Danfoss DHP-S Installation guide

Installation instruc-

tions

DHP-S

VMGFB102

If these instructions are not followed during installation and serv-

ice, Danfoss A/Sliability according to the applicable warranty is not

binding. Danfoss A/S retains the right to make changes to com-

ponents and specifications without prior notice.

The Swedish language is used for the original instructions. Other

languages are a translation of original instructions.

(Directive 2006/42/EG)

Contents

1 About the instructions..................................................................... 3

1.1 Introduction..................................................................................... 3

1.2 Symbols............................................................................................. 3

1.3 Terminology..................................................................................... 3

2 Important information..................................................................... 4

2.1 Refrigerant........................................................................................ 4

2.2 Noise and vibrations..................................................................... 5

3 Heat pump information................................................................... 9

3.1 Dimensions and components................................................... 9

3.2 Pipe connections......................................................................... 10

3.3 Required service space.............................................................. 10

3.4 Technical data............................................................................... 11

4 Drilling holes for brine pipes....................................................... 13

5 Unpacking and installation.......................................................... 14

5.1 Setting up....................................................................................... 14

5.2 Removing the front cover......................................................... 14

6 Piping installation........................................................................... 16

6.1 Safety valve.................................................................................... 16

6.2 Heating system supply pipe and return pipe.................... 16

6.3 System suggestion...................................................................... 17

7 Electrical Installation...................................................................... 18

7.1 Electrical connection.................................................................. 18

7.2 Connecting pump hot gas....................................................... 18

7.3 Connecting sensor for outside temperature..................... 19

7.4 Connecting hot water sensor.................................................. 19

7.5 Connecting sensor for system supply temperature........ 19

7.6 Connecting exchange valve for hot water......................... 19

7.7 Connecting room sensor (option)......................................... 19

7.8 Connecting pressure and flow sensor (option)................ 19

7.9 Connecting start and stop auxiliary heater........................ 19

7.10 Connecting control signal for auxiliary heater............... 19

7.11 Conversion table for sensors................................................. 19

8 Test operation................................................................................... 21

8.1 Installation checklist................................................................... 21

8.2 Manual test.................................................................................... 22

9 Start up................................................................................................ 25

9.1 Adaptation to the heating system......................................... 25

10 Installing the front cover............................................................ 26

11 Menu information......................................................................... 27

11.1 SERVICE menu............................................................................ 28

11.2 Important parameters............................................................. 36

12 References....................................................................................... 41

VMGFB102 – 1

1 About the instructions

1.1 Introduction

The installation instructions start by describing heat pump data. The installation instructions later give instructions

in a logical order covering unpacking, installation procedure, and checking the installation.

References to chapters and sections within the instructions are in italics, e.g.: About the instructions.

References to menu options in the heat pump’s control system are in upper case, e.g.: INFORMATION ->OPERAT. ->

AUTO.

All figures in the instructions are numbered to help installers and service technicians refer to them easily.

1.2 Symbols

The instructions contain different warning symbols, which, together with text, indicate to the user that there are risks

involved with actions to be taken.

The symbols are displayed to the left of the text and three different symbols are used to indicate the degree of danger:

DANGER! Hazardous electrical voltage!Indicates an immediate danger that leads to fatal or serious injury if

necessary measures are not taken.

Warning! Risk of personal injury!Indicates a possible danger that can lead to fatal or serious injury if necessary

measures are not taken.

Caution! Risk of installation damage. Indicates a possible hazard that can lead to item damage if necessary

measures are not taken.

A fourth symbol is used to give practical information or tips on how to perform a procedure.

Note! Information regarding making the handling of the installation easier or a possible operational technical

disadvantage.

1.3 Terminology

The instructions contain terms throughout that designate components and functions. The table lists the most com-

mon terms that are used in the instructions.

Table 1. Terminology

Term Meaning

Heating system The circuit that generates heat to the property or to the water heater.

Supply line The heating system’s supply line with flow direction from the heat pump to radiators/

under floor heating or water heater.

Return line The heating system’s return line with flow direction from radiators/under floor heating or

water heater to the heat pump.

Circulation pump Circulation pump for heating system.

Refrigerant circuit The energy carrying circuit between the outdoor air and heating system.

Refrigerant The gas/liquid that circulates in the refrigerant circuit.

Installation instructions VMGFB102 – 3

2 Important information

Caution! The heat pump must be located in a frost-free environment!

Caution! The installation may only be commissioned if the heating system is filled and bled. Otherwise the

circulation pump can be damaged.

Caution! If the electrician wishes to test his connections before the above is carried out, this should only

done when it has been checked that the heat pump, the electric boiler, the compressor and the heat shields

are disconnected.

Caution! When filling the coolant system the coolant pump must be operating but one must ensure that the

compressor and the heat transfer pump cannot start.

The system can be considered maintenance free but certain checks are necessary.

Before changing the control computer’s settings, first find out what these changes mean.

Contact your installer for any service work.

Caution! This apparatus is not intended for persons (including children) with reduced physical, sensory or

psychological capacity, or who do not have knowledge or experience, unless supervised or they have

received instructions on how the apparatus functions from a safety qualified person.

Note! Children are not permitted to play with the apparatus.

2.1 Refrigerant

The heat pump’s cooling system (refrigerant circuit) is filled with R407C refrigerant.

Caution! Work on the refrigerant circuit must only be carried out by a certified engineer!

Caution! Fire risk R407C is not combustible or explosive in normal conditions.

Toxicity

In normal use and normal conditions the refrigerant has low toxicity. However, although the toxicity of the refrigerant

is low, it can cause injury (or be highly dangerous) in abnormal circumstances or where deliberately abused.

The refrigerant vapour is many times heavier than air and in enclosed spaces, below the level of the door for example,

and in the event of leakage, large concentrations can occur with the risk of suffocation because of lack of oxygen.

Spaces in which heavy vapour can collect below the level of the air must therefore be well ventilated.

4 – Installation instructions VMGFB102

Warning! Risk of personal injury! Refrigerant exposed to a naked flame creates a poisonous irritating gas.

This gas can be detected by its odour even at concentrations below its permitted levels. Evacuate the area

until it has been sufficiently ventilated.

Warning! Risk of personal injury! Anyone with symptoms of poisoning from the vapour must immediately

move or be moved into the fresh air.

Work on the refrigerant circuit

When repairing the refrigerant circuit, the refrigerant must not be released from the heat pump – it must be destroyed

at a special plant. Draining and refilling must only be carried out using new refrigerant (for the amount of refrigerant

see manufacturer’s plate) through the service valves. Filling with refrigerant other than R407C/134a voids all guar-

antees from Thermia Värme AB, unless this new refrigerant has been approved in writing as an alternative refrigerant

together with other corrective action.

Scrapping

When the heat pump is to be scrapped the refrigerant must be extracted for disposal. The local regulations for

treatment of refrigerant must be followed. See the relevant Swedish Environmental Protection Agency refrigerant

statutes.

2.2 Noise and vibrations

2.2.1 Flexible hoses

All pipes should be routed in such a way that vibrations cannot be transmitted from the heat pump through the

piping and out into the building. This also applies to the expansion pipe. We recommend that flexible hoses are used

for all pipe connections to avoid the transmission of vibrations. Flexible hoses are available to purchase as accessories.

The figures below show how appropriate and inappropriate installations look using this type of hose.

Installation instructions VMGFB102 – 5

To avoid noise caused by pipe mounting, a rubber-coated pipe clamp should be used to prevent the transmission

of vibrations. However, installation should not be too rigid and the pipe clamp must not be too tight.

Figure 1. Do not twist the flexible hoses as they are installed. At threaded connections, use a counterhold spanner

Figure 2. Cut the hose to the correct length to avoid excess bowing-out or stretching at bends

Figure 3. Cut the hose to the correct length to avoid excess bowing-out or stretching and offset the ends so that the hose

is installed completely straight.

Figure 4. Use fixed pipe bends to avoid excess stress on bends next to connections

2.2.2 Preventative measures

Some of the following points can also be used when troubleshooting.

•

Do not install heat pumps on walls adjoining bedrooms.

6 – Installation instructions VMGFB102

•

Ensure that all pipes are elastically suspended, with mountings as illustrated or similar. This is so that the rubber

(or similar material) compresses 1 to 2 mm under vibration. It is not recommended to suspend the pipes from

too many points, as the force at each mounting is then not sufficient.

Figure 5. Elastic pipe suspension.

•

If the heat pump is located indoors and the ceiling in the area is unsuitable to suspend the aforementioned pipe

mountings, set up (or construct) special stands on the floor from which the pipes can be suspended.

•

Ensure that pipe lines do not lie against walls that they run along and that foam insulation is wrapped around

the entire pipe, not just on top of it.

•

Pipes inside the heat pump must not be against each other (if they are, clamp and secure suitable rubber, pulling

the pipes apart by hand only helps temporarily).

•

If the heat pump is on an unstable surface, position rubber feet designed for its weight underneath.

•

If necessary, use rubber straps to secure flexible hoses in position, so that they do not lie against each other or

create vibration bridges.

•

Ensure that electrical wiring is not put under strain, if it is it creates vibration bridges.

•

If possible, install the heat pump in a location that is sound insulated from areas that are frequented by residents.

Soundproofing measures to carry out afterwards:

•

Go through the aforementioned points and improve if possible.

•

Hood for compressor (most effective for high frequencies).

•

Improve the acoustic environment of the heat pump by installing acoustic panels on the walls and ceiling.

•

In some instances, it is recommended that the heat pump is moved to another area.

2.2.3 Electrical connection

Caution! Electrical installation may only be carried out by an authorized electrician and must follow

applicable local and national regulations.

Caution! The electrical installation must be carried out using permanently routed cables. It must be possible

to isolate the power supply using an all-pole circuit breaker with a minimum contact gap of 3 mm.

For information regarding maximum load for externally connected devices, see electrical installation instructions.

Installation instructions VMGFB102 – 7

Electrical current!

DANGER! The terminal blocks are live and can be highly dangerous due to the risk of electric shock. The

power supply must be isolated before electrical installation is started. The heat pump is internally connected

at the factory.

8 – Installation instructions VMGFB102

3 Heat pump information

3.1 Dimensions and components

1

2

3

4

5

6

7

8

455

596

690

40 ±10

60 ±10

1488 (±10)

234

333

856

1229

1348

1358

181

131

184

89

83

74

Figure 6. Measurements

11

14

15

9

12

5

4

3

7

8

1

6

16

18

13

17

10

2

Figure 7. Components

Symbol explanation

1 Coolant out (from heat pump)

2 Heat return (return line)

3 Return line hot-gas exchanger

4 Supply line hot-gas exchanger

5 Heat supply (supply line)

6 Coolant in (to heat pump)

7 Lead-in for communication cable

8 Lead-in for incoming supply and sensor

9 Supply line sensor

10 Condenser with draining for primary side

11 Evaporator

12 Return sensor

13 Compressor

14 De-superheater

15 Drying filter

16 Expansion valve

17 Heat transfer fluid pump

18 Coolant pump

Installation instructions VMGFB102 – 9

3.2 Pipe connections

Table 2. Connection diameter

Size Brine Heat De-superheater

Solid 20 35 28 28

Solid 26 35 28 28

Solid 35 42 35 28

Solid 42 42 35 28

When installing in confined spaces, pipe routing on the rear of the heat pump can be facilitated by connecting the

pipes before the pump is put in position. The following figure shows an example of how the pipes can be routed.

Note! Remember not to tighten the pipes in the heat pump’s panel casing as this transfers vibrations causing

noise problems.

1

2

3

4

5

6

Figure 8. Pipe connection

Symbol explanation

1 Coolant out (from the heat pump)

2 Heat return (return line)

3 Return line hot-gas exchanger

4 Supply line hot-gas exchanger

5 Heat supply (supply line)

6 Coolant in (to the heat pump)

3.3 Required service space

To facilitate the installation and subsequent testing and maintenance there must be sufficient free

10 – Installation instructions VMGFB102

space around the heat pump in accordance with the following dimensions:

300

50

500

300

600

Figure 9. Service space

3.4 Technical data

Table 3. Technical data

DHP-S 20 26 35 42

Refrigerant Type R407C R407C R407C R407C

Amount kg 3,4 3,5 3,6 4,4

Test pressuri-

sation

MPa 3,4 3,4 3,4 3,4

Calculated

pressure

MPa 2,95 2,95 2,95 2,95

Compressor Type Scroll Scroll Scroll Scroll

Oil POE POE POE POE

Electrical data

3-N ~50Hz

Electrical con-

nection

Volts 400/50Hz 400/50Hz 400/50Hz 400/50Hz

Rated output kW 9,50 12,60 15,65 19,35

Start current A 21,5 24 27 37,8

Fuse A 25 25 35 35

Nominal out-

puts

1)

Specified out-

put

kW 18 23 30 37

Heat factor COP 3,1 3,1 3,2 2,9

Nominal flow

2)

Coolant

3)

l/s 1,2 1,6 2,2 2,4

Heat factor l/s 0,5 0,6 0,8 1,0

External avail-

able pressure

4)

Brine kPa 133 66,5 130 127

Heat transfer

fluid

kPa 63 54 47 48

Internal pres-

sure drop

Condenser kPa 4,7 8,9 11 4

Evaporator kPa 36,2 72,5 58 53

Max/Min tem-

perature

Brine °C 20/-10 20/-10 20/-10 20/-10

Installation instructions VMGFB102 – 11

DHP-S 20 26 35 42

Heat transfer

fluid

°C 60/20 60/20 60/20 60/20

Pressure

switches

Low pressure MPa 0,08 0,08 0,08 0,08

Operation MPa 2,65 2,65 2,65 2,65

High pressure MPa 2,95 2,95 2,95 2,95

Anti-freeze Ethylene gly-

col/ Ethanol

Ethylene gly-

col/ Ethanol

Ethylene gly-

col/ Ethanol

Ethylene gly-

col/ Ethanol

Weight kg 274 278 297 315

Measurements are carried out on a limited number of heat pumps, which can give deviating results. Tolerances in the measurement methods can give variation.

1)At B0W45 according to EN14511. Heat transfer fluid Δ5K, brine Δ3K. 3) Anti-freeze in cooling medium: Ethanol-water.

2) Nominal flow: heat transfer fluid Δ10, cooling circuit Δ3K. 4) At nominal flow.

12 – Installation instructions VMGFB102

4 Drilling holes for brine pipes

Caution! Ensure that the holes for the insert pipes are positioned so that there is room for the other

installations.

Caution! The brine pipes shall have separate lead-ins. If the wall lead-ins are below the highest ground water

level watertight lead-ins must be used.

The brine pipes must be insulated from the heat pump, through the walls and outside the house all the way to the

collector so as to avoid condensation and prevent heat loss.

If the brine pipes are to be routed above ground, drill holes in the walls for them.

If the brine pipes are to be routed below ground see the instructions below.

1

2

3

4

Figure 10. Making holes

Symbol explanation

1 Insert pipe

2 Brine pipe

3 Mortar

4 Sealant

1. Drill holes in the wall for the insert pipes (1) for the brine pipes. Follow the dimension and connection diagrams.

If there is any risk of groundwater infiltration at brine pipe lead-ins, watertight grommets must be used.

2. Position the insert pipes (1) in the holes sloping downwards. The inclination must be at least 1cm every 30cm.

Cut them at an angle (as illustrated) so that rain water cannot get into the pipes.

3. Insert the brine pipes (2) into the insert pipes in the installation room.

4. Fill in the holes around the lines with mortar (3).

5. Ensure that the brine pipes (2) are centred in the insert pipes (1) so that the insulation is distributed equally

on all sides.

6. Seal the insert pipes (1) with a suitable sealant (foam) (4).

Installation instructions VMGFB102 – 13

5 Unpacking and installation

The heat pump is packed in boxes and wrapped in cardboard and delivered on a wood pallet.

1. Check that the delivery is complete and undamaged.

Caution! When moving the heat pump, do not use the protruding pipe connections to lift the heat pump.

The packaging should not be used to lift the heat pump either.

5.1 Setting up

1. Move the heat pump to the installation site.

2. Cut off the straps and remove the packaging.

3. Lift the heat pump from the pallet.

4. Install a condensation drain if required.

1

Figure 11. Make sure that the heat pump is level

using a spirit level

Symbol explanation

1 Adjustable feet

5. Adjust using the adjustable legs (1) so that the heat pump stands upright and level on the floor.

5.2 Removing the front cover

Remove the front cover plate as follows:

1. Unscrew the screws (1).

2. Slide the front cover (2) upwards and carefully lift it off upwards and forwards.

3. Place the front cover next to the heat pump.

14 – Installation instructions VMGFB102

2

1

Figure 12. Remove the front

cover

Symbol explanation

1 Screws

2 Front panel

Installation instructions VMGFB102 – 15

6 Piping installation

Caution! To prevent leaks ensure that there are no stresses in the connecting lines!

Note! Ensure that the pipe installation is carried out in accordance with the dimensions and connection

diagrams.

Note! Pipe installation must be carried out by an authorized installer.

Caution! It is important that the heating system is bled after installation.

Caution! Bleed valves must be installed where necessary.

6.1 Safety valve

Note! The heat pump must be connected to the expansion tank and the safety valve according to applicable

regulations. The connection between the reservoir and the safety valve must be routed in a continuous

incline. A continuous upwards slope means that the pipe must not slope downwards from the horizontal at

any point.

Caution! The brine circuit must be filled with the correct amount of fluid otherwise the installation may

become damaged. Ensure that system has the necessary pressure, however, not above maximum pressure

of 3 bar.

Caution! Heating systems with closed expansion tanks must also be supplied with approved pressure gauges

and safety valves.

6.2 Heating system supply pipe and return pipe

1. Install a filter (max mesh size 0.7 mm) in the heating system’s return pipe to protect the unit against foreign

particles.

2. Install the supply line with all the accompanying components.

3. Install the return line with all the accompanying components.

4. Insulate the supply and return lines.

16 – Installation instructions VMGFB102

6.3 System suggestion

50

72

36

51

117

83

80

77

86

97

86

84

111

80

92

1

90

34

91

53

55

82

81

19

115

112

84

83

82

31

82

83

88

19

75

Figure 13. System suggestion

Symbol explanation

1 Heat pump 82 Adjustment valve

19 Water heater 83 Non-return valve

31 Circulation pump (VVC) 84 Pressure gauge

34 Circulation pump, (hot gas) 86 Safety valve

36 Circulation pump (system) 88 Valve pipe (cold water)

50 Outdoor sensor 90 Dirt strainer (hp)

51 System supply line sensor 91 Dirt strainer (hot gas)

53 Hot water sensor start 92 Dirt strainer (heat transfer fluid)

55 Hot water sensor top (Installed in the heater that is hottest) 97 Flexible hose

75 Mixer valve 111 Venting and expansion tank (heat transfer fluid)

77 Reversing valve 112 Expansion vessel (closed)

80 Shut-off valve 115 Immersion heater

81 Filler valve 117 Auxiliary heat

A heat pump can produce both heat and hot water. With an external auxiliary heater (oil boiler, electric boiler, district

boiler or similar) heat production is supported but not hot water production. The exchange valve for heating and

hot water is located ahead of the external auxiliary heater, which allows the production of heating and hot water at

the same time. The heat pump control computer also controls an additional shunt located after the external addition.

The SERVICE menu selects AUX. HEATER, EXT.AUX.HEATER. Default setting is:

•

EXT.AUX.HEATER = ON

•

REV.V. HOT WATER = INT

When an oil boiler is used as addition, the after burning time is activated to 60 minutes.

The SERVICE menu selects AUX. HEATER, EXT.AUX.HEATER, TURN OFF DELAY, 60M

Installation instructions VMGFB102 – 17

7 Electrical Installation

7.1 Electrical connection

Caution! Electrical installation may only be carried out by an authorized electrician and must follow

applicable local and national regulations.

Caution! The electrical installation must be carried out using permanently routed cables. It must be possible

to isolate the power supply using an all-pole circuit breaker with a minimum contact gap of 3 mm.

DANGER! The terminal blocks are live and can be highly dangerous due to the risk of electric shock. The

power supply must be isolated before electrical installation is started. The heat pump is internally connected

at the factory.

1. Remove the front cover from the heat pump.

2. Pull the power supply cable through the opening in the rear of the heat pump to the terminal blocks.

3. Connect the supply cable to the designated terminal blocks.

See separate manual for wiring diagram.

DANGER! Electrical current! The power cable may only be connected to the terminal block intended for this

purpose. No other terminal blocks may be used!

Electrical cabinet layout

K2

K1

F10

F11

X1

F0

F3

F4

1

E1

1

F1

Figure 14. Electrical cabinet

Symbol explanation

K1 Contactor compressor

K2 Contactor brine pump

F10 Over current relay compressor.

F11 Over current relay brine pump

F1 Fuse brine pump

F0 Control fuse regulation, overheating

protection compressor

F3 Control fuse heat addition

F4 Control fuse Oil and Electricity

X1 Terminal blocks for incoming supply

and temperature sensor as well as ter-

minal blocks for external components

1 Space for extra board

7.2 Connecting pump hot gas

1.

Connect the hot gas pump to the designated terminal blocks. The voltage is 230 VAC. The pump is designed

to be placed outside the heat pump casing and must be connected with flexible hoses.

This pump runs in parallel with the compressor.

See separate manual wiring diagram.

18 – Installation instructions VMGFB102

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