WORCESTER GREENSTORE 6kW, 7kW, 9kW & 11kW System HEAT PUMP GB/IE INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING
Table of Contents BUILDING REGULATIONS ..................................................................................................................................3 For the Installer ................................................................................................ 5 Important information to the installer ................................................................. 6 Technical support ..................................................................................................
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.
PRODUCT CONTENTS LIST 600mm 600mm Greenstore System Heat Pump.
For the Installer Installation of the heat pump should be performed by a qualified installer. This chapter includes a section recommending how the heat pump installer should install, commission and service the heat pump. The installation consists of a plumbing section and an electrical section. These provide technical data such as measurements, wiring diagrams and installer menus.
Important information to the installer / Checklist Important information to the installer This manual provides all the information necessary to install the heat pump. The manual is divided into several sections. The order of these is based on the recommended installation sequence. Use the supplied checklist during installation. Before installation remember: Warning The main power supply must be disconnected before working on the heat pump.
What the shipment includes What the delivery includes The following components are included in the delivery of the heat pump: Rubber feet Quantity: 4 Filling link with insulation and filter Quantity: 1 Return sensor T1 (GT1) Quantity: 1 Cable: 4 m Circlip pliers Quantity: 1 Outdoor sensor T2 (GT2) with cable Quantity: 1 Literature pack User manual Installation manual Guarantee card Cylinder sensor T3 (GT3) Quantity: 1 Expansion vessel Quantity: 1 Room sensor T5 (GT5) with cable: Quantity: 1 Drain
Dimensions and connections Dimensions and plumbing connections The following illustrations show the dimensions of the heat pump and plumbing connections. All measurements are stated in millimetres. ≥ 100 In front of the heat pump a free area of 800 mm is required for installation and servicing. ≥ 400 Required installation space ≥ 100 1500 Allow a side clearance of at least 100 mm on the sides and behind the heat pump.
The heat pump and collector hose in general The heat pump and collector hose in general Transporting the heat pump The heat pump should always be transported and stored in an upright position, never horizontally. 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 heat pump and collector hose in general Collector hose The task of the collector hose is to convey the heat transfer fluid through the ground to gain a few degrees of heat. The hose is a thin-walled plastic hose of type PEM 40 x 2.4 PN 6.3. SDR11. Installation and backfilling around the collector hose Installation of the collector and backfilling the soil around the collector hose should follow applicable material and working descriptions and regulations.
The heat pump and collector hose in general Outline drawings for the collector hose in the ground and through a wall The drawings below show how to run the collector hose in the ground and through a wall. The soil filling around the hose must not contain stones. Collector in the ground 200 mm 800-1000 mm Filling of sand or stone free soil approximately 100 mm around the collector hose. 800-1000 mm Collector, PEM 40 x 2.4 PN 6.3.
The heat pump and collector hose in general The collector hose can be connected to the heat pump with one or more circuits. In a multi-circuit system, the collector pipes are connected in parallel as illustrated below. The parallel pipes are connected to two manifolds. Each coil should have a shut off valve and a flow control valve. The flow control valve is adjusted so that the flow rate is the same in each coil. The coils should have the same length.
The heat pump and collector hose in general Compact collector The following equipment is used for the collector installation: Compression connector Pipe coupling 1 inch BSP Hose pliers Hose welding equipment Fusion weld sleeve Ø40 mm Install the collector as follows: 1. The compact collectors are installed horizontally. The collector should lean with the connection side at least 30 cm above the bottom to aid the venting process. Trench measurements: depth: 1 - 1.3 m, width: 2.5 m.
Connecting the heat pump to the heating system Connecting the heat pump to the heating system It is important that all previously mentioned preparations have been carried out before the heat pump is connected to the heating system. Also ensure the system has been power flushed before it is connected to the heat pump. Flushing protects the heat pump from contamination. Note Only qualified installers may carry out the installation. The installer should observe applicable regulations.
Connecting the heat pump to the heating system Connect heat pump System model to the heating system The built-in control unit controls the heat pump using the outdoor sensor T2 (GT2) and the return sensor T1 (GT1) according to the outdoor compensated control curve. In the unlikely event the heat pump compressor is unable to meet the heating requirements, the electric heater starts automatically and together with the heat pump provides the required temperature.
Connecting the heat pump to the heating system Individual temperature control in each room and increasing volume of internal water This solution is used to control the temperature of each room, for example, where thermostatic valves are used on the radiators in each room. The function of the heat pump is to maintain a temperature in accordance with the heat curve (depending on outdoor temperature) in the 100 litre primary water storage tank.
Connecting the heat pump to the heating system Filling the heating system 1. Open and close the filling loop between the cold water system and the heating system in short time intervals whilst observing the pressure guage. 2. Vent the system and refill to the correct pressure. Filling the collector circuit The collector circuit is filled with heat transfer fluid to be able to collect energy from the ground. A heat transfer fluid consisting of bioethanol or glycol and water is recommended.
Connecting the heat pump to the heating system 2. Fill the filling pump with heat transfer fluid. If mixing the solution on site, pour water first into the filling pump, then anti-freeze liquid. See table 1 and 2 for correct mixture. Hose type: 40/35 Water (l) Anti-freeze (l) Bioethanol 0,71 0,29 Propylene/ethylene glycol 0,65 0,35 Water Anti-freeze Bioethanol 75% 25% Propylene/ethylene glycol 65% 35% Anti-freeze type Example: 200 metres of hose with anti-freeze gives 200 x 0.
Connecting the heat pump to the heating system 7. When the barrel is nearly empty, stop the pump and fill the barrel with more heat transfer fluid. 8. When the system is full and air no longer comes from the return pipe, run the system for at least a further 60 minutes. Use the internal HTF pump to speed up the air venting. Enter manual operation on the heat pump control panel under menu 5.3 and start the circulation pump G3(P3). See Commissioning the heat pump\Manual test run of the heat pump. 9.
Connecting the heat pump to the power supply Connecting the heat pump to the power supply Ensure the electricity has been switched off before connecting the heat pump to the mains. Check that cables and printed circuit boards are intact and connected. Warning High and low current cables should be routed separately in order to avoid interference on the sensors. The electrical installation may only be performed by a qualified electrician. Wiring diagram is supplied with the heat pump.
Connecting the heat pump to the power supply External connections to the heat pump The external connections must be made for the heat pump: Power supply 1-phase: The power supply is connected to terminals L, N, and Earth. Mixing valve on the heating circuit: If a second heat curve with a mixing valve is to be used, the mixing valve is connected to terminal block SV1. External main pump in the heating system G1 (P1): The external main pump must be connected to the terminal block if a bypass is required.
Connecting the heat pump to the power supply Connecting the general alarm and external input General alarm The general alarm is activated irrespective of which alarm has occurred. When a general alarm is required on the heat pump, it is connected according to the diagram opposite. The contact for the general alarm output carries no current and it closes at a general alarm. Connect max 24 V and 100 mA on the contact.
Commissioning the heat pump Installer and service menu (I/S) The controls contain an installer section of menus for settings, e.g. for commissioning. These are accessed from the control panel by holding down the menu button for approximately ten seconds. The menu displays are divided into lines and each display has a number to make it easy to find. If there is no activity for 30 minutes the menu display automatically returns to Customer level 1.
Commissioning the heat pump Commissioning the heat pump The heat distribution and heat transfer fluid circuits should be filled and fully vented before commissioning. Always check that there are no leaks before back filling with earth. If radiators are used, they should be fully open when connecting to an existing heating system. When connecting to an underfloor heating system at least half of all the floor coils should be open.
Commissioning the heat pump 5. Make the necessary settings on the control panel. a. Confirm that external sensors are connected. If T3 (GT3), T4 (GT4) or T5 (GT5) have been connected, confirm these in the control panel so the control unit knows they are installed. The displays presented by the sensors are only shown if the sensors have been confirmed. Commiss./Service Extra sensor/Anode in operation. 5.13 Return Select b. Set the maximum output to be used by the electric heater.
Commissioning the heat pump Commissioning/Ser vice Set when the electric heater should be activated, if necessary. On delivery the heat pump is set to activate the heater when necessary. Choose between yes or no. If no is chosen, the electric heater only engages during alarms, extra hot water and hot water peaks. Commiss./Service Select function add.heat yes/no 5.5 Return Select The Fast restart function avoids having to wait for the normal restart time to start the heat pump.
Commissioning the heat pump Timer readings There are a number of different menu displays to help check the status of the heat pump. The heat pump status is shown by the timer readings in menu 6. Read the electric heater timer The function shows the amount of time remaining before the electric heater is activated. If there is no countdown then there is no need of additional heat. Read the start delay The function shows the time remaining until the heat pump starts again after a previous stoppage.
Commissioning the heat pump Drying program for floor screed Note When the heat pump has been installed in a newly built house with underfloor heating, the Drying for floor screed function can be used. The function is designed to slowly heat up the floor for a set number of days. The temperature is then maintained for a set number of days, finally allowing the floor to cool slowly for a set number of days. The heat pump works during drying operations with the hysteresis set in the display 1.4.
Commissioning the heat pump Start the heat pump with only additional heat It might be necessary to run the heat pump before work on the heat transfer fluid circuit is complete. Start the heat pump with heat from the electric heater only. The heating system must have been filled and vented to run the heat pump with electric heater only. Go to the menu display Select function only add. heat (menu 5.4) and press the Select button. If the arrow points towards Normal operation press the Adjust button.
Maintenance Maintenance The heat pump requires a minimum of maintenance, however, it is recommended that the heat pump is checked annually by a qualified installer. Warning The main power supply must be disconnected before working on the heat pump. Sight glass Expansion vessel Particle filter Only an accredited refrigeration company is permitted to work on the refrigerant circuit. Unscrew the front cover Open the front cover to access some of the maintenance areas, e.g. the sight glass and filter.
Maintenance Filter The filter ensures that no debris enters the heat exchangers. Over time the filter can become blocked and will require cleaning. There are filters on both the primary and collector circuits. To clean the filters: Note On the primary circuit the filter is fitted inside the heat pump. 1. Disconnect the heat pump from the mains electricity supply. 2. Close the valve and unscrew the sealing cap. 3. Remove the circlip holding the filter in the valve using the circlip pliers supplied. 4.
What to do if a fault occurs What to do if a fault occurs The control unit has an advanced monitoring system that gives alarms if anything unforeseen happens in the heat pump. Most alarms are rectified by the user without any damage to the heat pump. Contact the Technical support in case of repeated alarms. Technical support Technical Pre & Post sales Tel: 08705-266241 Fax: 01905-752741 Example of an alarm: Time when the alarm occurred.
What to do if a fault occurs Fuses and reset buttons on the heat pump Filter Cleanable, with isolation valve. Fuse 1 Reset for motor cut-out on compressor. Fuse 2 Reset switch for the heat pump’s miniature circuit-breaker. Fuse 3 Reset switch for the electric heater’s miniature circuit-breaker. Fuse 4 Reset button for the electric heater overheat protection. Note: The button must be pressed in firmly. List of all alarms: All alarms There are many reasons why an alarm occurs.
What to do if a fault occurs Motor cut-out compressor (MB1) Possible cause 1: Action: Intermittent fault or overload on the power supply. 1. Press the Ackn. button. The alarm indication goes out even if the fault has not been rectified. 2. Reset the motor cut-out on the heat pump (Fuse 1). 3. Wait for the heat pump to start. Possible cause 2: Current level (A) on the motor cut-out is set too low. The current drawn by the compressor varies during summer/winter operations. Action: 1.
What to do if a fault occurs The menu display shows: Compressor temperature T6 (GT6) Possible cause 1: The working temperature of the compressor is too high. Action: 1. Press the Ackn. button. 2. Contact the Technical Support Department at repeated alarms. ALARM (GT6) Compr. superheat 060822 16:08:15 Info Ackn. Possible cause 2: Intermittent temperature rise due to abnormal operating conditions. Action: 1. Press the Ackn. button. 2. Monitor to see if fault clears.
What to do if a fault occurs High pressure switch (HP) Possible cause 1: Insufficient primar y flow over the heat pump. Action: 1. Press the Ackn. button. 2. Check that the heating system pump has not stopped. 3. Check that all the valves are open. Radiator thermostat valves should be fully open and underfloor heating systems should have at least half of the coils fully open. 4. Possibly increase the speed of the heating system pump. ALARM (HP) High press. switch 060822 16:08:15 Info Ackn.
What to do if a fault occurs High Heat transfer fluid delta T8/T9 (GT8/GT9) The heat pump gives an alarm when the temperature difference between the sensors T8 (GT8) and T9 (GT9) is too high. Possible cause 1: Insufficient flow over the heat pump. Action: 1. Check that the heating system pump has not jammed. 2. Check that all the valves are open. The thermostat valves should be fully open and in underfloor heating systems at least half of the coils should be fully open. 3.
What to do if a fault occurs Heat transfer fluid out max T8 (GT8) Sensor T8 (GT8) in the heat pump stops the compressor if the temperature of the water going out to the heating system becomes too high. Possible cause 1: Insufficient flow over the heat pump. Action: 1. Check that the heating system pump has not jammed. 2. Check that all the valves are open. Radiator thermostat valves should be fully open and underfloor heating systems should have at least half of the coils fully open.
Commissioning report Client / Installation address: Installer: Heat pump description: Commissioning date: Heat pump serial number: Type of ground collector (bore hole, horizontal loop, compact collector): Total length of collector: Other components of the installation: Additional heat source ...................................... Room sensor T5 (GT5) Hot water cylinder ...................................... Hot water cylinder temperature sensor T3 (GT3) Three-way valve .............................
Commissioning report Pressure test of collector carried out ..................................................................................................... Checks on fluid concentrations carried out (collector hose) ..................................................................................................... System pressure levels checked ..................................................................................................... Functional test carried out ....................
Technical information Technical information The heat pump’s factory settings Sensor table This table indicates the factory settings for all the settings likely to be changed by the installer. This table indicates the values of the sensor resistors to different temperatures. Menu Setting Factor y setting Temperature (ºC) kΩ 1.1 Temp. incr. / decr. 4 -40 154.00 1.2 Temp. Fine-tune 0º -35 111.700 1.3 Heat curve adjust. (break) n/a -30 81.700 1.4 Heat curve hysteresis 5º -25 60.
Technical information Technical information Greenstore System, Brine/Water heat pump Emitted/ Supplied output at 0/45°C 1 kW COP 1 6 7 9 11 5.19/1.80 6.55/2.20 8.20/2.67 9.63/2.92 2.89 2.97 3.06 3.29 Minimum flow heating side l/s 0.14 0.18 0.22 0.26 Nominal flow heating side l/s 0.20 0.25 0.31 0.38 Maximum pressure available heating side (at nominal flow) kPa 36 36 34 32 Nominal flow of antifreeze mixture to the collector hose l/s 0.30 0.38 0.46 0.
CONTACT INFORMATION WORCESTER, BOSCH GROUP: TECHNICAL: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 01905 752556 LITERATURE: 01905 752526 TRAINING: SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk Part no: 8-716-112-860 Issue c 11804, Issue 1.2 EXCELLENCE COMES AS STANDARD Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.
