WORCESTER GREENSOURCE
Contents
1. Trassportimg and suu eee 8 Positioning the heat Duspa 8 Minimum and maximum working temperatures 9 9 9 Different methods of hedhin Control 4s ied eti et e dese E SEE De frosting method sos ss Location ofthetemperature Sensors saei e IRE PIED 9320 32223 added AE is 10 Dimensions clearance and plumbing connect ons 13 Greensource Air to water heat bump 0010000 13 Hot water distribution unit MILER VUE se ete or a ka w A N aa Connecting to the heating system 15 Fitting the 15 hard water reas ESSE T AE Eais 15 Flushing the heating 18 Connecting the heat pump HWDU and heating system n rra 18 Pump diagram Available pump 18 Princtple method OF oberatioW ne tei eerte si ree eri e Pee Leva eee ark hus ese eye desse aureo emu p eese cure E 19 Filling the heating Sytem ES etate eere nee etie iter d preste Po e aei ro P eet eerte penne s s 20 Connecting to the power supply 20 Isolation switch and residual current deu2. 230V 1N 0 G2 To protect the heat carrier pump G2 during stand alone operation of HWDU it is not connected from the factory If the heat pump is to be used G2 is connected with the quick connector in the distribution box T2 Outdoor sensor T5 Room sensor It is recommended that a separate residual current device is fitted to the heating system 24 External connections External connections Greensource heat pump Power supply Connect to terminals L1 N and PE CANbus A Warning Communication cable between the heat pump and HWDU Connect to terminals GND CANL CANH and 12V See more under section Do not mix up the 12V and CAN CANbus bus connections If 12V or other incorrect voltage is supplied to the CANbus contacts the processors in the CANbus are destroyed CANbus 2 8 8 8 ES a CN gt pe EE 230V In N Dot uis az 25 External connections External connections Greensource HWDU Power supply Connect to terminals L3 N and PE CANbus Communication cable between the heat pump and HWDU Connect to terminals GND CANL CANH and 12V See more under section CANbus T2 Outdoor sensor Connect to terminals Ai2 and GND T5 Room sensor Connect if room sensor influence is required Connect to terminals Ai4 and GND 230V In N Do1 LOL 26 PX Do not mix up the 12V and CAN bu
3. A A Change in temperature Holiday A ADate A Change in temperature Heating season A Heating season limit A Interval Start time _ Stop temperature Hot water temperature T3 Start temperature _ T9 Stop temperature T8 Stop temperature _ Hot water maximum operating time at heating requirement Time control hot water Temperatures Correct sensor Defrost settings NT12 T11 settings A ATime for reached temperature differ ence A Delay ADifference at 10 C A Direct start limit A _ Difference at 0 C Heating maximum operating time at hot water requirement AShut down protection change over hot water to heating 40 _ Difference at 10 C Maximum outdoor temperature T11 Maximum temperature AMaximum time ADelay after compressor start Minimum time between defrosts Compressor pressure equalisation time M way valve pressure equalisation time _ Forced defrost A Heating cable time after defrost Advanced menu Fan defrost Level F value Advanced menu Mixing valve settings Technical information A Fan defros
4. Checklist The following checklist will give you a general description of how the installation should be carried out Position the heat pump on a solid base Install the incoming and outgoing pipes for the heat pump Install the drainage pipe for the heat pump Fit the filter valve Install the incoming and outgoing pipes for the HWDU Install the waste water hose for the HWDU Install the unvented kit and inlet control group external to the unit Connect the heat pump and HWDU 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 SO GOS OPT iz Oe BO What the delivery includes What the delivery includes The following components are included in the delivery of the heat pump and HWDU Ec CO Rubber feet Quantity 4 Outdoor sensor T2 GT2 with cable Quantity 1 Room sensor T5 GT5 with cable Quantity 1 Circlip pliers Quantity 1 DHW expansion vessel Quantity 1 Expansion vessel hose Quantity 1 Wall mounting kit for expansion vessel Quantity 1
5. WORCESTER GREENSOURCE 6 kW 7 kW amp 9 5 kW EAT PUMP WITH HOT WATER DISTRIBUTION UNIT OS OSS SS OUOGQDCGCOUX OG QOOOOOOOOO QOOOOOOOO 00100100000 OOOOOOQOCCG OOOOOOOOO OOOOOOOOQO COOOOOOOOO OOODQOCOOOCOCO INSTALLATION MANUAL WORCESTER pne N Bosch Group Ben 11701 A 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 amp 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
6. Sensor heat transfer fluid in Sensor condenser temperature Sensor refrigerant temperature evaporator Sensor air temperature evaporator Greensource Air to water heat pump 10 Hot water distribution unit General CANbus 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 wasa The CANbus cable must be screened and laid separately from t
7. mately 120 minutes 27 Menu overview Menu overview Here you find the upper levels for all functions under Menu and Advanced menu All setting functions can also be found in the table Factory settings see Technical information Menu Start up D Setting the clock I S Connected extra sensors I S Connection capacity I S Manual operation I S Additional heat options I S Language I S Correct sensor I S Fan defrost interval I S Fan defrost time I S Forced defrost I S Block crankcase heater at high outdoor temperature I S Anti jamming mode time I S Alarm buzzer signal length I S T1 Set point value maximum I S Display I S Room temperature setting T5 K Temperature increase decrease no T5 K Temperature increase decrease T S settings no T5 E Limit value for V or H Much colder warmer change Colder warmer change Temperatures E 28 Advanced menu Temperature Hot water Temperatures Defrost settings Timers Additional heat settings Heating system temperature Room sensor settings T5 Time limited settings Heating season Heating maximum operating time at hot water requirement Shut down protection change over hot water to heating Compressor working area settings Extra hot water Hot water peak Hot water temperature Time control hot water Hot water additional heat Shows temperatures inputs outputs Correct sensor T12 T11 settings Maximum outdoor temperat
8. which cannot absorb moisture Venting valves must be provided on the pipes Short outdoor pipes reduce heat losses Pump diagram Available pump head kPA Diagram Pump for heating system G1 60 50 2 40 2 o o 30 o 20 a 2 Pos 3 gt 10 lt h 7051 Pos2 0 T T T T T T T T T T T T T T T T 0 500 1000 1500 2000 0 0 139 0 278 0 417 0 556 Water flow 1 and 1 5 Connecting to the heating system 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 wa
9. 240 mm Insu lated wall Dimensions clearance and plumbing connections Pipe connections HWDU front view 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 622 CW and HW Clamping ring connection mm 622 To from connections Clamping ring connection mm 2022 inthe HWDU Clamping ring connection mm 628 nthe heat pump Hot water Cold water Waste water drainage mm 632 in both View connection area HWDU seen from behind 2 To the heat pump Connect to 2 in the heat pump picture Return heating system 1 From the heat pump Connect to 1 in the heat pump picture 558 347 194 Flow heating syste 300 HWDU top view 420 43 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 a
10. Filling loop with valve Quantity 1 Valve with filter Quantity 1 Literature pack User manual Greensource Heat pump User manual Hot water distribution unit Installation manual Guarantee card Blending valve Quantity 1 Flexible connection hose Quantity 2 High flow rate inlet control set Quantity 1 Acetal tundish Quantity 2 1x factory fitted 22 mm x1 1x15mmx22mm Waste coupler Quantity 1 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 0 C The heat pump must not be stored at temperatures below 0 C Positioning the heat pump m 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 E See more information under the heading Technical information Sound levels m 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 Note m The heat pump produces condensation in n
11. The function affects the window contrast and brightness On delivery the max rightness UE setting 10 is set on both Alarm during start up During start up there may be an alarm regarding Low temperature in condenser The cause is that the filled water is too cold colder than 5 C Check the sight glass inside the heat pump Bubbles may appear in the sight glass for a few minutes during start up The bubbles should then stop If it bubbles continuously this is a fault symptom which is probably due to insuf ficient refrigerant Sight glass Flow Other settings 90 C Go through the heating and hot water settings in the Menu and Advanced 80 C menu and make the necessary adaptations For example the temperature 70 C settings for underfloor heating must be lower than the factory settings Set ok HH appropriate V and H values A 50 C _ lt In the event of too low outdoor temperature the compressor in the heat 40 C pump is switched off and all heating and hot water heating is via the xc y electric element in HWDU The flow temperature will now be based on the hot water temperature sensor T3 If the H value is set so that it is higher than 55 C the max temperature for NE EE I TS A E cm T3 must be checked and changed 20 C Outdoor temperature To permit higher flow temperatures go to Advanced menu on 1 S level i Select Additional heat settings Def
12. 080 31919 9 doo snqN yD 90 ui pieoq 3In24I9 3se pue 751 u1 uo uonisod wal ul aq 1snu TS 21 bil OLL GL 81 9L dl BOYD sod N vod 206 N Lod N N a 1 la Ul AOEZ 0000 N T Qo NI AOE T1 22 Wiring diagram Wiring diagram Greensource HWDU Display card CANbus de 44 Open eX 13 Close 4 s TIZH 72731 73751 T5ZH To the heat pump ANS CANbus 9 e ele eje e e e U 1 Jumper S1 must be in Term position RT I on the first and last circuit sses board in the CANbus loop 99 El Electric heater 4 5 kW F1 Miniature circuit breaker F21 Overheat protection elecrical heat
13. 45 100 15 33 950 10 25 800 5 19 770 0 15 280 5 11 900 10 9 330 15 7 370 20 5 870 25 4 700 30 3 790 35 3 070 40 2 510 45 2 055 50 1 696 55 1 405 60 1 170 65 0 980 70 0 824 75 0 696 80 0 590 85 0 503 90 0 430 Technical information Supplementary technical information Maximum water supply pressure to the pressure reducing valve 16 bar Operating pressure DHW 3 bar Expansion vessel charge pressure 3 bar Expansion valve setting 6 bar Maximum primary working pressure 2 5 bar Set opening pressure of the combined temperature and pressure relief valve 7 bar 95 C Expansion vessel 19 Litres 3 bar Cylinder reheat times Inner cylinder 151 Litres of DHW Full volume heat up from 15 C to 55 C with a primary flow temperature of 60 C takes 2 hours and 15 minutes Full volume re heat to 55 C after 70 of the cylinders contents were drawn off takes 1 hour and 50 minutes Manufacturer Appliance IVT Industrier AB part of Bosch Thermotechnik GmbH Box 1012 SE 57343 Tran s Sweden Cylinder BoR Pannan AB Bang rdsv 1 SE 95231 Kalix Sweden Important note Only genuine Bosch Thermotechnology spare parts can be used with these products 44 45 Part no 8 716 115 330 Issue a 14658 Issue 1 0 EXCELLENCE COMES AS STANDARD Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 01905 754624 Fax 01905 754619 Worcester Bosch Group is a brand name of Bosch Therm
14. TE EE 42 OVENS NE hereto 43 SENSO TAD OLS S S a a aS S u Co a Se aa u u us lana R Qa u uA a Ss 43 Supplimentary technical 110718000 44 PRODUCT CONTENTS LIST Greensource Heat Pump Components included in delivery Literature pack Rubber feet User manuals Outdoor sensor T2 with cable Installation manual Room sensor T5 Guarantee card 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 OOGOCCOOOOO OOOOOOOOO OOOOOOOOO OOOOOOOOO OODOCGOOUOCDUD OOOOOOOOO COOOOOOOOO OOOOOOOOO OOOOOOOOO0 For the Installer 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 Contents Important information to the installer Checklist What the shipment includes G
15. Temperature increase decrease settings ej T5 ALimit value for V or H I S A State total output 13 5 kW Much colder warmer change I S Compressor mode output limitation 4 5 6 75 kW Colder warmer change I S A Additional heat only output limitation 9 0 13 5 kW Manual operation No Additional heat options Additional heat only Block additional heat Language Selected Correct sensor AFan defrost interval AFan defrost time _ Forced defrost ABlock crankcase heater at high outdoor temperature Anti jamming mode time Alarm buzzer signal length T1 Set point value maximum 39 Extra hot water K Technical information Advanced menu Temperature Advanced menu Hot water AHeating system temperature Extra hot water AHeat curve _ AHysteresis N A Maximum Number of hours _ Stop temperature AHot water peak A A LI Minimum A A _ Time factor ARoom sensor settings T5 ARoom temperature setting A Room sensor influence A A Change factor A A Blocking time NTime limited settings A ATime control heating A Day and time
16. an be corrected here The correction value is stated directly in C Normally one should avoid correcting a sensor The value that is given without correction is most often the correct one Correction of maximum 5 C up or down is possible 32 Connected extra sensors acknowledged vesi 13 17 59 Connection capacity State total nut E Compressor mode Additional o Note For single phase units change the con nection capacity which speeds up the additional electric heater ramp up time anual operation time 4 way value S way valve G2 Heat carrier pump 13 21 43 11 33 41 OYrect Sensor Correct 2 Correct T3 Correct TS Commissioning Fan defrost interval and Fan defrost time Because weather conditions vary from place to place some factory settings for defrosting may need adjustment This particularly applies to locations with high humidity where there is a risk that the fan will ice up Fan defrost means that warm air is blown upwards through the fan The fan defrost function is active when the value Fan defrost interval is between 1 and 10 factory setting is 1 The value 1 states that fan defrost ing will occur at each ordinary defrosting If the value is set to 3 then fan defrost occurs every third defrost Select how long fan defrost should last The factory setting is 1 min Min 1 and max 5 The function is deactivated by sele
17. cting 0 in Fan defrost interval Temperature limit for fan defrost is set to 5 C No fan defrost occurs below this temperature This setting can be changed under Fan defrost in the Advanced menu Forced defrost Forced defrost is used to by pass the timer and temperature conditions for defrost Temperature T11 refrigerant temperature evaporator must be below the set stop level for defrosting Disable compressor pre heater at high outdoor temperature Checked by outdoor sensor T2 When the outdoor temperature exceeds the set value the crankcase heating in the compressor is deactivated The compressor pre heater is active when the compressor is idle and the outdoor temperature is below the set value Factory setting 10 C Min 5 C and max 20 C Anti jamming mode time Hnti Jampinq mode time At the set time each day the circulation pumps G1 and G2 three way valve VXV and fan are run for one minute each provided that they have not been in operation during the previous twentyfour hours Factory setting 2 which means 02 00 Min 0 max 23 Alarm buzzer signal length In event of an alarm the alarm signal is sounded for the set time if the signal is not deactivated The factory setting is 1 minute max setting is 10 minutes T1 Set point value maximum This value is set to max that is 80 C on delivery The value may need to be reduced if only underfloor heating is used 33 Commissioning Pisplay MUT cM r
18. d down Defrost Displays the remaining time before defrosting the evapora tor 35 stra hot water ditional heat start Mixing value control delay Alarm mode delay Compressor start Heating maximum operating time at hot water require ment Displays the remaining time before the maximum time in heating mode is reached if there is a simultaneous hot water requirement Hot water maximum operating time at heating require ment Displays the remaining time before the maximum time for hot water operation is reached if there is a simultaneous heating requirement Heating season change delay Displays the remaining time until the heating season is activated in the heat pump Blocking low pressure switch Displays the time remaining when the low pressure switch is blocked Blocking room sensor influence Displays the time remaining when the room sensor is blocked Hot water peak Displays the remaining time for the hot water peak to be active Hot water peak interval Displays the time remaining to the next hot water peak Advanced menu Alarm functions Functions under Alarm Alarm In al i m Alarmlog Brn NN arning ing m Alarm history E m Warning log 14 02 05 All alarms and warnings are described in the User guide At Customer level you have access to alarm information in the alarm log As installer you can also Delete the Alarm log Read information in Alarm history Read information in Warning
19. d to the menu windows The selected language automatically becomes the factory setting that is is not changed by Return to factory settings To change language go to Language under Start up 3 Electrical connection 230V 400V Check that the correct voltage is set to 230V 4 Size of heatpump 6 11 kW 12 17kW Check that the correct size is set to 6 11kW 5 Select Setting the clock Select Set date to adjust the date yy mm dd if it is not correct Select Set time to adjust the time if it is not correct 6 Activate the installer and service menu see Installer and service menu 1 5 Start up When you have entered the access code and are in Menu select the function Start up All functions to carry out the basic settings for the heating installation are gathered in this menu Carry out go through these in turn Setting the clock See Start the heat pump 31 La i BUTS English Francais Horsk zu 400 ednesday 85 17 05 Set time E1 13 34 enu Fast restart of heat a No toom temperature EINE Extra hot water 013 Temperatures Start up Setting the rinr 1118180 extra Sensors Connection capacity Manual operation Additional heat options Commissioning Commissioning Connected extra sensors Yes must apply for T5 acknowledged when room sensor T5 is used Connection capacity Important and must be changed State total output Setting of total connected output on the additio
20. eneral 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 M 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 Important information to the installer Checklist Important information to the installer This manual gives you all the information necessary to install the heat pump Note and HWDU The guide is divided into several parts in the order in which installation and commissioning must be carried out T Only qualified installers may carry out the installation The installer must follow applicable rules and regula Before staring the installation tions and recommendations from the manufacturer B The heat pump may be temporarily tilted with the compressor downwards It must never laid down or transported horizontally See Transport and storage m Check that the plumbing connections in the heat pump and the HWDU are intact and have not shaken loose during transport m Before the commissioning the heating system must be filled up and A Warning completely vented For reasons of safety the main power supply must be disconnected before working on the heat pump and HWDU
21. er F31 Electronic anode in hot water heater G1 External pump for heating system for use with Primary store G2 Heat carrier pump Q1 Three way valve Q2 Three way valve Q3 Mixing valve E1 S1 Termination switch S2 Switch emergency operation LL Sensors L3 L2 L1 N N T Emergency thermostat T1 Sensor flow heating system T2 Outdoor sensor J 4 T3 Hot water sensor T5 Any room sensor accessory T T99 Emergency operation sensor 230V 1N HENS SURE 23 Wiring diagram Terminal diagram Greensource heat pump HWDU HWDU Pays aaa a 5 i i i i i i i i I IOB CPU i i i lalalalmfal laluja e e gt a lz z quee PPEP ese z 3 313318 553 T T I 1 1 i pg i i HF i o E Sibi cic ei 4 lj Leg M M N MW T2 T5 G2 x CANbus Heat pump Dok on the incoming supply to I I I I Measurement transformers I I I the house fuse box zi T Isolation switch not included Fusing Greensource 6 kW 16A Greensource 7 kW 25A Greensource 9 5 kW 25A HWDU 25A
22. g trapped gulley 16 Connecting to the heating system Maximum length of Deduct the figure below from the straight pipe maximum length for each bend or no bends or elbows elbow in the discharge pipe Size of discharge Size of discharge pipework D1 pipework D2 15mm lt G3 gt 4 22 mm Valve outlet size u 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 Startthe siphon effect by pumping or sucking at the drain end of the hose 6 Letthe whole volume drain out How to flush the system amp 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 17 Connecting to the heating system Flushing the heating system It is important that all previou
23. he power cable to prevent interference in the CANbus communication A 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 JN 2 22252225 Oza vS5 9989 i Tas HA 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 11 Handle the circuit boards with great care They are sensitive to ESD Elec trostatic discharge which can cause faults in electronic components General Components identification Hot water distribution unit Mixing valve Pressure gauge Heat carrier 0 5 1 5 bar pump G2 Pipes to and from the heat pump are con nected at the back Three way Three way Pump for heat
24. ice 21 pU ERREUR 21 Wiring diagram Greensource heat bumb iita 22 Wiring diagram Greensource AW DU Llu uere SRE 23 Terminal diagram Greensource heat pump 18111 Z4 External connections Greensource heat 25 External connections Greensource HWDU WR dS RS ERU X 26 Installer and service menu I S 27 Ment OVERVIEWS eS SELES oO otarLihe heat DUMD 5 usss usnu a Gum OE RETO DO GU SE 31 RAT PEE d ea ees 31 Other AMT RR 34 Important points to check after comwmissioning r 34 P SS Alarm functions ETAT Technical information u o to eo se ev eee aeu no Ce ee a n Yo Se ae aeo se sea ve anos ase Factory settings iR 39 Teehmicalinormahion SSE TE E
25. ing valve valve system G1 Heat pump Manual air vent Service connection Sight glass Four way valve Condenser Expansion valve Low pressure switch Non return valve Drying filter Service connection High pressure Compressor switch 12 Dimensions clearance and plumbing connections Dimensions clearance and plumbing connections Greensource Air to water heat pump outdoor Left hand side Front OOOOOOOOOO Back Condensator drain Cable entry 1 Flow to HWDU 2 Return from HWDU 101 165 201 m 640 820 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 105 220 411 M Note The waste coupler must be fitted to the condensator drain oulet 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 Y ZWZZIVZZVZZI Min 600 mm 2d NS wall Front HWDU Min 25 mm EN 13 Min space 1
26. ing surface This means that the flow temperature is kept low After testing vent the heating system again and top up with cold water if necessary See Filling the heating system 34 Advanced menu Timers There are a number of timers in the control unit The status for these are shown in the menu Timers Extra hot water Displays the remaining time for requested extra hot water Additional heat start Displays the countdown of the timer for delay of additional heat Mixing valve control delay Displays the time that the mixing valve function is delayed after the additional heat timer has counted down Alarm mode delay Displays the remaining time until the additional heat is activated when an alarm is triggered Compressor start Displays remaining time of compressor start delay Delay before defrost Displays the remaining time before defrosting is permitted T12 T11 reached temperature difference The heat pump regularly calculates the difference between T12 and T11 The result is compared to the set point value which is calculated based on actual outdoor temperature and settings in Defrost settings NT 12 T11 settings Difference at 10 C 0 C 10 C The timer starts when the difference exceeds the set point value and if it lies above the set point value continuous defrosting is permitted to start when the timer has counted down PLEASE NOTE For defrosting to start the Delay before defrost must have also counte
27. k 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 Diagram 1 Typical discharge pipe arrangement 500 para 3 9 metal discharge pipe D1 from temperature relief value to tundish 500mm maximum 300mm minimum metal discharge pipe D2 from tundish with continuous fall See 3 9d i iv Table 1 and worked example safety device e g temperature relief valve tundish Discharge below fixed grating 3 9d gives alternative points of discharge fixed gratin
28. log Delete the Warning log Alarm history Alarm information Alarms are stored in chronological order Turn the menu dial to read off all information about the most recent alarm continuing to turn will show the previous alarms Alarm information consists of a heading and then detailed information about the time temperatures of all sensors and status for each output when the alarm occurred Warning log The alarm log stores alarms in chronological order Deleting Warning log and Alarm log can be appropriate when commission ing has been completed 36 Client Installation address Heat pump description Commissioning report Commissioning date Heat pump serial number HWDU serial number Other components of the installation Outdoor sensor T2 Room sensor T5 Hot water cylinder temperature sensor T3 i 525 os H R R P Points to be checked prior to commissioning Heating system filled O checked L pressurised and vented Electric heater set to 4 5 kW set O checked L1 Filters checked L cleaned O Sight glass green checked L Heating system pump G2 working correctly Heat carrier pump G3 working correctly Temperatures after 10 minutes heating or hot water mode Heat flow out T8 C Heat return in T9 mo Sensor condenso
29. lways 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 14 Connecting to the heating system Connecting to the heating system Fitting the unvented kit Parts to assemble m Expansion vessel High flow rate inlet control set CD Expansion vessel hose Tundish factory fitted Tundish 15mm x 22 mm supplied separately l r Wall mounting kit for expansion vessel Blending valve q CD Filling loop with valve Connection o Note Mount the expansion vessel with the wall mounting kit Connect the The relief valve connections should expansion vessel hose to the expansion vessel not be used for other purpose 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 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 15 Connecting to the heating system Detailed discharge pipe installation requirements The discharge pipewor
30. m Warning TN The hot water cylinder must always be filled and pressurised before the heat ing system is filled After flushing the heating system the hot water cylinder must be filled first and then the heating system can be filled and pressurised The installation must not under any circumstances be switched on without The filling of the heating system is carried out via the supplied filling loop al sited externally to the unit M Itis recommneded that the DHW inner tank is filled and pressurised first Pressure gauge 0 5 1 5 bar 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 A Warning and give false readings on the sensors Handle the circuit boards with great care They are sensitive to ESD Elec trostatic discharge which can cause faults in electronic components 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 20 Isolation switch and residual current device Isolation switch All heating installations must be preceded by a safety switch Residual current device It is recommended that a separate residual current device is fitted to the hea
31. nal heat The factory setting is 13 5 kW Change this to 4 5 kW Compressor mode output limitation Setting permitted output when the compressor is in operation The factory setting is 5096 of the setting in State total output that is 6 75 kW Min 0 25 kW max the value set in State total output Change this to 4 5 kW Additional heat only output limitation Setting permitted output when the compressor is not in operation Factory setting is the setting in State total output that is 13 5 kW Min 0 25 kW max the value set in State total output Manual operation Make a check of all the functions before you commission the heating installation You can manually start and stop the pumps and valves from the menu Manual Operation Select Yes to activate NOTE The function is deactivated by selecting No in Manual Operation Additional heat options Additional heat only blocks the start of compressor and fan Heating and hot water is supplied via the additional heat Block additional heat blocks the additional heat function but not during alarm mode hot water peak extra hot water or operation with additional heat only NOTE Normally this is not recommended Language This allows you to change the language to one other than that selected when the heat pump was first started The selected language automatically becomes the factory setting that is is not changed by Return to factory settings Correct sensor All sensors c
32. ormal 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 The amount of condensation water can amount to 30 40 litres during days of high humidity It is non acidic unit to a suitable drain This will keep the discharge pipe free of frost as air is drawn from inside the house B 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 W 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 Minimum and maximum working temperatures Maximum working temperatures The heat pump can work with a maximum return temperature of approxi mately 59 C 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 62 C This can be changed by the installer to max 70 C If a value higher than 65 C is set a mixing valve must be installed See Commissioning Minimum working temperatures The heat pump stop
33. otechnology Ltd www worcester bosch co uk CONTACT INFORMATION WORCESTER BOSCH GROUP TECHNICAL 08705 266241 SERVICE 0845 7 256206 SPARES 01905 752571 LITE RATURE 01905 752556 TR AINING 01905 752526 SALES 01905 752640 WEBSITE www worcester bosch co uk AANIORCESTER Bosch Group
34. p temperature 55 C ARamp time increase 20 min Ramp time decrease 10 min 41 Return to factory settings Deactivate alarm buzzer Technical information Technical information Output data at 47 35 and 7 45 are stated according to the European standard EN 14511 d aM type fuse D characteristic MCB Both units require a means of electrical isolation 2 Dimensions excl feet supplied min 20 mm max 30 mm depending on adjustment 42 Greensource 6 kW 7 kW 9 5 kW Emitted Supplied output at 47 35 kW 55 1 5 7 1 2 1 8 8 2 3 Emitted Supplied output at 47 45 kW 51 17 6 9 2 5 8 5 2 8 Heat carrier flow nominal l s 0 19 0 29 0 34 Internal pressure drop heat carrier kPa 5 6 7 Air flow m h 2200 2200 2200 Electrical consumption fan A 0 44 0 44 0 44 Electrical supply 230V 1N Fuse size AT 16 25 25 Compressor Scroll Highest outgoing heat carrier temperature C 65 65 65 Refrigerant filling R 407C kg 2 2 3 2 4 HTF connection clamping ring mm Hose 1 inch internal thread Defrost system Hot gas with four way valve Operating temperature C 20 35 Dimensions WxDxH 2 mm 820x640x1190 Weight kg 140 145 155 Outer casing Galvanised enamelled plate Greensource Hot water distribution unit Control unit Rego 800 Out
35. put electric element kW 4 5 Output circulation pump kW 0 2 Electrical supply 230V 1N Max power consumption kW 4 7 Fuse size AT 25 Max working pressure bar MPa 2 5 0 25 DHW volume i 151 CH Buffer volume l 55 Expansion tank 1 12 Overheat protection C 90 Min flow heating system l s 0 Pump for heating system G1 Wilo Star RS 25 6 3 Heat carrier pump G2 Wilo Star RS 25 6 3 Dimensions WxDxH mm 600 615 1660 Weight excluding water kg 122 Weight including water kg 347 Technical information Sound levels Sound pressure level Sound pressure level is defined as the sound level which at an ear level of 1 8 metres is perceived one metre from the heat pump Measured in a sound measurement room without echo at an outdoor temperature of 7 C and 50 C flow temperature Example When the heat pump is installed outside with free sound propaga tion the sound level drops by 6dBa with each doubling of distance Sensor table The table shows all sensor resistance at different temperatures 43 1111 Sound pressure level Lp ear dBa Greensource 6 kW 49 Greensource 7 kW 49 Greensource 9 5 kW 53 Example Greensource 6 kW Distance Lp ear dBa 1 metres 49 2 metres 43 4 metres 37 8 metres 31 Temperature C ko 40 154 300 35 111 700 30 81 700 25 60 400 20
36. r temp T10 CN C Refrigerant temp T11 sasa C Defrost sensor T12 Ne 37 Commissioning report System pressure levels checked Functional test carried out Ensure that primary circuit has been correctly flushed Check fan operation on outdoor unit Check for insulation of pipe work Check that CANbus is fitted correctly Check term switches positioned correctly Check condensation drain operates Electricity reading on the house taken The instructions about how to use the heat pump have been given to the client to the user Documentation about the heat pump has been handed over Date and signature of the installer 38 Technical information Factory settings The table displays the factory values F value of the settings that you as a customer K can change via the customer menus Menu and Advanced menu The functions of Installer Service level I S under Menu and Advanced menu in the table are accessed by the installer after changing the access level Menu Menu Technical information Start up Setting the clock A Set date A ASet time Display _ Contrast A 2110117655 Room temperature setting T5 K AConnected extra sensors Temperature increase decrease ej T5 K A NT5 acknowledged T5 AConnection capacity Electric element
37. rost settings Then select Electric additional heat settings and T3 Stop temperature Factory setting is 62 C You can change this to max 70 C NOTE At settings above 65 C a mixing valve must be installed The Power guard Factory settings table lists all functions which can be changed by the Connection capacity 4 customer and installer Go through the list to see if any other settings need top temperature So LE lO be cb d amp time INCASE E 0 be changed Ramp time decrease 13 42 23 Important points to check after commissioning For the installation to perform at its best it is important to check the flow on the hot side of the heat pump Usually the heat carrier pump has a speed selector switch This must be set correctly for the pressure drop in the system A recommended temperature difference across the heat pump on the hot side is between 5 10 C The nominal flows provided inTechnical information shows a difference of 7 C in operating mode 7 45 C Check this by reading the sensors T9 heat transfer fluid in and T8 heat transfer fluid out When commissioning is carried out at a low outdoor temperature below 0 C the temperature difference should be between 5 C and 7 C When commissioning is carried out at an outdoor temperature above 15 C the temperature difference must be between 8 C and 10 C The flow through the heating system should be sufficient to keep the whole radiator warm and thereby increase the heat emitt
38. s connections If 12V or other incorrect voltage is supplied to the CANbus contacts the processors in the CANbus are destroyed Installer and service menu Installer and service menu 1 5 First read about Commissioning A Warning As the installer you have your own section of menus for settings e g for commissioning and maintenance The installer and service menu I S is only for installers Under no circum The User Guide for the heat pump contains a complete description of how stances may the user access this level the control panel functions and of all customer functions under Menu and Advanced menu Read it before you start A four digit access code is required to access the I S menus This is what to do 1 Press the menu dial for approximately five seconds to get to Advanced menu 2 Select Access level 3 Enter your four digit access code using the menu dial and press the menu dial to confirm The access code is the present date given as two digits for the month and two digits for the date for example 0920 Access service is shown in the display Press the dial to get to Menu Under Menu there are now both customer functions and I S functions To reach Advanced menu press the menu dial for approximately five seconds 4 Return to customer level by selecting Access level in Advanced menu and enter 0000 as access code The control unit automatically returns to customer level after approxi
39. s if the outdoor temperatures falls below approx 20 C 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 20 C 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 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 General General Location of the temperature sensors T1 T2 T3 T5 T6 T8 T9 T10 T11 T12 Flow sensor Outdoor sensor Hot water sensor Room sensor Sensor compressor temperature Sensor heat transfer fluid out
40. 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 1 the requirements of the Water Fittings Regulations 1999 for England and Wales the Water Byelaws 2000 Scotland and the Water Regulations Northern Ireland 2 therequirements of the UK Building Regulations The Building Regulations 1991 England amp 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 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 O 2008 Table of Contents Contents Important information to the installer Checklists see 6 6 What the delivery includes 8 General sss
41. sly 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 M Note the heat pump from contamination Faults in the heat pump can be caused by poor water quality in the radiators ENS cos 1118 st underfloor coils or that air is penetrating the system continuously Oxygen causes follow applicable rules and regula corrosion products in the form of magnetite and sediment which is detrimental to tions and recommendations from the the heat pump components and reduces its working life manufacturer 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
42. t interval A Neutral zone AFan defrost time N NTemperature limit Additional heat settings _ Running time extension IA A Increase signal extension IA ZI Decrease signal extension Start delay NTime control additional heat Additional heat options Additional heat only A Block additional heat Electric additional heat settings Power guard A A Power guard IA A ASupply voltage A A Main fuse A A Display Correction of current transformer A A Current margin A A Time from tripped power guard to possible reconnection A A Time between possible reconnec tions Additional heat maximum temperature MA Mixing valve limitation start temperature IA ZI Mixing valve force close Limitation at temperature increase A Limitation time Setting the clock Set date ASet time Alarm MAlarm log Delete alarm log Warning log Delete warning log Connection capacity Electric element Access level A ZA State total output 13 5 kW A A ACompressor mode output limita tion 4 5 6 75 kW A A AAdditional heat only output limitation 9 0 13 5 kW T3 Sto
43. ter heating is via the built in electric heater Greensource heat pump and HWDU Safety valve Heating system pump Fan 3 way valve 3 way valve Air vent Filter heating system LA Q45 2 E10 Radiator system C11 Expansion vessel i C12 Primary water storage tank T2 G1A Radiator pump ES F42 618 Radiator pump ies reese gauge E ixing valve Y F21 E41 LN P 22 Q12 Isolating valve T5 JA Water outlet Heating system Heat pump Tap water system Expansion vessel Hot water cylinder Hot water Cold water Temperature amp pressure A relief valve Q20 h Isolation valve Pressure reducing valve Non return valve Tundish Heating system flow sensor indoor unit Outdoor sensor DHW sensor V21 Room sensor Hot gas sensor Heat pump flow sensor outdoor unit Heat pump return sensor indoor unit Condenser Evaporator temp Air intake V40 C41 NH Te N T6 age mi Bet W40 gt lt I I E10 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 19 Connecting to the heating system Filling the heating syste
44. ting system Comply with applicable regulations Emergency operation The heat pump is equipped with emergency operation which means that the additional heat takes over the heating production in the event of faults in the control unit Read more about emergency operation in the User Guide There is a thermostat for flow temperature during emergency operation on the AHB circuit board It is factory set to 35 C which is the normal setting for the underfloor heating system If the heating system only has radiators the setting must be increased to 55 C 21 Connecting to the power supply 20 lt 35 sss 55 Ola O j5 ks ot Ole ol Ole O fs 00 0 0 70 Wiring diagram g diagram Greensource heat pump W d Q 10sseJduioo jeduunf T exe JV TTL duo 1018106813 TTL 4959000 OTL urpinjJejsueJ 12H 6L jno piny 19 500 12H 8l seZ 104 1055916000 gl YOUMS 9175596 MO dl uoi s 9 55916 ysIH dH siosu s YOUMS uoneuiuJ9 TS 191185 YOS TM fejoJ jenue1od H 81 AeMinoy g O JosseJduioo 1 0170 1030W TAN 10559160100 TW 10559160000 103261002 TM ueq 9 9719 10 1170110 917811 T4 1105590208 91680 801169 v3 Jojeou 95800810 3 10108680 uny S9 101 8
45. ure T11 Maximum temperature Maximum time Delay after compressor start Minimum time between defrosts Compressor pressure equalisation time 4 way valve pressure equalisation time Forced defrost Heating cable time after defrost Fan defrost Shows timers Start delay Time control additional heat Additional heat options Electric additional heat settings Mixing valve settings Connected electrical capacity shows present value 29 Menu overview l s T S l s 1 6 l s 1 6 l s I S l s I S I S K I S l s 1 6 l s I S l s I S Menu overview Setting the clock Set date Set time Alarm g Alarm log Alarm history Warning log Access level Return to factory settings Deactivate alarm buzzer Program version 30 K I S I S I S K I S K I S K I S Commissioning Before commissioning the heating system must be filled up and completely vented Check that there are no leaks As many radiators as possible should be fully open when connecting to an existing water system When connecting to an underfloor heating system at least half of all the floor coils should be open When connecting a fan assisted radiator system the fans are started first and then the taps on the fan assisted radiators are opened fully Start the heat pump 1 Connectthe mains and press the ON OFF switch on the control panel A language selection window is shown 2 Start by selecting the language to be applie
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