RVR Hybrid System Installer Instructions RVR Hybrid System Controller Installation Instructions

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1 RVR Hybrid System Controller Installation Instructions 1

2 Introduction to Hybrid Systems The RVR Hybrid system uses a combination of the Immergas Audax range of heat pumps with gas or oil boilers to create very high efficiency hybrid heating systems. It is at its best when used with the Immergas range of Victrix boilers but may also be used with other conventional boilers. The system is managed by the RVR Hybrid System Manager. This will automatically select either the Audax or the boiler depending on the weather conditions and the temperature needed in the heating system. In some situations it will employ a combination of both to provide the ultimate performance. It takes into account the cost of electricity, gas, oil and other fuels and will always ensure that the most cost effective energy source is used. The Hybrid system manager also monitors system operation and if a problem is detected, it will send an to a designated address. 2

3 Hybrid System Configurations There are a number of different system configurations possible. Simple Parallel Configuration A simple parallel configuration may be used as shown below: In this case the hybrid system manifold must be used to interconnect the Audax and the boiler. Ideally, an Immergas Victrix boiler should be used but if this is not possible any boiler may be substituted. 3

4 Buffered Systems A buffered system may be designed using the PROCLEAN and FS tank accessories. This type of system offers the advantage that better use may be made of night rate electricity. It is very important that the connections to the tank are made exactly as shown below: It is important that the PROCLEAN or FS tank is correctly connected. The following connections are recommended. 4

5 Important Points to check regarding Audax Installation Ensure that all equipment is installed as per the relevant installation instructions. Audax heat pumps should be installed in strict accordance with the Immergas instructions, IEE regulations and other relevant standards and codes of practice. Pay strict attention to the clearances in order to ensure correct operation. Boilers should be installed in accordance with the relevant manufacturer's instructions, national standards, IEE regulations and other relevant standards and codes of practice. Particular attention should be paid to the following important points: 1. The power supply to the heat pump should have adequate protection and should be checked by a qualified electrician prior to connection to the electricity supply. Type C motor rated MCBs with a rating of 20A should be used Ensure that the condensate drain from the Audax is piped to a suitable drain to avoid the possibility of frozen condensate becoming a hazard The DIP switches on the Audax HYDI PCB must be set as follows. Switch No Switch 1 Switch 2 Switch 3 Switch 4 Position ON OFF OFF OFF Isolation valves must be fitted to the flow and return pipes at the Audax and boiler A suitable filter/strainer must be fitted to the return line to the Audax

6 5. The Audax has in-built freeze protection. However in the event of power failure or electrical isolation of the heat pump, this will not be active. We recommend that a suitable anti-freeze (propylene glycol) should be used to ensure the freezing point temperature of the circuit is well below lowest expected winter temperatures

7 RVR Hybrid System Manager There are two models available - the standard RVR Hybrid System Manager and a version with optional touchscreen. Both models are shown below. Both models come with an external power supply unit. This is shown below. Mounting the HyBRID Controller The control panel can be mounted without removing the main cover. The box has a keyhole on the back which allows it to hang on a screw (marked 1 on the picture). Once hanging, the bottom front panel may be removed, allowing two more screws to be inserted through the bottom corners at the locations marked 2 7

8 Internet Connection The HSM is connected to the internet via the mobile telephone network. This is integrated into the HSM. The in-built antenna is adequate in most locations. However, in some cases where signal is poor, a special external antenna may be required. Connection of External Web Browser to HyBRID The HyBRID is fitted with an RJ45 socket which allows a device with a web browser to be plugged in. In this case, the operation of the unit may be viewed and settings may be changed even if an internet connection is not available. 8

9 Connecting to the Hybrid System Manager Once you have finished wiring the Hybrid System Manager, and power it on for the first time, it will attempt to connect to the internet. 1. To verify the internet access, look for the internet light on the side of the Hybrid System Manager. This is a round viewing hole with a blue or green light visible behind it. When the controller is first powered up, it can take up to 90 seconds for the internet connection to become active. When first powered on, the light will be off. When a flashing blue or green light is visible then the internet is attempting to connect. Only when the light turns solid blue or solid green is the internet connected. Blue = 3G (faster connection), Green = 2G (standard connection). If the device will not connect to the internet after 5 minutes (e.g. solid blue or green light is not visible) then the signal strength may be low. In this case then power off the controller and power it back on and monitor the connection light to see if a connection can be achieved. If this fails repeatedly then several options are possible. 1) Re-try the process later (to rule out a mobile network issue). 2) Move the controller closer to a door or window (and away from sheet metals or foil backed insulation) 3) Contact RVR to discuss using an external antenna to boost the signal. Once a connection has been established, the controller constantly monitors the connection to ensure it is working correctly. From time to time the connection may disconnect and re-connect. This is normal, however during the re-connection process it will not be possible to connect to the controller over the internet.. 2. Each Hybrid SYstem Manager has a unique web address. This is printed on the data label together with the user name and password. To connect, type the unique web address into the address bar on a web browser (on a PC, mobile phone or Pad) and click Go or Connect. Please note the address shown in the picture below is for demonstration purposes only, you should use the address from the data label on your Hybrid System Manager. 3. You will see a screen asking you to enter a username and password. The username (usually user) and unique password are printed on the datalabel of the HSM. Enter the username and password, and if you wish to save these details so you do not have to log in again, click Remember my credentials. Finally, click Ok. 9

10 4. At this point the system interface will load and should look similar to below. Please note if you receive a Page not found, 404 or other error, please check the HSM to ensure it has an internet connection. If it has a connection but you still cannot connect, please check to make sure your web browser has an internet connection. 5. At this point, you can access the different pages of the site. Main Page gives an overview of the operation of the system. Operating Data gives information on running hours. 6. In order to access Installer Settings a special password needs to be entered. In order to do this, click on Installer Settings and a prompt will appear for username and password. The username is installer and the password is the same as the user password, however with an x added to the end. For example: If user password is 1234 then installer password is 1234x Enter the details and click Ok, and you will be presented with the installer settings page. 10

11 Full details explaining the parameters are given later in this document. Electrical The Hybrid System Manager has the following electrical connections: 1. The controller is supplied with an external power supply (PSU). The three core cable to the PSU should be wired to a 230V supply and fused at 3A. WARNING - DO NOT connect a 230V supply directly to the terminals marked 24V on the wiring terminals of the controller as this will damage the controller. WARNING - The controller must be earthed by connecting an earth wire to the terminals labelled EARTH Other electrical connections which must be made include: Connection to the Audax Heat Pump. Connections to two temperature sensors. Connection to the boiler. Heat Demand signal from the central heating system. Optional demand signal from the hot water heating system. The electrical connections will vary with the system configuration. Please see the schematics and wiring diagrams on the following pages for the system which is closest to yours. 11

12 Parallel Hybrid System with Audax and Immergas Victrix boiler This system contains an Audax with an Immergas Victrix boiler. These are connected using the special Audax Hybrid system manifold. Electrical Connections Notes: These are volt free dry contacts with a maximum load capacity of 2A. They are suitable for use with small loads such as domestic boilers, small pumps and valves. An additional relay should be used if it is desired to power a larger load. *** These enable signals are provided by external volt free dry contacts such as valve switches or relays. Mains voltages must not be connected to these terminals as the controller will be destroyed. 12

13 Full parameter settings are given in the section Parameter Settings. For this configuration, the following parameters should also be set in the Installer Settings tab: Parameter Parameter Name Value to be used Value Set P34 DHW Controller Enable 1 P38 System Type 2 P55 Condensing Boiler Used 1 13

14 Parallel Hybrid System with Audax and conventional boiler This system contains an Audax with a conventional gas or oil boiler. These are connected using the special Audax Hybrid system manifold. Electrical Connections Notes: These are volt free dry contacts with a maximum load capacity of 2A. They are suitable for use with small loads such as domestic boilers, small pumps and valves. An additional relay should be used if it is desired to power a larger load. *** These enable signals are provided by external volt free dry contacts such as valve switches or relays.mains voltages must not be connected to these terminals as the controller will be destroyed. 14

15 Full parameter settings are given in the section Parameter Settings. For this configuration, the following parameters should also be set in the Installer Settings tab: Parameter Parameter Name Value to be used Value Set P34 DHW Controller Enable 1 P38 System Type 2 P55 Condensing Boiler Used 1 or 0 depending on boiler type 15

16 Proclean Hybrid System with Audax and Immergas condensing boiler This system contains an Audax, PROCLEAN (or FS) combi tank with a conventional gas or oil boiler. Electrical Connections Notes: These are volt free dry contacts with a maximum load capacity of 2A. They are suitable for use with small loads such as domestic boilers, small pumps and valves. An additional relay should be used if it is desired to power a larger load. *** These enable signals are provided by external volt free dry contacts such as valve switches or relays. Mains voltages must not be connected to these terminals as the controller will be destroyed. Parameter settings are given in the section Parameter Settings. For this configuration, the following parameters should also be set in the Installer Settings tab: 16

17 Parameter Parameter Name Value to be used Value Set P34 DHW Controller Enable 1 P38 System Type 2 P55 Condensing Boiler Used 1 Proclean Hybrid System with Audax and Conventional boiler This system contains an Audax, PROCLEAN (or FS) combi tank with a conventional gas or oil boiler. Electrical Connections 17

18 Notes: These are volt free dry contacts with a maximum load capacity of 2A. They are suitable for use with small loads such as domestic boilers, small pumps and valves. An additional relay should be used if it is desired to power a larger load. *** These enable signals are provided by external volt free dry contacts such as valve switches or relays. Mains voltages must not be connected to these terminals as the controller will be destroyed. 18

19 Full parameter settings are given in the section Parameter Settings. For this configuration, the following parameters should also be set in the Installer Settings tab: Parameter Parameter Name Value to be used Value Set P34 DHW Controller Enable 1 P38 System Type 2 P55 Condensing Boiler Used 1 19

20 Parameter Settings The Hybrid System Manager is supplied with default parameters. However, some of these may need to be adjusted to suit your system. To access these, click on the Installer settings tab Go to the relevant parameter.... Change.... Click. Save Settings to save the setting. System Type The Audax model system type must be set. Set the following Parameters Parameter Parameter Name Notes Default Set Value P35 Audax Model 1=Audax 6, 2 = Audax 8, 3 = Audax 10, 4 = Audax 16, 5= Audax 18 3 P38 System Type 1 - Combi Tank, 2 - Parallel connection 2 Flow temperature Control The system flow set point may be controlled in two different ways: Fixed Flow Temperature Control The set point is fixed and is set in P10. e.g. If a system flow temperature of 45C is required ; set P10 to If a system flow temperature of 50C is required ; set P10 to 5000, etc. Weather Compensated Set Point. Weather compensation is a feature that varies the flow temperature in proportion to the outside air temperature. This increases the system efficiency. Weather compensation is turned on by setting P12 to 1. The slope of the weather compensation line is set using parameters P14 to P17. See the graphic below: 20

21 Night Boost The Flow/Tank set point may be raised during night rate electricity hours if a buffer tank is used. The amount of temperature elevation is set in P41. The value of P41 is added to the set point whenever night rate electricity tariffs are available. If the value of P41 is 0 then the set point is not changed. Pre-Night Rate Setpoint Reduction In order to maximise the use of night rate electricity, it is sometimes advantageous to reduce the set point for a period before night rate starts. This is most applicable to systems where a buffer tank is used. The setpoint reduction is set in P39. The time during which the reduction is active, before the beginning of night rate is set in P40. 21

22 Parameter Parameter Name Notes Default Set Value P10 Fixed Flow Temperature Setpoint This is the flow temperature if weather compensation is not enabled. It is set in hundredths of a degree = 45 0 C 4500 P12 Enable Weather Compensation This is used to enable weather compensation ; 1 = Enable, 0 = Disable 0 P14 Maximum Flow Temperature in WC mode This is the maximum flow temperature in weather compensation mode. It is set in hundredths of a degree = 60 0 C 6000 P15 Minimum Flow Temperature in WC mode This is the minimum flow temperature in weather compensation mode. It is set in hundredths of a degree = 25 0 C 2500 P16 Weather Compensation Low OAT Limit This is the low outside air temperature limit for weather compensation. If the OAT is below this level then the flow temperature setpoint is the value set in P14. It is set in hundredths of a degree = 25 0 C -500 P17 Weather Compensation High OAT Limit This is the high outside air temperature limit for weather compensation. If the OAT is above this level then the flow temperature setpoint is the value set in P15. It is set in hundredths of a degree = 20 0 C 2000 P39 Pre-night rate - PROCLEAN Temperature Setback This is the reduction in PROCLEAN setpoint before the start of the night rate tariff. It should be set at 0 for systems which do not use the PROCLEAN. The recommended value is 500. It is set in hundredths of a degree. 500 = 5 0 C 0 P40 Pre-night rate - Temperature Setback Time This is the time period in minutes before the start of the night rate tariff when the PROCLEAN temperature setback (set in P39) is active. The recommended value is P41 Night Rate PROCLEAN temperature Boost The setpoint temperature of the PROCLEAN may be boosted during night tariff hours. It should be set at 0 for systems which do not use the PROCLEAN. This parameter sets the boost level. The recommended value is 500. It is set in hundredths of a degree. It is set in hundredths of a degree. 500 = 5 0 C 0 Domestic Hot Water Temperature Control Hot water heating may be controlled either by using a thermostat or using the in-built hot water 22

23 temperature controller. DHW Control using DHW Thermostat If using a thermostat, connect it to the DHW enable terminals and set the parameter P34 to 0. Hot water demand mode may be time controlled using the DHW time schedule. If time control is not required then P146 should be set to 1. DHW Control using Sensor If using the controller, connect the DHW sensor to the DHW sensor input. This is installed on the hot water heating tank or at the top of the PROCLEAN. The DHW temperature controller is turned on by setting P34 to 1. The control strategy for DHW is a simple ON/OFF strategy with differential. The DHW output is switched off when the set point (P30) is reached and switched back on when the DHW temperature drops below the setpoint minus the DHW differential (P31). 23

24 If time control is automatically available by default for DHW. If this is not required then the DHW time control may be overidden ; set P146 to 1. A boost function is also available which allows the user to temporarily enable DHW heating outside of the time period. This is enabled by setting P33 to 1 and setting a time in P32. Parameter Parameter Name Notes Default Set Value P30 DHW Temperature Setpoint This is the DHW temperature setpoint when the DHW controller is enabled (P34=1). It is set in hundredths of a degree = 60 0 C P31 DHW Control Differential This is the control differential for DHW. It is set in hundredths of a degree. 500 = 5 0 C P34 DHW Controller Enable When this parameter is set to 1, the DHW temperature controller is enabled. This parameter may be set to 1 (ON) or 0(OFF) P146 DHW Time Schedule Override There is a time clock function for DHW. It may be disabled by setting this parameter to Fuel Cost Parameters The operation of the system is affected by fuel costs. It is important that the correct fuel costs are used. The following parameters must be set. Parameter Parameter Name Notes Default Set Value P50 Summer Day Electricity rate This is the cost of electricity when the summer daytime tariff is active. It is set in hundredths of a cent per kwh = 18.5 c / kwh

25 P51 Summer Night Electricity Rate This is the cost of electricity when the summer nighttime tariff is active. It is set in hundredths of a cent per kwh. 850 = 8.5 c / kwh P52 Winter Day Electricity Rate This is the cost of electricity when the winter daytime tariff is active. It is set in hundredths of a cent per kwh = c / kwh P53 Winter Night Electricity Rate This is the cost of electricity when the winter nighttime tariff is active. It is set in hundredths of a cent per kwh. 876 = 8.76 c / kwh P54 Price of Gas Oil or other fuel This is the cost of boiler fuel. It is set in hundredths of a cent per kwh. 876 = 8.76 c / kwh P55 Condensing boiler used This is used to set the boiler type. Set 0 for non-condensing boiler or 1 for a condensing boiler P56 Date of Winter Electricity Tariff Start Date on which winter electricity tariff starts. This is entered in Day/Month format - DDMM. 110 = 1st October (01/10) 110 P57 Date of Winter Electricity Tariff End Date on which winter electricity tariff ends. This is entered in Day/Month format - DDMM = 31st March (31/03) 3103 P58 Summer NR Start Time Time at which the summer night rate tariff starts. This is entered in Hour/Minute format - HHMM. 0=Midnight P59 Summer NR End Time Time at which the summer night rate tariff ends. This is entered in Hour/Minute format - HHMM. 900=9 am P60 Winter NR Start Time Time at which the winter night rate tariff starts. This is entered in Hour/Minute format - HHMM. 2300=11 pm P61 Winter NR End Time Time at which the winter night rate tariff ends. This is entered in Hour/Minute format - HHMM. 800=8 am NOTES 25

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