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WarmFlow A Series User Instructions

High efficiency variable speed air source heat pumps
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High Efficiency
Variable Speed
Air Source Heat Pumps
Models covered by this manual:
A-Series
Air Source
Incorporating:
AS01-R32
User Instructions
Installation Instructions
Service Instructions
Guarantee Terms & Conditions
AS02-R32
AS03-R32

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Summary of Contents for WarmFlow A Series

  • Page 1 High Efficiency Variable Speed Air Source Heat Pumps Models covered by this manual: A-Series Air Source AS01-R32 AS02-R32 AS03-R32 Incorporating: User Instructions Installation Instructions Service Instructions Guarantee Terms & Conditions...
  • Page 2 TECHNICAL, SPARES & GUARANTEE CLAIMS For technical advice about the installation, commissioning, servicing or use of this appliance, please contact the Warmflow Customer Care Centre by post, phone, fax or email at the addresses below. Please also refer to our website.

  • Page 3: Table Of Contents

    Contents Contents ..................................1 User Instructions ..............................3 Intended Use ..............................3 Compliances ..............................3 Basic Operation ............................3 Product Data ..............................4 1.4.1 Starting Current ............................. 6 Construction ..............................7 Supplied Components ..........................7 Storage / Transport ............................8 Air Source Heat Pump Installation ........................
  • Page 4 5.2.1 Faults ..............................54 5.2.2 Troubleshooting ..........................60 Your Guarantees, Terms & Conditions ......................61 Period of Guarantee ........................... 61 Warmflow’s Obligations ..........................61 Your Obligations ............................61 Exclusions of Guarantee ..........................62 6.4.1 Repairs ..............................62 6.4.2 Other property ............................. 62 6.4.3...

  • Page 5: User Instructions

    1 User Instructions 1.1 Intended Use The Warmflow Air Source Heat Pump appliances are intended for the production of hot water for space heating and sanitary water. The appliances can be used to provide heating and domestic hot water (DHW) via underfloor heating circuits, radiators and approved hot water cylinders. The appliances are designed to extract heat from the air.

  • Page 6: Product Data

    Heat is extracted from the air by blowing air through a finned radiator, known as the evaporator, with a fan. The extracted energy from the air is transferred into the refrigerant which circulates around the evaporator. The heat pump then converts this low grade heat to a high grade by compressing the refrigerant using the compressor.
  • Page 7 Table 2 Product information AS01- AS02- AS03- Model Air-to-water heat pump Water-to-water heat pump Brine-to-water heat pump Low-temperature heat pump Equipped with a supplementary heater Heat pump combination heater Symbol Value Unit Rated heat output Prated Declared Capacity of heating for part load at indoor temp. 20°C and outdoor temp., T (~ 55°C) = -7°C = 2°C...

  • Page 8: Starting Current

    Table 3 Product Fiche Warmflow Warmflow Warmflow Supplier AS01 AS02 AS03 Model A+++ Energy Efficiency Class Rated Heat Output (kW) Seasonal Space Heating Energy Efficiency 1838 2750 5355 Annual Energy Consumption, GCV (kWh) Sound Power Level, LWA (dB) Rated Heat Output in Colder Climate (kW)

  • Page 9: Construction

    Upon delivery, it is important that the appliance is unpacked carefully and checked for any sign of damage. If something is missing or damaged please report it to Warmflow immediately. The appliances are secured to the shipping pallet using screws which must be removed.

  • Page 10: Storage / Transport

    Upon delivery, it is important to check that all components are included. If something is missing or damaged please report it to Warmflow immediately. 1.7 Storage / Transport The appliances come on a pallet (Dimensions of shipping sizes are shown below) and are secured to the pallet using screws.

  • Page 11: Air Source Heat Pump Installation

    150mm above the ground. Flexible feet are available separately from Warmflow in order to provide this gain in height. This must then be installed on a smooth horizontal surface capable of supporting the weight of the appliance together with any accessories and other plant.
  • Page 12 SIDE FRONT Figure 4 AS02-R32 Casing Dimensions & Heating Connection Locations Page 10...

  • Page 13: Clearance & Access

    SIDE FRONT Figure 5 AS03-R32 Casing Dimensions & Heating Connection Locations The heating flow and return connections are located on the right side panel of the AS01-R32, AS02-R32 and AS03-R32 appliances as shown in the images above. The heating flow (Water Outlet) is the top connection with the heating return (Water Inlet) at the bottom.

  • Page 14: Unpacking

    BEFORE the appliance is connected to the heating system. Thereafter, a suitable treatment/thermal fluid, such as Warmflow HPC Fluid, must be added to the heating medium circuit to protect the appliance and heating system against freezing, corrosion, scale and biological growth.

  • Page 15: Freeze Protection

    As per 2.4.1 above, a suitable treatment/thermal fluid such as Warmflow HPC Fluid, when correctly added to the heating medium circuit will provide long term protection against freezing, as well as corrosion, scale and biological growth.

  • Page 16: Bypass / Open Zones

    Table 5 Heating flow rate requirements Min circuit Heat Output (kW) Required Flow Rate (l/min) volume (L) Heat Pump @ Max. Minimum Maximum @ Min. Output Output AS01-R32 AS02-R32 AS03-R32 2.4.5 Bypass / Open Zones It is essential that the heating circuit can always achieve a minimum flow rate of at least 10 litres per minute even when no zones are calling for heat.

  • Page 17: Heating Circuit Line Components

    A full flow 3-port motorised valve may also be required for some systems; this can be ordered separately, please contact Warmflow for details. Please see section 2.9 for more details of installing and wiring the 3-port motorised valve. These air source heat pump appliances come with the following items included integrally, a high flow circulating pump, a manual air vent, flow switch and temperature sensors.

  • Page 18: Defrosting

    An in-line buffer tank accessory is available separately from Warmflow (AS01 – 18l capacity, AS02 – 30l capacity, AS03 – 50l capacity).

  • Page 19: Bypass Valve

    If an in-line buffer tank is not incorporated into the installation, a calculation must be performed to determine the circulating volume of water which is available to the appliance for the purposes of defrosting. The minimum circulating volume required for each appliance model is given in Table 6.

  • Page 20: Electrical Installation

    correct position. The actuator should then be clipped onto the valve body. A rotation switch can be found on the right side of the actuator and must be in the ‘CW’ (clockwise) position. Figure 10 3-port Motorised Valve Actuator Positions The valve turns clockwise when DHW is enabled as shown on the right in the figure above.

  • Page 21: Digital Inputs

    The appliances must be protected by a Type C MCB and RCD according to the table below. Table 6 Electrical Installation Specification Model Minimum Wire Gauge MCB Rating (Type C) RCD Rating (Type F) 30mA ≤0.1 seconds AS01-R32 2.5mm 30mA ≤0.1 seconds AS02-R32 4.0mm 30mA ≤0.1 seconds...

  • Page 22: Temperature Sensors

    On/Off’ and ‘Heat/Cool On/Off’ from a remote source such as a timeclock, programmer or room stat. Connecting the terminals for ‘DHW On/Off’ (5 & 6) will set the appliance into DHW mode. Connecting the terminals for ‘Heat/Cool On/Off’ (7 & 8) will set the appliance into heating mode (provided the link wire is connected between the ‘Mode Heat/Cool’...
  • Page 23 3 WAY 3 WAY ELEC HEATER AUX PUMP VALVE VALVE (STAGE 1) PERM LIVE CONTROL Figure 14 Installer’s Digital Output Connections (AS03) 3 Port Motorised Valve –The 3 Port Motorised valve is detailed in section 2.9. The valve actuator is 230V ac and has 3 wires, a brown, a blue and a white wire. The brown wire is the permanent live to the valve and must be wired into the permanent live terminal (17 - AS01 &...

  • Page 24: User Interface (Controller)

    Once installed, the appliance can be set up using the Warmlink App together with the QR Code on the side of the appliance. For more details and help with registration, please see the Warmlink App or visit www.warmflow.co.uk. Page 22...

  • Page 25: User Interface

    3 User Interface The appliance’s user control interface (see Figure 15) has been designed to maximise the ease of use and efficiency of the heating system. The interface is a touchscreen with all interactions being performed on the screen itself. On powering the appliance up, the following start up screen will be displayed.
  • Page 26 Figure 16 Screen Icons There are a number of icons/buttons on the home screen as shown above. The meaning and features of these are explained in the points below: ON/OFF Button - Press this button to switch the appliance from OFF to ON or vice versa. When the appliance is switched ON, the symbol on the button will be red and the screen will appear in full colour as shown above.
  • Page 27 Figure 17 Appliance OFF Screen Display LOCK Button - Press this button to lock the display. This function prevents unwanted adjustments of parameters or changing of functions and timeclock on/off periods. When the lock function is activated, the display will ignore all key presses. To unlock the device, press the Lock Button again and then enter the password.
  • Page 28 MODE Button - Press this button to switch between operating MODES. Pressing the button will bring up the following menu screen where the required MODE can then be selected. Figure 18 MODE Menu Screen The required MODE can be selected by pressing one of the five MODE buttons. Details of each MODE are below.
  • Page 29 Temperature Setting Button - Press this button to set the desired temperatures. Pressing the button will bring up the following menu screen where the required temperature can then be set. Figure 19 Temperature Setting Menu Screen Depending on the current mode of the appliance, the Temperature Setting Menu Screen will display the relevant temperatures available to be modified.
  • Page 30 Figure 20 Temperature Setting Menu Screen The required setting must be entered using the keypad and then confirmed with the ‘Enter’ button. To return to the setting screen, press the ‘Return’ button. To modify another setting, repeat the above procedure. To return to the Home Screen press the ‘Return’ button located at the top left of the Temperature Setting Menu Screen.
  • Page 31 Timeclock Button - Press this button to set the internal timeclock. When the button is green, it indicates that the timeclock function is active. If the timeclock function is not active, the button will be white. Pressing the button will bring up the following setup screen where the required timeclock can then be set.
  • Page 32 Settings Button - Press this button to enter the Setting Menu. Pressing the button will bring up the following menu screen where five further Settings Menus can be found. Figure 22 Settings Menu Screen The Settings Menu Screen features six further Setting Sub-Menus. These include Status, Clock, Electric heating, Mute, Factory &...
  • Page 33 Status – Press this button to enter the Status Sub-Menu. Pressing the button brings up the following display screen which displays the current status of the appliance, the current mode the appliance is running in and live data for a number of parameters. These parameters include Inlet Water (Heating Return) Temperature, Outlet Water (Heating Flow) Temperature, Water Tank (DHW Cylinder) Temperature and the Ambient Outdoor Temperature.
  • Page 34 Clock – Press this button to enter the Clock Sub-Menu. This sub-menu allows the clock to be set to the current time and date. This must be accurately set to enable the timeclock functionality and monitoring system to operate correctly. The clock sub-menu is shown below. Figure 24 Clock Sub-Menu Screen The date and time can be set using the up and down arrows shown in the display above (hold the buttons down to speed up the adjustment).
  • Page 35 Electric (Fast) Heating - Press this button to enable or disable Fast Heating (when available). Fast Heating is only available when an auxiliary electric heater such as an immersion heater in the hot water cylinder has been fitted. Pressing the button will bring up the following menu screen, where the fast heating function can be enabled or disabled.
  • Page 36 Mute – Press this button to enter the Mute Sub-Menu. This sub-menu allows the appliance to be switched into or out of Quiet Mode and also for Quite Mode to be scheduled at certain times of the day/night. In Quiet Mode, the appliance will run at a slower speed with the fan speed also reduced to provide quiet operation.
  • Page 37 Figure 27 Mute Timer Sub-Menu Screen The functionality can be enabled or disabled by pressing the ON button on the left as shown above. Pressing the ON button will turn it green, indicating it is active and the ON time is set using the Hour and Minute settings above.
  • Page 38 Factory – Press this button to enter the Factory Settings Password Screen. The Password Screen is shown below. Figure 28 Factory Password Entry Screen Enter Password ‘0022’ to enter the Engineer Parameter Sub-Menu. NOTE: This Sub-Menu must only be accessed by a suitably trained engineer. Modifying parameters can cause operating errors and malfunction of the appliance.
  • Page 39 Figure 29 Factory Password Entry Screen Parameters – Press this button to enter the Parameters Sub-Menu. Pressing the button brings up the following configurable display screen which features a large number of editable parameters spread across a number of pages. These parameters are detailed in section 3.2. Figure 30 Parameters Sub-Menu Screen Page 37...
  • Page 40 Defrost – Press this button to enter the Defrost Sub-Menu. This sub-menu allows the appliance to be switched into or out of manual Defrost mode. Switching the Defrost Button to ‘On’ will switch the appliance into Defrost mode which will continue until a full defrost cycle has occurred. Manual defrost mode can be exited at any time by switching the Defrost Button to ‘Off’.
  • Page 41 Unit State – Press this button to enter the Unit Status Sub-Menu. Pressing the button brings up the following display screen which displays the current status of a number of outputs spread across a number of tabs. These outputs and their functionality are detailed in Table 5 at the end of this chapter: Figure 32 Unit Status Sub-Menu Screen Page 39...
  • Page 42 Failure – Press this button to enter the Failure Logging Sub-Menu. Pressing the button brings up the following display screen which displays the stored fault codes (most recent first). The date and time are displayed as follows: DAY-MONTH HOUR:MINUTE:SECOND in order to record the exact time when the fault occurred.
  • Page 43 Brightness – Press this button to enter the Brightness Setting Sub-Menu. Pressing the button brings up the following display screen which allows the display brightness to be increased or decreased using the slider. The Brightness Setting Screen is shown below: Figure 34 Brightness Setting Screen Page 41...
  • Page 44 Temperature Curve – Press this button to enter the Curve Sub-Menu. This sub-menu displays a graph showing the Heating Flow, Heating Return and Ambient temperatures when the appliance is running (data will not be recorded if the appliance is not running). The data is recorded every 5 minutes and displayed in either °C or °F dependent on the user setting (parameter H03).
  • Page 45 Defrosting Icon – The Defrosting Icon (melting Snowflake) indicates that the appliance is currently in Defrost Mode. The defrosting icon will continue to show until defrosting is complete. Alarm/Fault Icon – This icon will flash when a fault or alarm is active. Pressing the icon will bring up the Fault History Sub-Menu.
  • Page 46 Table 7 Monitored Parameters Ref. Text Description Expected Value(s) Inlet Water This is the temperature at which the heating Ambient temperature if the appliance (Return) Temp. water returning from either the heating circuit has been off for a time. or to the hot water storage cylinder is No greater than 65°C in normal entering the heat pump.
  • Page 47 This appliance must be serviced annually or as indicated by the user interface controller. Contact Warmflow for further details. In the event of a breakdown please refer to section 5.2 - Alarms and Troubleshooting. Alternatively, contact your commissioning engineer who must then contact our service department whilst at your home, to report the fault.

  • Page 48: Parameter List

    3.2 Parameter List Installer Parameters Parameter Name Range Default Description Antifreeze Temperature below which Antifreeze Protection is 4°C Temperature enabled Temp Difference A Compressor frequency limited if difference Of Limiting 7°C between Inlet and Outlet temperatures is greater Frequency than A27 Temp Difference B Compressor frequency limited if difference Of Limiting...
  • Page 49 Parameter Name Range Default Description Running Interval Time between pump operating cycle when the 0~120min 30min Time compressor is off Pump operating cycle time when the compressor Running Duration 0~30min 3min is off Auxiliary Pump Selects the operating mode of the pump, 0 = 0/1/2 Mode Ordinary, 1 = Special, 2 = Interval...

  • Page 50: Commissioning

    4 Commissioning The following tasks must be completed in order to commission the ground source heat pump: 4.1 Recorded Details The following details must be recorded in the commissioning certificate. • Householder’s Name and Address • Installation Date • Installing Engineer •...

  • Page 51: Setpoints

    Press the Mode button (see Figure 15) and select Hot Water (only) mode (see Figure 18). Wait for any movement of the valve actuator to complete. Check the valve is in the correct position for Hot Water operation. 4.4 Setpoints The Heating and Hot Water setpoints are available in the parameters list (sect 3.2) in addition to the thermometer button on the main screen.
  • Page 52 Figure 36 Heating Setpoint Icon with Weather Compensation. Sample setting for weather compensation curves for underfloor heating and radiators are shown below. The flow temperature setpoint must be adjusted to match the calculated flow temperature requirement at the design day temperature. The default flow temperature setting is 50°C. Figure 37 Weather Compensation Activation &...

  • Page 53: Dhw Cylinder Heat Up Test

    Slope 0.65 Offset Figure 38 Sample Weather Compensation settings for Radiators & UFH 4.7 DHW Cylinder Heat Up Test A DHW cylinder heat up test must be completed for appliances in a system providing both heating and DHW. The cylinder storage temperature should be set to maximum and the appliance switched to DHW ‘ON’.

  • Page 54: Parameter Backup

    Warmflow and a copy to remain with the appliance. All product warranties will be invalidated if the appliance is not commissioned by a Warmflow engineer or other trained and competent engineer and the combined installation/commissioning certificate (See Section 0 of this manual) returned to Warmflow within 30 days from the date of installation and 90 days from the date code stamped on the appliance.

  • Page 55: Servicing

    The appliance must be serviced at least annually or as indicated by the user interface controller (whichever occurs sooner) by a Warmflow Engineer or other competent Engineer. This is necessary in order to optimise performance of the appliance and to ensure its efficiency and safety for the user.

  • Page 56: Faults And Troubleshooting

    Suggested actions for each fault condition are also included. The suggested actions are attributed to the user (typically the homeowner) or a Warmflow engineer or other trained and competent engineer and should be conducted in the order suggested.
  • Page 57 Alarm Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Test the operation of the heating The temperature sensor is faulty or ✓ Heating Return Temperature Sensor Error return temperature sensor and disconnected. re-connect/replace if necessary. Test the operation of the heating The temperature sensor is faulty or ✓...
  • Page 58 Alarm Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Test the operation of the ✓ Low Ambient Temperature Warning The ambient temperature is too low. ambient temperature sensor and re-connect/replace if necessary. Check the operation of the fan ✓...
  • Page 59 Alarm Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Check there is enough water in ✓ E071 Outlet Water Temp. Lowtemp. The temperature of the outlet water is too low. the system and there are no air locks/lack of flow. Check the wiring and connection There is a communication error between the fan ✓...
  • Page 60 Alarm Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Check the current measurement ✓ Inverter IPM Overcurrent Shutdown Inverter IPM input current is too high. and adjust/replace if necessary. Check the voltage Voltage too low. ✓ Compressor Start-up Failure measurement.
  • Page 61 Alarm Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Check the current ✓ IGBT Power Device Error A transducer has overheated. measurement. Check the operation of the ✓ Overload Error The compressor input current is too high. refrigeration circuit in terms of gas pressure and charge.

  • Page 62: Troubleshooting

    5.2.2 Troubleshooting Other faults or problems with the appliance that may not trigger an alarm are listed below Symptom Possible Cause(s) Suggested Action(s) Action By User Engineer ✓ Ensure timer mode is enabled in ‘Timer’ menu. No heat supplied to the property or hot water Timer mode not enabled.

  • Page 63: Your Guarantees, Terms & Conditions

    In the event that components are not capable of repair, Warmflow will provide replacement parts for any such components. Warmflow reserves the right to repair or replace components within the period of guarantee at a time and location that is most convenient to the company.

  • Page 64: Exclusions Of Guarantee

    Warmflow. Invoices for call out and/or repair by any third party or parts supplied by a third party will not be accepted unless previously authorised by Warmflow in writing.
  • Page 65 (l) Defects caused by the improper use or storage of the appliance and in particular (but without limitation) Warmflow shall not be liable in the case of defects arising from normal deterioration or improper or faulty handling or processing of the appliance by the customer;...

  • Page 66: End-Of-Life Information

    7 End-of-Life Information Warmflow High Efficiency Air Source Heat Pumps must be disposed of according to local regulations by using a public or private waste collection service. 7.1 Safety Risks Prior to disassembly, the appliance must be electrically isolated and disconnected.
  • Page 67 • Ensure that the certificate is signed by both the Competent Person and the Customer. • Register the Appliance. • Remove the white copy of the Installation/Commissioning Certificate. • Send the certificate to Warmflow By post to: Warmflow Engineering Co. Ltd. Lissue Industrial Estate...

  • Page 68: Appendix A: Tables For Minimum Circulating Volume Calculation

    8 Appendix A: Tables for Minimum circulating volume calculation. Typical Pipe Volumes Pipe Type O.D. (mm) I.D. (mm) Volume per metre (l) 13.6 0.145 20.2 0.320 Copper (Table X) 26.2 0.539 32.6 0.835 0.043 0.050 0.113 0.113 Plastic (Push Fit) 0.254 22.8 0.408...

  • Page 69: Appendix B: Wiring Diagrams

    9 Appendix B: Wiring Diagrams Page 67...
  • Page 70 Page 68...
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  • Page 72: Appliance Service Records

    • The appliance must be serviced in accordance with the service schedule and instructions laid out in this manual. • Details of the service conducted must be fully recorded by the Warmflow or other competent engineer conducting the service. Documented records of annual services must be retained by the user.
  • Page 73 ASHP MAN This manual is accurate at the date of printing (E&OE) but will be superseded 7723 and must be disregarded if specifications and/or appearances are changed in ISSUE B the interests of continued product improvement. APR 2024 Page 71...

This manual is also suitable for:

As01-r32As02-r32As03-r32

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