Worcester GREENSOURCE User manual

WORCESTER GREENSOURCE
Air to Water Outdoor Heat pump
6 kW, 7 kW & 9.5 kW
USER MANUAL
GB/IE
GB/IE
Please read carefully prior to
installation and user guide

User manual for the Worcester Greensource heat pumps
Worcester, 16.06.08
Part number: 8-716-115-328
Issue: a
Copyright © 2008

3
Table of Contents
Table of Contents
FOR THE USER..................................................................................................... 4
Important information........................................................................................................................... 4
How a heat pump works ........................................................................................................................ 5
Technology in and around the heat pump ...........................................................................................................................5
Component parts of the heat pump......................................................................................................... 7
Greensource A/W heat pump 6, 7 and 9.5 kW....................................................................................................................7
Control unit Rego 800........................................................................................................................... 8
Automatic defrosting...........................................................................................................................................................8
The control unit’s operating mode.......................................................................................................................................9
The control unit’s control method for heating ....................................................................................................................10
Control panel...................................................................................................................................... 11
Status LED.......................................................................................................................................................................11
Menu dial.........................................................................................................................................................................12
Power switch (ON/OFF)..................................................................................................................................................12
Menu display ....................................................................................................................................................................12
How to use the control panel .............................................................................................................................................12
Symbol overview ...............................................................................................................................................................12
Menu levels ........................................................................................................................................ 13
Menu ................................................................................................................................................. 13
Menu overview .................................................................................................................................................................13
Set the heating..................................................................................................................................................................14
Extra hot water.................................................................................................................................................................14
Temperatures....................................................................................................................................................................15
Advanced menu .................................................................................................................................. 16
Overview .........................................................................................................................................................................16
Set the heating..................................................................................................................................................................17
Set the desired room temperature......................................................................................................................................19
Time limited settings.........................................................................................................................................................19
Heating season .................................................................................................................................................................20
Heating, maximum operating time for hot water requirement...........................................................................................20
Hot water settings .............................................................................................................................................................21
Timers..............................................................................................................................................................................22
Setting the clock................................................................................................................................................................22
Alarm log .........................................................................................................................................................................23
Access level .......................................................................................................................................................................23
Return to factory settings...................................................................................................................................................23
Deactivate alarm buzzer ...................................................................................................................................................23
Program version ...............................................................................................................................................................23
Maintenance....................................................................................................................................... 24
What to do if a fault occurs .................................................................................................................. 26
Dimmed menu display......................................................................................................................................................26
Emergency operation ........................................................................................................................................................26
All alarms and warning windows .....................................................................................................................................27
Technical information.......................................................................................................................... 33
Factory settings.................................................................................................................................................................33
Technical information ......................................................................................................................................................34
Sound levels......................................................................................................................................................................34
Sensor table ................................................................................................................................................. 35

4
Important information
The Greensource is a family of heat pumps, that extract energy from outdoor
air to produce water based heating and, if required, hot water for your house.
The sizes available are 6, 7 and 9.5 kW.
The Greensource heat pump can only be used in conjunction with the
Worcester Greensource hot water distribution unit.
The heating installation is controlled by a control unit, which is in Green-
source hot water distribution unit. The control unit controls and monitors the
total system using different settings for heating and hot water. The settings
are factory set, however can be adjusted to suit the householders require-
ments.
When the heat pump has been installed and started there are a number of
points you should check regularly. This may concern an alarm triggering or
performing basic maintenance actions. Initially you should perform these
actions on your own. This manual describes each step in detail. If the problem
remains you should contact your installer.
This guide contains a description of the Greensource heat pump, what it
consists of, maintenance, settings etc.
Operating instructions for Greensource hot water distribution unit are
described in its own guide.
Important information for the user
Note
It is important as the user that you
read through this guide.
Under no circumstances may you
make settings that are designed for
the installer. This can cause serious
malfunction of the heat pump.
For the user
Only a trained and qualified technician may carry out repairs to this machine. Incorrect repairs
can lead to serious risks to the user, and a reduction in savings.
Visits from an authorised Service representative to make corrections or adjustments after
such a repair, cannot in such cases be carried out free of charge, not even during the warranty
period.
Note

5
How a heat pump works
The heat pump collects heat from the outdoor air
The Greensource heat pump has been manufactured for easy and reliable use as well as
to provide your house with inexpensive and environment friendly heating. The easiest
way to describe how a heat pump works is to say it works like a refrigerator, backward.
In a refrigerator heat is moved from the inside to the outside. In a heat pump the heat, in
the outdoor air, is moved into the house. The heat pump is placed on the outside of your
house. The heat that is in the air, even at temperatures below zero, is converted by the
compressor, heat exchanger and condenser into hot water, which heats your house.
The heat pump will also produce domestic hot water when used in conjunction with the
Greensource hot water distribution unit, which has an inbuilt cylinder for DHW and CH.
There may be very cold days when the heat pump requires additional energy, e.g. at
very low outdoor temperatures. This is obtained from the inbuilt additional electric
heater which is fitted to the hot water distribution unit.
Boiling point in relation to the
pressure
The boiling point of different liquids
varies with pressure, the higher the
pressure, the higher the boiling point.
For example, water boils at +100ºC at
normal pressure. Double the pressure
and water boils at +120ºC. Half the
pressure and water then boils at +80ºC.
The refrigerant in the heat pump acts in
the same way, the boiling point changes
when the pressure changes. However,
the boiling point of the refrigerant
is as low as approximately -40ºC at
atmospheric pressure. Consequently,
it is also suitable for low heat source
temperatures.
Note
Technology in and around the heat pump
The heat pump consists of four main parts:
1. Evaporator
Evaporates the refrigerant to gas and at the same time transfers the
heat from the air to the refrigerant circuit.
2. Condenser
Condenses the gas to fluid again and releases the heat to the heating
system.
3. Expansion valve
Lowers the pressure of the refrigerant.
4. Compressor
Increases the pressure of the refrigerant.
These four main parts are linked in two closed circuits. A refrigerant
circulates in the heat pump, which in some parts of the circuit is in a liquid
state and in other parts in a gas state. Read more about the properties of the
refrigerant in the sidebar to the right.
See the detailed description of the technologies used in the heat pump on
the next page.
How a heat pump works

6
The route of the refrigerant through the heat pump in heating mode
In the outdoor unit, the refrigerant meets the outdoor air in the evaporator (heat exchanger). The air is drawn
through the evaporator by a fan located on top of the heat pump. The refrigerant, which was previously in a liquid
state, will evaporate in this process. The pressure is low and heat is required. Heat is taken from the outdoor
air. A sensor in the expansion valve (6) ensures the evaporator utilises as much of the "free energy" as possible
before the refrigerant (in a gas state) is led into the compressor.
The compressor increases the pressure of the refrigerant. The temperature of the vapour reaches approximately
+100ºC. The warm gas is then led into the condenser.
The condenser is the heat pump’s heat emitting part. In the condenser, which is a fully brazed heat exchanger
in stainless steel, the refrigerant (gas state) meets the water from the heating system (radiators and floor coils).
When the warm gas is cooled by the circulating heating water, it changes into a liquid state (condenses). Energy
is emitted in this process to the heating system or the hot water. After the condenser, the refrigerant, which is
now in liquid form, continues through a drying filter.
The drying filter is used to collect any moisture in the system. After the filter, the refrigerant passes through a
sight glass.
The sight glass is used to check the level in the system. There should be no bubbles in the sight glass during
normal operations. However, there might be bubbles when the heat pump is started and stopped or during
defrosting. After the sight glass, the refrigerant continues on to an expansion valve.
The refrigerant pressure is lowered in the expansion valve. This also causes the temperature to drop. When the
refrigerant has left the valve and passes the evaporator it changes to vapour again. This completes the refrigerant
circuit. The expansion valve is equipped with a sensor (bulb) just before the compressor. The sensor controls the
amount of fluid entering the evaporator.
1
2
3
4
5
6
1
2
3
4
5
6
Heat transfer fluid out.
Heat transfer fluid in.
Refrigerant flow in heating
mode.
Refrigerant flow in defrost
mode.
Service
connec-
tion
Non-return
valve
Suction accumulator
Bulb
Pressure
switch
low
Service
connec-
tion
Pressure
switch
high
4-way valve
How a heat pump works
Service
connec-
tion

7
Component parts of the heat pump
Greensource A/W heat pump 6, 7 and 9.5 kW
Both the control and the additional electric heater is integrated in the Greensource
hot water distribution unit.
The heat pump is installed outside, the hot water distribution unit is installed
indoors.
Component parts of the heat pump
Greensource outdoor A/W unit
Control
panel
Hot water distribution unit
Hot water
heater

8
Control unit Rego 800
The control unit makes sure the heat pump gives the best energy savings
and that it runs for many years. The control unit controls and monitors the
heating and hot water supply in your house. The monitoring function is es-
pecially important, it shuts down the heat pump in the event of operational
disturbances so that no critical parts are damaged.
Additional heat gives more output
Additional heating is required when the heat pump is unable to meet the
heating requirements or when it has stopped due to an outdoor temperature
that is too low. The additional heat is provided by an additional electric
heater inside the hot water distribution unit. Note that when the heat pump
is running, the hot water distribution unit only supplies the heat that the
heat pump cannot produce. When the heat pump is once more able to meet
the heating demand, the additional electric heater is automatically switched
off.
Hot water is given priority over heating water
In a house with water based heating a difference is made between heating
water and hot water. The heating water is for radiators and underfloor coils
and hot water is for showers and taps.
The heating water passes through the hot water cylinder’s outer shell and
heats up the hot water heater’s inner tank. The control unit makes sure the
heating of hot water is given priority over the heating of the heating water.
Control unit
Automatic defrosting
Ice may form on the evaporator at outdoor temperatures below +3ºC. When
ice forms to an extent that it obstructs the air flow through the evaporator
automatic defrosting starts. Defrosting is controlled by a four-way valve.
The valve reverses the flow of the refrigerant in the circuit so that the hot
gas melts the ice on the evaporator fins. See Refrigerant flow in defrost mode
in the figure under the heading How a heat pump works.
There is also a fan defrost function, which means that hot air blows upwards
through the fan to prevent it freezing solid.
Heating
water
Hot water

9
The control unit’s operating mode
When a heat pump is installed, it is already factory set to operate when
both units are connected. However, the settings can be adjusted to suit the
housholders requirements.
Heat pump with Greensource hot water distribu-
tion unit
When the heat pump is used with the Greensource hot water distribution
unit, the control unit sets itself for this operation. This means that the heat
pump operates with additional heat from the hot water distribution unit and
that the hot water is produced in the hot water distribution unit´s hot water
heater. A sensor located on the outside of the house sends information
about the outdoor temperature to the control unit. The control unit controls
heating and hot water production based on the read off current values and
the set values.
Control unit

10
The control unit’s control method for
heating
The control unit controls heating production based on an outdoor sensor or
an outdoor sensor in combination with a room sensor.
Control with an outdoor sensor
Control with an outdoor sensor is the most common method used by
the control unit to control the heat pump. A sensor is mounted on the
external north face on the wall of the house (the wall that is the coldest
and subjected to the least amount of sun). The sensor sends signals to the
control unit in the heat pump. Control with an outdoor sensor means that
the heat pump automatically regulates the heating in the house depending
on the outdoor temperature.
You are able to determine the temperature of the heating system, in relation
to the outdoor temperature, with the help of a number of settings (curves)
stored in the control unit. The curve indicates the flow temperature for
heating water in relation to the outdoor temperature. Selecting a lower
curve gives a lower flow temperature and therefore higher energy savings.
Control with an outdoor sensor and a room sensor
Control with an outdoor sensor supplemented with a room sensor means
that you also place a sensor in a reference position inside the house. This is
connected to the heat pump and provides the control unit with information
about the current room temperature. The signal affects the heat curve’s
flow temperature. For example, it falls when the room sensor shows a
higher temperature than the one set.
A room sensor is used when factors other than the outdoor temperature
influence the indoor temperature of the house. For example, this can be
when a stove or fan-assisted radiator is used in the house, or if the house is
sensitive to the wind or exposed to direct sunlight.
It is only the room where the room
sensor is located that can influence
regulation of the temperature.
Note
Control unit

11
Control panel
Control panel
All settings are made in the control panel and any alarms can be
viewed in the panel. The control unit is controlled via the panel in
accordance with your requirements.
When the heat pump is combined with the hot water distribution
unit, the control panel and control unit are in the hot water distribu-
tion unit.
Menu dial
Switch
(ON/OFF)
Menu
window
Status LED
Status LED
The control cabinet’s status LED is on the outside of the unit.
LED lights green: Switch ON/OFF in ON position.
LED flashes green: Switch ON/OFF in OFF position.
LED not lit: No voltage to control unit.
LED flashes red: An alarm has been triggered and the alarm has not
been acknowledged.
(See section What to do if a fault occurs.)
LED lights red: A fault has occurred. Contact the installer.
(See section What to do if a fault occurs.)
Greensource hot water distribution unit

12
Control panel
Menu dial
The menu dial is used to navigate between the menus and to confirm your
selection. You are also able to determine the values of different settings by
using the dial. If, for example, you turn the menu dial clockwise the value
will increase. Always press the menu dial to confirm your selection.
Power switch (ON/OFF)
You start and stop the heating installation using the power switch button.
Menu display
The menu display gives you information and several settings options.
You are able to:
Select different temperatures for heating and hot water.
Select time control settings (different heat at different times).
See alarm causes and receive corrective instructions.
How to use the control panel
Navigate the menus using the menu dial. Turn the menu dial clockwise to
move down through the menus. Turn the menu dial anti-clockwise to move
up through the menus. When the desired menu is highlighted, press the
menu dial to confirm your selection.
Certain functions have longer names than available space in the menu
window. In such cases, the row switches to show the different parts of
the text. Example: Room temperature setting: First, Room temperature... is
displayed, this then goes out and ...setting is displayed for a few seconds,
whereupon Room temperature... is displayed again. At the top and bottom
of each sub menu there are back arrows that take you back to the previous
menu. Press the menu dial when these are marked.
Back arrows
Symbol overview
Symbols for different functions and components that are
in operation are displayed in the lower part of the menu
window.
Compressor
Hot water mode
Fan
Hot water peak
Additional heat
Extra hot water
Holiday operation Alarm
Timer Control Power guard
Heating mode

13
Menu overview
=The menu display is only shown in
combination with an extra sensor or in a
specific operating mode.
Menu
The initial menu in the control unit is called Menu. Here you will find the
functions most frequently used and the ones you have the most benefit of.
The functions available in your heating installation are shown in Menu. For
example, either Temperature increase/decrease or Room temperature setting
(if you have a room sensor) is shown. Extra hot water is only displayed if
you have a hot water heater connected.
Menu
Menu levels
The menus are divided into different levels for different purposes.
Menu Customer level, here you will find the most common functions.
Advanced menu Customer level, here you will find further functions.
Installer/Service Installer/Service level, relevent settings are made here by the installer/service technician.
As a user of the heating installation, you only see what is available in the two customer levels.

14
Set the heating
There are two ways to set the heating level depending on whether the
heating installation is supplemented with a room sensor or not.
Setting the heating, room sensor not installed:
Select Temperature increase/decrease in the menu. Select one of the
following alternatives:
++ Much warmer (approximately +1ºC)
+ Warmer (approximately +0.5ºC)
= Unchanged temperature
− Colder (approximately 0.5ºC)
−− Much colder (approximately -1ºC)
Then press the menu dial. Select Save to confirm your selection.
Setting the heating, room sensor installed:
1. Select Room temperature setting in the menu.
2. Enter the desired room temperature. Min = +10ºC, max = +35ºC.
3. Select Save to save the change or Cancel to return without saving.
Under Advanced menu you can change how much the room sensor is to
affect the heating system, see Set the desired room temperature.
Extra hot water
With the hot water distribution unit you can temporarily increase the tem-
perature of the hot water to approximately 65ºC, via the function Extra hot
water. A higher water temperature gives more hot water when, for example,
several people wish to shower. The heat pump uses the additional electric
heater to increase the temperature to 65ºC.
In Extra hot water you choose how long the function should be active. This
is what to do:
Select Extra hot water in the menu. Turn the dial clockwise to increase the
number of hours and reduce by turning it anti-clockwise.
Select Save to save the setting or Cancel to return without saving.
To find out how much time remains until the Extra hot water function
switches off, go to Timers under Advanced menu. You can also change the
number of hours during an ongoing Extra hot water function.
Menu
You should wait at least twenty-four
hours when increasing or decreas-
ing the heating before making a new
adjustment.
Note

15
Menu
Temperatures
There are several different temperature sensors connected to the heating
installation. Each sensor plays an important part in the heat pump's daily
operations. The current temperatures for the sensors which are most
important for controlling heating and hot water production are given under
Temperatures.
Select Temperatures in the menu.
The menu display shows the current temperatures for the following
temperature sensors:
Flow sensor (T1)
Shows the temperature in the heating unit’s flow temperature, i.e. the
temperature of the heating water that is fed into the heating system.
In the example, the sensor shows 32ºC.
Outdoor sensor (T2)
Shows the outdoor temperature. Some deviation may occur due to
thermal radiation from the house to the installed outdoor sensor.
In the example, the sensor shows -2ºC.
Hot water sensor (T3)
Only shown when there is a hot water heater installed. The sensor
shows the temperature in the lower section of the outer container in
the hot water heater. The temperature is approximately 5ºC lower than
the temperature of the hot water inside the inner container.
In the example, the sensor shows 50ºC.
Room sensor (T5)
Only shown if a room sensor is installed. The menu shows the
temperature in the room where the sensor is installed.
In the example, the sensor shows 20ºC. The values for V and H are also dis-
played in the window. In the example,
V is 20.0ºC and H 55.2ºC. V and H are
described under Set the heating.
Note

16
Advanced menu
Advanced menu
The initial menu in the control unit is called Menu. In this menu you will
find the functions most frequently used and the ones you have the most
benefit of. In addition, there are extra functions that can be used to affect
your heating installation. These are provided in the Advanced menu. To the
right you will find all functions under Advanced menu.
To access Advanced menu press the menu dial and keep it pressed in for at
least 5 seconds.
Overview
=The menu display is only shown in
combination with an extra sensor
or in a specific operating mode.
Advanced menu
•Temperature
•Hot water
•Timers
•Setting the clock
•Alarm
•Access level
•Return to factory settings
•Deactivate alarm buzzer
•Program version

17
Advanced menu
Set the heating
The simplest way to set the heating has been described earlier under
the heading Menu. There is a more controlled way of setting the
heating. However, before we explain how to do this it is important to
understand the relation between the outdoor temperature and flow
temperature . The easiest way to explain the relation is by a Heat curve.
Heat curve
The heat curve is used to set the desired indoor temperature. The heat
pump is controlled by the outdoor temperature. When the weather
becomes colder the heat pump ensures more heating is produced
automatically.
The following example shows that an outdoor temperature of –2.5ºC
gives a flow temperature of 35ºC at the current heat curve.
Flow temperature:
The flow temperature is the temperature of the water that is fed into the
heating system.
Outdoor temperature:
The outdoor temperature determines how much heating the heat pump
should produce. The outdoor sensor sends signals to the control unit,
which then affects the heat pump.
Curve slope:
By offsetting the left (V) and /right (H) end points, the slope of the heat
curve can be altered. Use the left end point to adjust the flow tempera-
ture at high outdoor temperatures and the right end point to adjust the
flow temperature at low temperatures.
Adjusting a single value:
You can also adjust a single value on the curve up or down every fifth
outdoor degree. You can, for example, create an increase in the heat
curve at 0ºC.
Outdoor tem-
perature (ºC)
Curve slope
Flow temperature (ºC)
On delivery of the heat pump, the
curve slope is set at V=20, H=55.2.
Curve slope:
V=22, H=30: Normal basic setting for
underfloor heating in concrete.
V=22, H=35: Normal basic setting for
underfloor heating in wooden joists.
V=20, H=55: Normal basic setting for
radiators.
V=20, H>65: Abnormal high setting.
Note

18
Set the heat curve
1. Select Heat curve in the menu Heating system temperature. The current
curve is shown here. The value 32.8 is the flow temperature at 0ºC.
2. Start by finding the value you wish to change. It can be V, H or some
other value. To find the correct value, turn the dial clockwise or
anti-clockwise. At the top of the display, various outdoor temperatures
with corresponding flow values on the curve are shown, at the bottom,
a dash can be seen that shows the position on the outdoor temperature
axis. Continue turning the dial and you will eventually find the H value.
Continue turning the dial even when you see a back arrow.
3. The most common adjustment is to increase the H value slightly to
obtain more heating in cold weather. In the display you will see that the
H value has been located and then marked by pressing the dial. The H
value can now be changed by turning the dial. When you are happy with
the H value, press the dial and select Save.
4. It may also be necessary to change a specific value on the curve, e.g. to
increase the heating at temperatures around 0ºC. Turn the dial to find
the value at 0ºC and press the dial to mark the value.
In the example to the right, the value at 0ºC has been changed to 36.8ºC,
i.e. the flow temperature has been increased by four degrees. The dial
has been pressed and Save has been marked. The changed curve is
now saved by pressing the dial.
Recommended values: Increase by 4ºC at outdoor temperature of 0ºC
and by 2ºC at outdoor temperature of +5ºC.
5. To exit the Heat curve function turn the dial until you see a back arrow.
Press the dial.
You should wait at least twenty-four
hours when increasing or decreas-
ing the heating before making a new
adjustment. Only change one value at
a time until you are happy with your
temperature settings.
Note
Advanced menu

19
Advanced menu
Hysteresis
Hysteresis settings can be made under Heating system temperature. The
hysteresis determines when the heat pump (compressor) is to start/stop in
relation to the heat curve’s value. The compressor continues slightly longer
than according to the curve and starts again when the flow temperature has
dropped somewhat below the value of the curve. In this way, the heat pump
is prevented from starting and stopping continuously.
There is usually no reason to adjust the hysteresis factory settings.
Set the desired room temperature
If a room sensor is connected to the heat pump you can set the required
temperature in the room from the Room sensor settings menu. This is carried
out in the same way as in Menu (initial menu).
You can also set how much the sensor is to affect the heating system by
selecting Room sensor influence and adjusting the Change factor. Min = 0,
max = 10. A higher factor gives a greater influence from the room sensor.
After a heat lowering period, e.g. time control or holiday, the room sensor
influence is blocked for a set time, factory setting is 4 hours. Min = 0 and
max = 24 hours. The function Blocking time is under Room sensor influence
and means that the heat pump is given time to increase the flow tempera-
ture more slowly than if the room sensor is allowed to influence.
Time limited settings
Time control
The Time control heating function can be used to lower or increase the
temperature on different week days at chosen times.
1. Select Time control heating in the menu Time limited settings under
Temperature.
2. Select Day and time.
3. Enter the week day and the time at which time control is to occur.
Select On.
4. Select Save to save the change or Cancel to return without saving.
5. Select Change in temperature and set the desired value.
Min = -20ºC, max = +20ºC.
6. Select Save to save the change or Cancel to return without saving.
To remove a time control setting, find the desired setting and select Off.
Time control is not recommended
in normal conditions as it can affect
consumption negatively.
Note

20
Advanced menu
Holiday
Using the Holiday function, you can reduce (or increase) the temperature
between two set dates.
1. Select Holiday in the menu Time limited settings under Temperature.
2. Select the start date and end date according to year-month-day.
3. Select Save to save the change or Cancel to return without saving.
4. Select Change in temperature and set the desired value. Min = -20ºC,
max = +20ºC.
5. Select Save to save the change or Cancel to return without saving.
To cancel the function and remove a time setting, go to Holiday and change
the end date.
Heating season
The Heating season function means that the heat pump only produces
heating water when the outdoor temperature drops below a preset tempera-
ture. The preset temperature, Heating season limit, can be adjusted (factory
setting 18ºC, min = 10ºC, max = 35ºC), as can the delay before activation
(factory setting 4 hours, min = 0, max = 24 hours). The delay means that
the heat pump does not need to switch off and on as often when the outdoor
temperature is close to the limit value.
By increasing the value to above 35ºC the heat pump is set to continuous
heating season mode.
There is also an adjustable Direct start limit (factory setting 10ºC,
min = 5ºC, max = 17ºC) that means that the delay is ignored. Heating pro-
duction starts immediately when the temperature drops below the set value.
Heating, maximum operating time at hot
water requirement
This function is provided to satisfy hot water requirement during heat pro-
duction, when a hot water heater is fitted. The factory setting is 20 minutes,
min = 0 and max = 60 minutes.
If base heat is required, e.g. in cellars,
it may be suitable to increase the
Heating season limit value.
Note