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WarmFlow A Series User Instructions, Installation Instructions, Service 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:
WARNING: This product contains the refrigerant R290. Any action requiring the product to
be unpackaged or access gained to the internal parts must only be taken by personnel
with knowledge of the properties of and risks associated with the refrigerant R290
AS01-R290
User Instructions
Installation Instructions
Service Instructions
Guarantee Terms & Conditions
AS02-R290
AS03-R290

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  • Page 1 High Efficiency Variable Speed Air Source Heat Pumps Models covered by this manual: A-Series Air Source AS01-R290 AS02-R290 AS03-R290 Incorporating: User Instructions Installation Instructions Service Instructions Guarantee Terms & Conditions WARNING: This product contains the refrigerant R290. Any action requiring the product to be unpackaged or access gained to the internal parts must only be taken by personnel with knowledge of the properties of and risks associated with the refrigerant R290...
  • 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 ..................................2 User Instructions ..............................4 Intended Use ..............................4 Compliances ..............................4 SAFETY ICONS ............................5 SAFE HANDLING ............................5 SAFETY ................................ 6 Basic Operation ............................6 Product Data ..............................7 1.7.1 Starting Current ............................. 9 Construction ..............................10 Supplied Components ..........................
  • Page 4 Faults and Troubleshooting ........................54 5.2.1 Faults ..............................54 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 .............................

  • 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 domestic hot water (DHW). The appliances can be used to provide heating and domestic hot water (DHW) via underfloor heating circuits, radiators and approved hot water cylinders.

  • Page 6: Safety Icons

    1.3 SAFETY ICONS WARNING HOT SURFACE Indicates instructions to avoid personal Indicates operations with a danger of injury and/or material damage burning. ELECTRICITY ROTATING PARTS WITH AUTOMATIC START Indicates operations with a danger of electric shock. Indicates operations with a danger of entanglement.

  • Page 7: Safety

    1.5 SAFETY The appliances are suitable only for installation in GB and IE and should be installed in accordance with the rules in force. Installations must be carried out in accordance with the relevant requirements of: • The appropriate Building Regulations, either the Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland), Irish Building Regulations •...

  • Page 8: Product Data

    grade by compressing the refrigerant using the compressor. The compression of the refrigerant increases the pressure and the temperature. This high grade heat is then transferred to the heating system via another heat exchanger known as the condenser. The heat can now be used to provide space heating and DHW.
  • Page 9 Table 2 Product Technical Parameters AS01- AS02- AS03- Model R290 R290 R290 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.

  • Page 10: Starting Current

    Table 3 Product Fiche Warmflow Warmflow Warmflow Supplier AS01- AS02- AS03- Model R290 R290 R290 A+++ A+++ A+++ Energy Efficiency Class Rated Heat Output (kW) Seasonal Space Heating Energy Efficiency 2031 3988 5587 Annual Energy Consumption, GCV (kWh) Sound Power Level, LWA (dB)

  • Page 11: 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 12 Table 4 Shipping Details Product Data AS01-R290 AS02-R290 AS03-R290 Shipping Width 1300 1420 1380 Dimensions Depth (mm) Height 1080 1480 Shipping Weight (kg) Page 11...

  • Page 13: 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 should then be installed on a smooth horizontal surface capable of supporting the weight of the appliance together with any accessories and other plant.
  • Page 14 FRONT SIDE REAR Figure 4 AS02-R290 Casing Dimensions & Heating Connection Locations FRONT SIDE REAR Figure 5 AS03-R290 Casing Dimensions & Heating Connection Locations The heating flow and return connections are located on the rear panel of the AS01-R290, AS02- R290 and AS03-R290 appliances as shown in the images above.

  • Page 15: Installation Location

    2.2 Installation location In order to maximise air flow and provide access for maintenance, a minimum clearance of 500mm must be provided to each side, 1500mm provided to the front and 200mm provided to the rear of the appliance. There must also be a minimum clearance of 1000mm above the appliance. These dimensions are shown below.

  • Page 16: Unpacking

    Below ground feature e.g. open grating, light well. 2200mm 2200mm 200mm 500mm 1500mm Safety Zone Air Flow Zone Figure 7 Safe Zones for Ground Installation Near a Wall 2.3 Unpacking The appliance is supplied on a small pallet and is covered with a cardboard box. The cardboard box should be removed to reveal the appliance with the supplied components.

  • Page 17: Heating Circuit Connection

    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 18: Heating Connections To The Heat Pump

    Note: The activation of antifreeze valves will result in a loss of fluid from the heating circuit and consequently a loss of protection treatments for corrosion, scale and biological growth. The heating circuit must be re-commissioned by a Warmflow engineer or other trained and competent engineer and the concentration of protection treatments checked before operating the appliance.

  • Page 19: 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 20 Pressure Relief Valve Figure 8 Heating & DHW Schematic Pressure Relief Valve Figure 9 Heating Only Schematic Page 19...

  • Page 21: Defrosting

    An in-line buffer tank accessory is available separately from Warmflow. 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.

  • Page 22: Bypass Valve

    Actual Total Pipe Total Emitter Model Circulating Volume Volume * Volume Volume See Appendix A See Appendix A for See Table 1 for for guidance guidance Model Fluid Content = Radiators without TRVs, open UFH loops, etc. 2.8 Bypass Valve In order to provide sufficient flow rates and to facilitate defrosting, 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 23: Electrical Installation

    Figure 12 3-port Motorised Valve Actuator Positions The valve turns clockwise when DHW is enabled as shown on the right in the figure above. 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 to power it in order to return to the default position and should be wired into the permanent live connection in the installers wiring enclosure.

  • Page 24: Digital Inputs

    The appliances must be protected by a Type C MCB and RCD according to the table below. Table 6 Electrical Installation Specification Appliance Minimum Wire Gauge MCB Rating (Type C) RCD Rating (Type F) 30mA ≤0.1 seconds AS01-R290 2.5mm 30mA ≤0.1 seconds AS02-R290 4.0mm 30mA ≤0.1 seconds...

  • Page 25: Temperature Sensors

    Pump – The default output configuration is for controlling an auxiliary pump which may be used to activate an auxiliary DHW pump (as fitted to the Warmflow Nero Heat Pump Cylinders). The pump live should be wired into the Aux pump live terminal 19. The pump neutral and should be...

  • Page 26: 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 25...

  • Page 27: User Interface

    3 User Interface The appliance’s user control interface 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, a start up screen will be displayed. The screen displays the firmware and software version which are installed on the controller.
  • Page 28 There are a number of icons/buttons on the home screen as shown in Figure 4. The meaning and features of these are explained in the table below: 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.
  • Page 29 Mode, Temp & Power timer icon: This icon will be displayed when this timer function is enabled. Smart Grid (SG) Ready Icon: This icon will be displayed when SG Ready function is enabled. SG Ready includes five modes: Solar Sleep Mode, Solar Low Mode, Solar Medium Mode, Solar High Mode, Normal Mode.

  • Page 30: Mode Button

    3.1.1 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 17 MODE Menu Screen The required MODE can be selected by swiping up or down to the desired mode. Details of each MODE are below.

  • Page 31: Target Button

    3.1.2 Target Button. Press this button to set the desired temperatures. Pressing the button will bring up the following menu screen where the required temperatures can then be set. Figure 18 Target Temperature Menu Screen Depending on the current mode of the appliance, the Target Temperature Menu Screen will display the relevant temperatures available to be modified.

  • Page 32: Settings Menu

    Figure 19 State Display 3.1.4 Settings Menu Figure 20 Settings Menu Screen The Settings Menu Screen is accessed by swiping left from the Main Screen. The Settings Menu Screen features 7 further Setting Sub-Menus. These include Time, Parameter, Curve, Brightness, Fault, Electric heating & Smart Grid as shown above and detailed below. These Sub- Menus are detailed in the following pages.

  • Page 33: Time Menu

    3.1.4.1 Time Menu Press this button to enter the Time Sub-Menu. Pressing the button brings up the following display screen which displays 4 sub menus as detailed below. Figure 21 Status Display Screen System Time – Press this button to set the System Time and Date. This sub-menu allows the clock to be set to the current time and date.
  • Page 34 Power Timer – Press this button to set the Power Timer. The Power Timer Setup Screen allows the times for the appliance to be powered on to be set. The functionality can be enabled or disabled by moving the slider on each timer. When the slider is blue, it indicates that the timeclock function is active.

  • Page 35: Parameter Menu

    at a slower speed with the fan speed also reduced to provide quiet operation. As such the maximum heat output available will be reduced when Quiet Mode is enabled. The Mute Sub- Menu Screen is shown below. Figure 25 Mute Timer Screen The functionality can be enabled or disabled by swiping the ON slider, on the left as shown above, to the right.
  • Page 36 Enter Password ‘0022’ to enter the Engineer Parameter (Factory Setting) Sub-Menu. This will display the screen shown in Figure 27 with 6 sub menus as detailed below. NOTE: This Sub-Menu should only be accessed by a suitably trained engineer. Modifying parameters can cause operating errors and malfunction of the appliance.
  • Page 37 Defrosting – Press this button to activate or deactivate manual Defrost mode (when conditions allow i.e. Inlet Temp >23⁰C Coil Temperature <13⁰C). The icon is bright (blue) when manual Defrost mode is active and grey when inactive. AT (Ambient Temp) Compensation / Weather Compensation – Press this button to enter the Ambient Temperature Compensation (otherwise known as Weather Compensation) Sub-Menu.
  • Page 38 About – Press this button to enter the About screen. Pressing the button brings up the following display screen which displays the codes and software versions for the control mainboard and display. The DTU Barcode is also displayed. This information may be requested by Warmflow technical support.

  • Page 39: Curve Menu

    Activating the digital outputs using the manual load controls can assist with commissioning and diagnostics. Not all the digital outputs shown in the manual control section will be available depending on the system configuration. Please contact Warmflow for further details. Figure 32 Manual Load Control 3.1.4.3 Curve Menu...

  • Page 40: Brightness Menu

    3.1.4.4 Brightness Menu Press this button to enter the Brightness Setting. 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 Control 3.1.4.5 Fault Menu Press this button to enter the Fault Log.

  • Page 41: Electric Heating

    The Smart Grid function is for future development. Do not try to use or make any changes to the Smart Grid settings. This appliance must be serviced annually. Contact Warmflow for further details. In the event of a breakdown please refer to section 5.2 - Alarms and Troubleshooting.
  • Page 42 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 The value should be approximately 5.0 entering the heat pump.
  • Page 43 Ref. Text Description Expected Value(s) Operation Freq. This is the current speed of the compressor. Between 30Hz and 90Hz when the of Compressor appliance is running, 0Hz when the appliance is off. Max Frequency This is the maximum adjusted speed of the Varies between 0 Hz and 120 Hz Allowed for compressor.
  • Page 44 Ref. Text Description Expected Value(s) Exhaust This is the superheat temperature of the Not greater than 20°C in normal Superheat disharge line (the gas leaving the compressor operation. travelling to the condenser). Suction This is the superheat temperature of the Not greater than 5°C in normal Superheat suction line (the gas entering the compressor...

  • Page 45: Parameter List

    3.2 Parameter List Table 8 Installer Parameters List System Tab Parameter Name Range Default Description Enable Cooling Enables or Disables Cooling Mode (0 for Function Disabled, 1 for Enabled) Display Sets the appliance as display controlled Control/Remote (previously Master) (0) or remote controlled Control (previously Slave) (1) Unit Address...
  • Page 46 Protect Tab Parameter Name Range Default Description Antifreeze Temperature below which Antifreeze Protection is 4°C Temperature enabled. Min. Outlet Water Minimum Outlet Temp below which the appliance 5°C Temp. Protect will shut down. Temp. Diff. of Differential between Inlet & Outlet temperatures 7°C Limiting Frequency above which compressor speed will be limited.
  • Page 47 Temperature Tab Parameter Name Range Default Description DHW Target Temp. 15~70°C 50°C Hot water target setpoint Heating Target 15~75°C 35°C Heating target setpoint Temp. Cooling Target 7~28°C 7°C Cooling target setpoint Temp. Temp. Diff. for Hysteresis differential for Heating to reactivate 0~10°C 2°C Power-on in Heating...
  • Page 48 Disinfection Tab Parameter Name Range Default Description Disinfection Water 60~70°C 63°C Hot water thermal disinfection target temperature Temp. Duration of disinfection cycle. Time DHW tank Time of Duration of 0~60min 10min temperature is held at or above the setpoint (G01) Disinfection (0 is off) Disinfection Start...

  • Page 49: Commissioning

    4 Commissioning The following tasks must be completed to commission the air source heat pump: 4.1 Recorded Details The following details must be recorded at commissioning, this may be completed online by scanning the QR code found in Section 8 of this manual. •...

  • Page 50: Remote Operation

    The Turn Off Condition for the Heating setpoint is +2.0°C above the setpoint. The maximum recommended value for the Hot Water setpoint is 60.0°C The maximum recommended value for the Heating setpoint is 53.0°C 4.5 Remote Operation If the appliance is to operate in ‘Remote Control’ mode (Parameter H07 (Display Control/Remote Control) = “Remote Control”) the operation of the remote switches can be checked by operating the remote switches and checking the switch status.

  • Page 51: Dhw Cylinder Heat Up Test

    Figure 36 Weather Compensation Activation & Setting Slope 0.65 Offset Figure 37 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.

  • Page 52: Thermal Disinfection

    4.8 Thermal Disinfection The appliance can activate the immersion heater in the DHW cylinder to sanitise the cylinder and prevent legionella formation. The immersion heater contactor should be connected to the DHW Electric Heater output on the installer terminals (see 2.10.4). The recommended parameter settings for activating the immersion heater every 7 days for a 10- minute cycle at 1am to 63°C are shown below.

  • Page 53: System Hand Over

    Warmflow engineer or other trained and competent engineer and the appliance registered with Warmflow within 30 days from the date of installation, and 90 days from the date code stamped on the appliance. Registration may be completed online by scanning the QR code found in Section 8 of this manual.
  • Page 54 Note: All product warranties will be invalidated if the appliance is not serviced at least annually by a Warmflow engineer or other trained and competent engineer, details must be recorded and service records retained.

  • Page 55: 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 56 Fault 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 re- disconnected. connect/replace if necessary. Test the operation of the heating The temperature sensor is faulty or ✓...
  • Page 57 Fault Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Test the operation of the The temperature sensor is faulty or refrigerant discharge line ✓ P181 Discharge Temperature Sensor Error disconnected. temperature sensor and re- connect/replace if necessary. Test the operation of the Discharge Overheat Temperature Sensor The temperature sensor is faulty or discharge line overheat...
  • Page 58 Fault Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Check the operation of the low The low pressure switch in the refrigeration ✓ Low Pressure Protection pressure switch and refrigeration circuit has been tripped. circuit in terms of gas pressure. Test the operation of the ambient ✓...
  • Page 59 Fault Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer Check the plumbing circuit, valves The temperature of the heating circuit water is and operation of the circulating ✓ E171 Anti-freezing Protection too low. pump. Check the inlet & outlet water temperatures and sensors Check the current measurement ✓...
  • Page 60 Fault Action By Fault Possible Cause(s) Suggested Action(s) Code User Engineer ✓ IGBT Power Device Error A transducer has overheated. Check the current measurement. Check the operation of the ✓ Overspeed Error The compressor is running abnormally. refrigeration circuit in terms of gas pressure and charge.

  • Page 61: Troubleshooting

    5.3 Troubleshooting Other faults or problems with the appliance that may not trigger a fault 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 62: 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 63: 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 64 (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 65: 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 This product contains the refrigerant R290. Any action requiring the product to be unpackaged or access gained to the internal parts must only be taken by personnel with knowledge of the properties of and risks associated with the refrigerant R290.

  • Page 66: Appliance Registration

    Register the Appliance. • Registration may be completed online by scanning the QR code below and following the instructions provided. • Alternatively register online at the below web address: https://www.warmflow.co.uk/support/product-registration If the appliance is not registered, warranty may be invalidated. Page 65...

  • Page 67: Appendix A: Tables For Minimum Circulating Volume Calculation

    9 Appendix Tables Minimum Circulating Volume Calculation. Typical Pipe Volumes Pipe Type O.D. (mm) I.D. (mm) Volume per meter (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 Typical Radiator (Emitter) Volumes Volume per meter (L)

  • Page 68: Appendix B: Wiring Diagrams

    10 Appendix B: Wiring Diagrams Page 67...
  • Page 69 This page is intentionally left blank. Page 68...
  • Page 70 This manual is accurate at the date of printing (E&OE) but will be superseded CODE 9049 and should be disregarded if specifications and/or appearances are changed in ISSUE A the interests of continued product improvement. Refer to www.warmflow.co.uk AUG 2024 for current edition of Warmflow product manuals.

This manual is also suitable for:

As01-r290As02-r290As03-r290

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