STANDALONE
www.glow-worm.co.uk
System Installation
Standalone system
for heating and hot water
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INTRODUCTION
1 Instructions guidance .........................................................................................................................3
1.1 Product documentation...........................................................................................3
1.2 Associated documents ...........................................................................................3
1.3 Explanation of symbols...........................................................................................3
1.4 Guarantee registration ............................................................................................3
2 System description .............................................................................................................................3
2.1 Concept of operation ..............................................................................................3
2.2 Example of Installation – Diagram 4 (4.1) : Standalone with 1 low heating
temperature zone (30-40°C) or 1 middle heating temperature zone (< 60°C) .......4
2.3 Example of Installation – Diagram 4 (4.2) : Standalone with 2 low heating
temperature zones (30-40°C) or 2 middle heating temperature zones (< 60°C) .... 5
2.4 Example of Installation – Diagram 4 (4.3) : Standalone + with 3 low heating
temperature zones (30-40°C) or 3 middle heating temperature zones (< 60°C) .... 6
2.5 Example of Installation – Diagram 4 : Standalone with Domestic Hot Water
cylinder ................................................................................................................... 7
3 Safety instructions and regulations ....................................................................................................8
3.1 Safety instructions ..................................................................................................8
3.2 Regulations.............................................................................................................8
INSTALLATION
4 System appliance installation ............................................................................................................9
4.1 Recommendations before installing .......................................................................9
4.2 Mounting ...............................................................................................................10
5 Hydraulic connection ........................................................................................................................10
5.1 Heat pump circuit..................................................................................................10
5.2 Heating circuit .......................................................................................................12
5.3 Domestic Hot Water circuit ...................................................................................13
6 Electrical connections ......................................................................................................................15
6.1 Heat pump ............................................................................................................ 15
6.2 Electrical wiring.....................................................................................................15
6.3 Hydraulic module ..................................................................................................16
6.4 Systempro control unit .......................................................................................... 16
TABLE OF CONTENTS
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COMMISSIONING
7 Filling the glycol circuit .....................................................................................................................18
8 Activating the heat pump .................................................................................................................19
9 Activating the room thermostat ........................................................................................................20
10 Activating the control unit .................................................................................................................20
10.1 Confi guring the installation ...................................................................................20
10.2 Wiring summary....................................................................................................21
10.3 "Thermostat / sensor" menu .................................................................................21
10.4 Thermostat(s) .......................................................................................................22
10.5 Outdoor sensor .....................................................................................................22
10.6 Self check ............................................................................................................. 23
10.7 Settings.................................................................................................................23
10.8 Commissioning ..................................................................................................... 25
10.9 Status reports .......................................................................................................29
10.10 Options ................................................................................................................. 30
10.11 Heating system test ..............................................................................................30
10.12 Finishing ............................................................................................................... 30
11 Re-check and restart ........................................................................................................................31
12 User information ...............................................................................................................................31
MAINTENANCE
13 Trouble-shooting ..............................................................................................................................32
13.1 Fault diagnosis ..................................................................................................... 32
13.2 Fault codes ........................................................................................................... 32
13.3 Heat pump status .................................................................................................33
14 Servicing ..........................................................................................................................................33
14.1 Annual Maintenance .............................................................................................33
14.2 Control unit maintenance menu ...........................................................................33
TABLE OF CONTENTS
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INTRODUCTION
INTRODUCTION
1 Instructions guidance
1.1 Product documentation
The instructions are an integral part of the system appliances
and must be handed to the user on completion of the
installation in order to comply with the current regulation.
• Carefully read the manual, to understand all the information
to enable safe installation, use and servicing. No liability can
be accepted in the event of damage for not complying with
the guidance in this instruction manual.
These instructions consist of, Installation, Servicing, Fault
Finding. The instructions are an integral part of the appliance
and must be handed to the user on completion of the
installation.
1.2 Associated documents
- Heat pump use and installation instructions
- Hydraulic module use and installation instructions
- Systempro Control unit use and installation instructions
- Climapro2 RF programmable Room thermostat use and
installation instructions
- Wireless outdoor sensor installation instructions
- Accessories installation instructions (motorized 2 port valve...)
1.3 Explanation of symbols
a
DANGER: Risk of injuries.
e
DANGER: Risk of electric shock.
b
ATTENTION: Risk of damage to the appliance or
to its surroundings.
i
IMPORTANT: Important information.
1.4 Guarantee registration
We recommend you complete and return as soon as possible
your guarantee registration card (delivered with the hydraulic
module). If your guarantee registration card is missing you can
obtain a copy or record your registration by telephoning the
Glow-worm Customer Service number 01773 596510.
2 System description
2.1 Concept of operation
The Standalone system consists of the following components:
-A Glow-worm Envirosorb 5 heat pump,
- A "Standalone" hydraulic module,
- The Systempro control unit
- A Climapro2 RF wireless programmable room thermostat,
- A wireless photovoltaic outdoor sensor
The following options may be added to the system:
- 2 port valves for zoning,
- A domestic hot water cylinder.
2.1.1 Operating principle in heating
The system is designed to provide a heating need of 6kW max
at the reference temperature.
The heat generator consists of a heat pump and a hydraulic
module equipped with an electric heater. The heat emitters can
also be low temperature (heated fl oor, gentle heat radiators...)
or medium temperature (steel panels...). In order to always
obtain the best comfort/economy trade-off, the module heat
pump and/or electric heater supply the heating installation with
hot water at the temperature necessary to obtain the desired
ambient temperature.
When the power of the heat pump is insuffi cient to provide
heating, the self-controlled electric heater in the module
can operate simultaneously, up to a power of 4kW, as a
backup. This guarantees optimal use of the heat pump while
guaranteeing that the total electrical power consumption will
never exceed 6kW. When the heat pump is not operating, the
electric heater can reach a power level of 6kW.
The changeover point between the heat pump and the electric
heater is managed automatically, depending on the outside and
ambient temperatures. Thus, the system always optimises the
use of the heat pump with respect to the electric top-up heater.
2.1.2 Operating principle of the domestic hot
water system
The domestic hot water heating circuit consists of a heat pump,
a 3-way valve and a FLUROCYL hot water tank equipped with
an electric heater.
In order to always obtain the best comfort/economy trade-off,
the heat pump and/or the FLUROCYL tank electric heater
provide the energy needed to maintain the stored water at the
required temperature.
The lower part of the tank is heated 3 times a day by the heat
pump. In order to provide maximum economy, the electric
heater heats the top part of the tank just to provide the comfort
desired by the user.
The lower the hot water temperature setting, the more the
heat pump will provide energy and, therefore, more economic
operation.
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INTRODUCTION
2.2 Example of Installation – Diagram 4 (4.1) : Standalone with 1 low heating temperature zone (3040°C) or 1 middle heating temperature zone (< 60°C)
Key
1 Heating circuit (UFH shown, but can be underfl oor or
radiators)
2 "Electrical" hydraulic module
3 Climapro2 RF programmable wireless room thermostat
4 Systempro control unit
5 Wireless outdoor sensor
6 "Electrical" hydraulic module electrical supply + protection
(This must have it's own single isolation)
7 Heat pump electrical supply + protection (This must have it's
own single isolation)
8 Heat pump
9 Heat pump circuit fi lter (not supplied)
10 Glycol PRV discharge
11 Overheating safety (if underfl oor heating)
A Heating circuit return
B Heating circuit fl ow
C Heat pump circuit safety valve discharge
D Heat pump circuit fl ow
E Heat pump circuit return
i
Refer to the chapters “Hydraulic connection” and
“Electrical Connection” to connect the system.
b
This diagram shows the case of an installation with
a single zone low temperature heating fl oor (= outlet
temperature < 40°C).
EBUS
D
E
C
A
B
230V230V
1
11
2
3
4
6
5
7
10
9
8
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INTRODUCTION
2.3 Example of Installation – Diagram 4 (4.2) : Standalone with 2 low heating temperature zones (30-
40°C) or 2 middle heating temperature zones (< 60°C)
i
Refer to the chapters “Hydraulic connection” and
“Electrical Connection” to connect the system.
b
This diagram shows the case of an installation with a
dual zone low temperature heating fl oor
(= outlet temperature < 40°C).
Zones must be same temperatures.
230V
EBUS
D
E
C
B
A
230V
2 1
3
5
4
6
7
8
9
11
10
12
15
14
13
Key
1 Overheating safety (if underfl oor heating)
2 Heating circuit "zone 1" (UFH shown, but can be underfl oor or
radiators)
3 Climapro2 RF programmable wireless room thermostat "zone 1"
4 2 port valve "heating zone 1"
5 "Electrical" hydraulic module
6 Heating circuit "zone 1" (UFH shown, but can be underfl oor or
radiators)
7 Climapro2 RF programmable wireless room thermostat "zone 2"
8 2 port valve "heating zone 2"
9 Systempro control unit
10 Wireless outdoor sensor
11 "Electrical" hydraulic module electrical supply + protection
(This must have it's own single isolation)
12 Heat pump electrical supply + protection (This must have it's
own single isolation)
13 Heat pump
14 Heat pump circuit fi lter (not supplied)
15 Glycol PRV discharge
A Heating circuit return
B Heating circuit fl ow
C Heat pump circuit safety valve discharge
D Heat pump circuit fl ow
E Heat pump circuit return
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INTRODUCTION
2.4 Example of Installation – Diagram 4 (4.3) : Standalone + with 3 low heating temperature zones
(30-40°C) or 3 middle heating temperature zones (< 60°C)
i
Refer to the chapters “Hydraulic connection” and
“Electrical Connection” to connect the system.
b
This diagram shows the case of an installation with a
three zone low temperature heating fl oor
(= outlet temperature < 40°C).
Zones must be same temperatures.
230V
EBUS
D
E
C
B
A
230V
2 1
3
5
6
4
7
14
13
15
18
17
16
8
9
11 12
10
Key
1 Overheating safety (if underfl oor heating)
2 Heating circuit "zone 1" (UFH shown, but can be underfl oor or
radiators)
3 Climapro2 RF programmable wireless room thermostat "zone 1"
4 2 port valve "heating zone 1"
5 "Electrical" hydraulic module
6 2 port valve "heating zone 2"
7 Heating circuit "zone 2" (UFH shown, but can be underfl oor or
radiators)
8 Climapro2 RF programmable wireless room thermostat "zone 2"
9 Climapro2 RF programmable wireless room thermostat "zone 3"
10 Heating circuit "zone 3" (UFH shown, but can be underfl oor or
radiators)
11 2 port valve "heating zone 3"
12 Systempro control unit
13 Wireless outdoor sensor
14 "Electrical" hydraulic module electrical supply + protection
(This must have it's own single isolation)
15 Heat pump electrical supply + protection (This must have it's
own single isolation)
16 Heat pump
17 Heat pump circuit fi lter (not supplied)
18 Glycol PRV discharge
A Heating circuit return
B Heating circuit fl ow
C Heat pump circuit safety valve discharge
D Heat pump circuit fl ow
E Heat pump circuit return
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INTRODUCTION
2.5 Example of Installation – Diagram 4 : Standalone with Domestic Hot Water cylinder
A Heating circuit return
B Heating circuit fl ow
C Domestic hot water fl ow
D Cold water supply
E Heat pump circuit return
F Heat pump circuit fl ow to cylinder circuit
G Heat pump circuit fl ow to module circuit
H Heat pump circuit return
Key
1 Overheating safety (if underfl oor heating)
2 "Electrical" hydraulic module
3 Systempro control unit
4 Power relay for the electric heater (not supplied)
5 Exchanger tank electric top-up heater
6 Domestic hot water tank
7 "Electrical" hydraulic module electrical supply + protection
(This must have it's own single isolation)
8 Heat pump electrical supply + protection (This must have it's
own single isolation)
9 Heat pump
10 Heat pump circuit fi lter (not supplied)
11 3 port valve
12 Glycol PRV discharge
i
Refer to the chapters “Hydraulic connection” and
“Electrical Connection” to connect the system.
EBUS
230V230V
H
G
E
F
C
D
A
B
1
2
3 4
8
10
5
1112
7
8
6
9
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INTRODUCTION
3 Safety instructions and regulations
3.1 Safety instructions
e
Incorrect installation can cause electric shock or
appliance damage.
• Never disable security devices and do not try to adjust them.
• Be sure to consider the following handling techniques and
precautions:
- Grip the appliance at its base
- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
• Ensure safe lifting techniques are used:
- Keep back straight.
- Avoid twisting at the waist.
- Avoid upper body/top heavy bending.
- Always grip using the palm of the hand.
- Use designated hand holds.
- Keep load as close to body as possible.
- Always use assistance if required.
• Under no circumstances must the user interfere with or
adjust sealed parts.
• When assembling the connections, correctly position the
seals to avoid any leakage of water.
• This appliance contains metal parts. Care should be taken
with regard to edges.
The basic safety instructions must be followed before
attempting to maintain or replace spare parts:
• Stop the appliance.
• Electrically isolate the appliance from the power supply.
• Hydraulically isolate the appliance using the isolation valves
if provided.
• Should you need to replace hydraulic components, drain the
appliance.
• Protect all the electrical components from water while
working on the appliance.
• Use only original spare parts.
• Use only new O-rings and gaskets.
• After having completed work on water carrying components,
check for their tightness.
• When work on the appliance is completed, perform an
operational test and check for safety.
R410A Refrigerant Fluid
b
Important: any action carried out on the
refrigerant circuit must be performed by
qualifi ed authorised personnel.
• Use only R410A refrigerant.
b
Venting refrigerating fl uid into the atmosphere
is prohibited. The refrigerant must be properly
recovered in a container suitable for recycling.
a
The draining and refi lling operations must be
performed in a well-ventilated area and with the
necessary protective equipment (risk of burns).
3.2 Regulations
3.2.1 Statutory requirements
IMPORTANT
Where no British Standards exists, materials and equipment
should be fi t for their purpose and of suitable quality and
workmanship.
The installation of this appliance must be carried out by a
competent person in accordance the rules in force in the
countries of destination.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
Standards
On installing and commissioning the appliance you must adhere to
the technical rules, standards and provisions in effect at the time.
Reminder of existing regulatory acts
- EC regulation No. 20372000 from the 29th of June 2000
This European regulation repeals regulation No. 3093/94
and presents the elimination schedules of CFC and HCFC.
It also deals with the collection of refrigerants, system leaks,
particularly systems containing more than 3 kg of CFC or
HCFC, as well as the minimum level of qualifi cation required
by the technicians.
- EC regulation No. 0842/2006 from the 17th of May 2006
regarding the containment, use, collection and disposal
of the fl uorinated greenhouse gases, the labelling and
elimination of the products and equipment containing these
gases, the restriction of use and banning of certain products
from the market, as well as the training and certifi cation of
personnel and companies operating in the activities targeted
by this regulation: refrigeration, air-conditioning, heat pumps
and fi re protection systems containing greenhouse gases.
3.2.2 Other regulations
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act 1974, we
are required to provide information on substances hazardous to
health. The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
The refrigerant used in this appliance is R410a the use of which
is strictly controlled by F Gas regulation EN842/2006.
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INTRODUCTION
INSTALLATION
4 System appliance installation
4.1 Recommendations before installing
4.1.1 Heating circuit design
General
The heat transmitters may be low temperature (eg underfl oor
heating or high temperature (radiator...).
The pipe sections are to be determined using a fl ow / pressure
curve (refer to the chapter
"Activating the control unit" ►
Commissioning ► Heating circuit adjustment"). The distribution
will be determined by the fl ow corresponding to the power
actually required, regardless of the maximum power that can be
provided by the installation’s generators.
b
We recommend that you allow for suffi cient fl ow
to ensure that the temperature difference between
the fl ow and the return is equal to 7 K for fl oor
heating and 15 K for radiators.
b
Make sure the heating circuit water fl ow is greater
than 900 l / h.
Installation pipework must be designed and installed to ensure
venting of air from the system is possible.
b
TRVs must be fi tted on all radiators, with the
exception to reference rooms.
The total volume of water for the heating circuit depends,
among other factors, on the cold static load of the Hydraulic
module's expansion vessel.
i
The heating system volume should be calculated to
ensure that the expansion vessel is suitable, it may
be necessary to add an additional vessel.
- In GB, Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
Il est recommandé de prévoir un robinet de vidange au point le
plus bas de l’installation.
- Drain taps shall be to the current issue of BS2879.
It is recommended that a drainage valve be installed at the
lowest point of the installation.
- Drain taps shall be to the current issue of BS2879.
• Install the following components in the return of the heating
circuit (not supplied):
- a heating fi lter
- a ¼ turn shut-off valve,
- an air separator (if necessary),
- an anti-sludge fi lter (if necessary).
• In the case of a heated fl oor, install a manual reset overheat
safety device (55°C) on the heating circuit fl ow (refer to the
Chapter - System description). Connect the overheat safety
device to the electric supply for the module circuit board
(refer to the module installation manual).
Water treatment
Existing system- It is essential that prior to installing the new
appliances the system is thoroughly fl ushed.
New system- For optimum performance after installation, the
appliances and its associated central heating system should
also be fl ushed.
Flushing shall be carried out in accordance with BS 7593, a
chemical cleanser can be used either Sentinel X300, X400 or
Fernox F3 are suitable.
It is recommended to fl ush existing systems fi rst before fi tting
the new appliances.
• Ensure all cleanser is removed from the whole system before
adding an inhibitor.
For long-term corrosion protection after fl ushing, an inhibitor
suitable for stainless steel heat exchangers can be used. Either
Sentinel X100 or Fernox F1 inhibitor can be used.
The module is suitable for use on systems using softened water.
4.1.2 Heat pump circuit design
Installation pipework must be designed and installed to ensure
venting of air from the system is possible.
b
Make sure the circuit’s water fl ow corresponds
to the appliance’s nominal water fl ow.
• Install the following components to the hydraulic module, in
the direction of the heat pump (not supplied):
- a fi lter,
- a ¼ turn shut –off valve on each side of the fi lter,
• Install a ¼ turn shutoff valve in the fl ow of the heat pump.
i
In order to avoid the transmission of vibrations to
surrounding structures, use hoses for the hydraulic
connections at least 1 metre from the heat pump.
b
Insulate the pipes with an UV- and hightemperature-resistant insulation.
4.1.3 Domestic hot water circuit design
Water pressure
The maximum working pressure of the domestic hot water
circuit is 10 bar. If the cold water supply pressure exceeds this,
then a pressure-reducing valve must be fi tted in the supply to
the boiler.
‘Hard’ water areas
In areas where the water is ‘hard’ (i.e. more than 200 mg/L
of calcium carbonate), it is recommended that the hot water
setting is reduced and that a scale reducer is fi tted, refer to the
manufacturer’s instructions or consult the local water company
for additional advice.
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INSTALLATION
4.2 Mounting
i
Install the Systempro control unit near the hydraulic
module to facilitate system commissioning.
• Consult the corresponding installation manual and install the
following elements:
- the heat pump,
- the hydraulic module,
- the Systempro control unit,
- the Climapro2 wireless room thermostat,
- the wireless outdoor sensor.
5 Hydraulic connection
• Take care to clean the pipes before assembly removing any
debris or burrs. Grease and oils may need to be removed
they are not possible to remove by cleansing and fl ushing.
Foreign bodies in the system may enter the appliance and
interrupt its operation.
• Do not use any solvent products, due to the risk of damaging
the circuit.
• Only use original seals supplied with the appliance.
• Check that there are no leaks. Repair if necessary.
5.1 Heat pump circuit
• Comply with the values given in the table below when
making the hydraulic connections of the heat pump circuit.
Linear distance (without elbows or
additional pressure drops)
Min. diameter of tubes to
be installed
≤ 20 m Ø ¾"
≤ 30 m Ø 1"
b
In the case of an installation with the domestic
hot water tank option, deduce the pressure drop
of the 3-way valve with respect to the max. linear
distance allowed between the domestic hot water
tank and the PAC + between the PAC and the
hydraulic module (see chapter "Connection of an
exchanger tank for domestic hot water").
5.1.1 Connection to the heat pump
b
Insulate the pipes with an UV- and hightemperature-resistant insulation.
1m min.
4
2
1
3
5 6
7
8
key
1 Heat pump fl ow circuit ¼ turn shut-off valve in the direction of
the building (not included)
2 Return circuit ¼ turn shut-off valve in the direction of the heat
pump (not included)
3 Return circuit hose in the direction of the heat pump (not
supplied)
4 Cap
5 Return connection (Ø1 ") to the heat pump
6 Flow heat pump connection (Ø1 ") to the building
7 Flow heat pump circuit hose in the direction of the building
(not supplied))
8 Insulation (not supplied)
• Remove the protection caps (4) located on the connections.
• Connect a hose (3) and a shut-off valve (2) to the return
connection (5) to the heat pump.
• Connect a hose (7) and a shut-off valve (1) to the fl ow heat
pump connection (6) in the direction of the building.
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