened
metal bag/packaging or before exposing an installed
board. The bracelet should be worn until the circuit
board is enclosed in its screen packaging or closed
electric box. Replaced, returned circuit boards should
be handled in the same way.
Fig. 6
CAUTION: Wearing a ground-connected
bracelet is highly recommended.
6 720 614 366-24.1I
6 720 614 366-25.1I
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GENERAL
6 720 641 467 (2010/01) 11
5.10 APPLIANCE LAYOUT
5.10.1 HEAT PUMP
Fig. 7 Greensource 6-9.5
1Compressor
2Dry filter
3Heat exchanger
4Sight glass
54-way valve
6Low pressure switch
7Expansion valve
8Non-return valve
9High pressure switch
Fig. 8 Greensource 6-9.5 control panel
1Terminal
2Overload relay
3Capacitor
4Soft starter
5PCB (IOB board)
5.10.2 INTERNAL UNIT HWDU-151
Fig. 9 Connection chamber, internal unit
1Pressure gauge (System operating pressure 0.5 – 1.5 bar)
2Mixing valve
3Heat carrier pump (G2)
4Pump for heating system (G1)
5Heating three-way valve
6Hot water three-way valve
7Drain point
6 720 616 818-08.1I
1
3
2
7
6
5
4
9
8
6 720 641 467-70.1I
123 4 5
3
4
1
6 720 641 935-05.1I
2
5
6
7
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DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
6 720 641 467 (2010/01)
12
6 DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
6.1 HEAT PUMP
Fig. 10 Greensource 6-9.5 dimensions
1Drain
2Cable entry
3Flow to the HWDU (hose, 1" fem. thread)
4Return from the HWDU (hose, 1" fem. thread)
REQUIRED MINIMUM CLEARANCES FOR THE HEAT
PUMP
A minimum clearance of 1 m is required in front of the
pump; the minimum clearance to the back and sides is
0.3 m.
If a roof is installed it must be positioned at least 1.5m
above the heat pump to avoid the recirculation of cold.
818
839
1223
665
60
50
643
78
147
178
92
217 408
3
4
2
1
6 720 616 817-27.1I
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DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
6 720 641 467 (2010/01) 13
6.2 INTERNAL UNIT
Fig. 11 Internal unit
REQUIRED MINIMUM CLEARANCES FOR THE
INTERNAL UNIT
A minimum clearance of 0.8 m is required in front of the
internal unit. No clearance to the sides is required.
A minimum clearance of 50 mm is required between the
internal unit and fixed installations, such as walls, wash
basins etc. Preferably install the unit on external walls or
insulated intermediate walls.
PIPE CONNECTIONS
Fig. 12 Internal unit front
1Hot water
2Cold water
3Drain point
The following connections must be made at the internal
unit:
BConnect the heating flow to the outlet marked flow.
BConnect the heating return to the outlet marked
return.
BConnect the cold water supply to the outlet marked
cold water.
BConnect the DHW pipe to the outlet marked DHW.
The following connections must be made at the heat
pump:
BA 32 mm drain pipe from the drain connection to the
drain.
Installation of the valve with filter
BInstall the valve with filter horizontally in the return to
the heat pump and as near to the heat pump as
possible.
Between the heat pump and the house we recommend
22 mm pipe to be used, the maximum distance is 15
metres. The external pipe must be insulated using class
0 insulation.
_
>
800
_
>
50
_
>
1240
6 720 614 056-08.2I
>
400
_
1
2
3
6 720 641 935-06.1I
Pipe dimensions mm
Heating
Locking ring connection Ø 22
Cold water and domestic hot water
Locking ring connection Ø 22
Heating water inlet, heating water outlet and drain
Locking ring connection Ø 22
Waste water/drain Ø 32
Tab. 2
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DIMENSIONS, CLEARANCE AND PIPE CONNECTIONS
6 720 641 467 (2010/01)
14
Fig. 13 Back and top view of the internal unit
1Heating return
2Heating water inlet (from the heat pump)
3Heating flow
4Heating water outlet (towards the heat pump)
6.3 FITTING 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 must always be fitted on the return pipe, between
the HWDU and the outdoor heat pump. It should be
fitted as close to the heat pump as possible and be
horizontal.
347
1
2
3
4
103
152
194
300
420
543
30
558
6 720 616 817-06.1I
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01) 15
7 HEATING SYSTEM CONNECTION
7.1 FITTING THE UNVENTED KIT
7.1.1 PARTS TO ASSEMBLE
Fig. 14
1Expansion vessel
2High flow rate inlet control set
3Expansion vessel hose
4Tundish G1" x 28 mm incl. straight fitting. Tundish 15 mm x
22 mm
5Wall mounting kit for expansion vessel
6Blending valve
7Filling loop with valve
7.1.2 CONNECTION
BMount the expansion vessel with the wall mounting
kit. Connect the expansion vessel hose to the
expansion vessel.
BConnect the expansion vessel and inlet control set
externally to the appliance in line with G3 regulations.
We recommend that this be positioned above the
HWDU.
The blending valve should be fitted between the cold
and the DHW outlet to the tap.
7.2 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.
7.3 DETAILED G3 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 600mm 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
6 720 641 467-80.1I
2
6
1
4
3
5
7
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01)
16
Fig. 15 Typical discharge pipe arrangement
1Safety device (e. g. temperature pressure relief valve)
2Metal discharge pipe (D1) from temperature relief value to
tundish
3Tundish
4Metal discharge pipe (D2) from tundish, with continuous
fall. See 3.9d i-iv, Table 1 and worked example.
5Fixed grating
6Trapped gulley
7Discharge below fixed grating (3.9d gives alternative points
of discharge)
7.4 TUNDISH (HWDU)
Fit the tundish and straight fitting G1" x 28 mm as shown
on the illustration. The tundish and fitting are supplied
together with the HWDU as part of the G3 regulations.
Fig. 16
1Tundish
6 720 641 467-75.1I
7
1
2
4
3
5
6
600 mm maximum
300 mm
maximum
6 720 641 467-76.1I
1
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01) 17
7.5 HOW TO DRAIN THE HOT WATER
CYLINDER
Fig. 17
1Mains cold water in
2Domestic hot water out
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.
7.6 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.
7.7 FLUSHING THE HEATING SYSTEM
The heat pump is a part in a heating system. Faults in the
heat pump can be caused by poor water quality in the
radiators/under floor heating or air penetrating the
system continuously.
Oxygen causes the formation of corrosion products in
the form of magnetite and deposits.
Magnetite has a grinding effect on the heating system's
pumps, valves and components with turbulent flows
such as the condenser.
Heating systems which require regular filling or where
the heating water is not clear when drained, require
remedial measures before the installation of a heat
pump, for example the heating system must be fitted
with filters and air vents.
Do not use any water treatment additives except agents
for raising the pH level. Recommended pH value is 7.5 –
9.
The water inside the heating system must be neither
aggressive nor indicate a high chloride content. Very
high and very low pH values are not allowed.
To protect the heat pump against contamination:
BThoroughly flush the pipework prior to connecting the
heat pump.
Valve outlet
size
Size of dis-
charge pipe-
work D1
Size of dis-
charge pipe-
work 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
Tab. 3 Valve outlet size
6 720 641 467-77.1I
2
1
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01)
18
7.8 CONNECTING THE HEAT PUMP TO
THE HEATING SYSTEM
BThe heating system pipes must be laid so that they
withstand temperature differences in the heating
water, without the risk of noise or clicking in the
heating system.
To prevent vibrations between the heat pump and the
remaining system:
BInstall the flexible hoses at the inlet and outlet for the
heat pump supplied as standard.
For the connection between the internal unit and the
heat pump, up to 20 m length with a 28 mm diameter
such as Microflex or Ecoflex.
BOutdoor pipes must be insulated with a material that
cannot absorb moisture, such as Armaflex class 0.
PUMP CURVES
Fig. 18 Heating circuit pump
2000150010005000 [l/h]
0
10
20
30
40
50
1
2
3
[kPA]
6 720 614 056-11.1D
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01) 19
7.9 CONNECTION PRINCIPLE OF THE
INTERNAL UNIT
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
regulates the heat pump in accordance with the set
heating curve with the actual temperatures captured by
outside temperature sensor T2 and flow temperature
sensor T1.
When the heat pump can no longer meet the entire
heating demand on its own, the electric additional heat
in the internal unit starts and generates the temperature
required inside the building together with the heat
pump.
DHW heating has priority. DHW is regulated by means of
the actual temperature captured by cylinder
temperature sensor T3. Heating is switched off via the 3-
way valve when the DHW cylinder is being heated up.
The heating system will be supplied with heating water
again once the DHW cylinder has reached its set
temperature.
Operation in extreme cold conditions:
At an outside temperatures below approx. – 20 °C, the
heat pump stops automatically and can no longer heat
DHW. Under those conditions, the additional electric
heater in the internal unit automatically takes over the
DHW heating.
Fig. 19 Internal unit
Q46
E10 Radiator system
C11 Expansion vessel
C12 Primary water storage tank*
G1A Heating system pump
G1B** Heating system pump
P11 Pressure gauge
Q10 Mixing valve
Q12 Isolating valve
Q13 Water outlet
E20 Heating system
E21 Heat pump
F21 Safety valve
G2 Heat carrier 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
Q46 Blending valve
Sensors
T1 Heating system
sensor (indoor unit)
T2 Outdoor sensor
T3 DHW sensor
T5 Room sensor
T6 Hot gas sensor
T8 Heat pump
sensor
(outdoor unit)
T9 Heat pump return sensor
(indoor unit)
T10 Condenser
T11 Evaporator temp.
T12 Air intake
primary water storage tank is not required
** G1B is not supplied and should only be used in conjunction with the Primary water storage tank.
6 720 641 467-83.1I
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HEATING SYSTEM CONNECTION
6 720 641 467 (2010/01)
20
7.10 FILLING THE HEATING SYSTEM
After flushing the heating system the hot water heater
must be filled with water. The heating system is then
filled.
Fill the heating system:
1. Open the shut-off valve with non-return valve to fill
the DHW cylinder.
2. Open the valve to fill the system with heating water.
3. Open the air vent valve at the top of the DHW cylinder
to vent the heating system.
4. Also vent via the heat pump air vent valve.
5. Fill the heating system up to the correct pressure. The
standard pressure is 1-2 bar.
6. Shut the heating water filling cock when the correct
pressure is reached.
Fig. 20 Connection chamber, internal unit
1Pressure gauge (0.5-1.5 bar)
Fig. 21 Heat pump
1Air vent valve
WARNING: The water heater can crack if
filling is performed in the wrong order.
BFill and pressurise the hot water heater
before the heating system is filled.
1
6 720 641 935-07.1I
6 720 616 817-25.1I
1
For latest prices and delivery to your door visit MyTub Ltd - www.mytub.co.uk - [email protected] 0844 556 1818