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Installation techniques
Installation techniques
Poster guidance exemplar pdf.pdf
An in-depth review on an Air Source Heat Pump installation, looking at the benefits, disadvantages, and potential savings to be made.
The 9kW unit has 1 inch BSP male connections; these should be connected to flexi hoses. To maintain flow rate we recommend 28mm pipework is used with this machine. NEVER use 22mm plastic tube, if you insist on using plastic use 28mm throughout All Pipework including the flexis need to be insulated with 23mm lagging It is essential to connect an expansion vessel, pressure gauge, pressure relief valve, filling loop, magnetic filter/strainer and automatic bypass. A pump will be required, normally in the flow. Dependant on system resistance some times, 2 pumps may be required. Either a 3 port diverter valve or 2 x 2 port valves need to be installed for domestic hot water prioritisation. A flow meter / setter and flow switch should be installed and a strainer in the return. The domestic hot water cylinder must be manufactured specifically for the heat pump and have a coil with a surface area of more than 3m^2 equivalent..
Dimensions: Size 16 - 1420mm (h) 940mm (w) 330mm (d) 103kg Size 9 - 998mm (h) 940mm (w) 330mm (d) 75kg
The 16 kW unit has 1 inch BSP male connections, these should be connected to flexi hoses (supplied). To maintain flow rate we recommend 28mm pipework is used with this machine. NEVER use 22mm plastic tube, if you insist on using plastic use 28mm throughout All Pipework including the flexis need to be insulated with 23mm lagging It is essential to connect an expansion vessel, pressure gauge, pressure relief valve, filling loop, magnetic filter/strainer and automatic bypass. A pump will be required, normally in the flow. Dependant on system resistance some times, 2 pumps may be required. Either a 3 port diverter valve or 2 x 2 port valves need to be installed for domestic hot water prioritisation. A flow meter / setter and flow switch should always be installed and a strainer in the return. The domestic hot water cylinder must be manufactured specifically for the heat pump and have a coil with a surface area of more than 3m^2 equivalent.
Dimensions: Size 16 - 1420mm (h) 940mm (w) 330mm (d) 103kg Size 9 - 998mm (h) 940mm (w) 330mm (d) 75kg
Other Component Parts
Other Component Parts
An expansion vessel, pressure gauge, pressure relief valve and filling loop Most heating engineers use a robokit with the appropriate size expansion vessel, this is sized exactly the same way as when using a boiler.
Pump Your pump needs to supply 20l/min for the 9kW and 30l/min for the 16kW unit. The static resistance through the unit is 10kPa for the 9kW and 15kPa for the 16kW unit. The flow meter has a resistance of around 5kPa The cylinders (Gledhill) have a static resistance of 5kPa for the heat pump coil and 19kPa for the solar coil. The total resistance of the components will be approximately 39kPa for the size 9 unit and if the cylinder is piped using both coils and approximately 44kPa for the size 16 unit if using both coils.
Flow switch and flow meter The unit requires 16L / min flow at all times, if you don’t achieve this E911 error will occur to check this flow switch is installed. The flow switch comes with the control box. The flow Switch MUST be installed in horizontal pipe with at least 150mm of straight pipe either side, connection is 1” female BSP. The wire is 2m long and needs to connect into the wiring station. This wire can be extended to suit. We recommend a flow meter is installed into the flow side of the flow switch as per the photo. Adaptors may be required to enable this join. The flow switch is not IP65 rated (weatherproof) and so must not be installed externally.
Diverter valves If you require domestic hot water and heating, diverter valves are required, you need to supply these. You can use a three port or 2 port valves. The three ports must be of the diverter variety or wired as a diverter, see wiring.
Bypass Valve You must install a bypass valve in the heating circuit as far away from the heat pump as possible. The bypass valve enables flow to be maintained as the tevs shut down at all times to prevent unit flow fault.
Buffer vessels
We don’t normally use buffer vessels; as long as the water volume circulating is over 20 Litre. The inbuilt variable speed compressor means the unit can operate without a buffer. 1m of 22mm pipe holds 380 ml of water, if you add the volume in the unit and components and make sure you put the bypass valve more than 25m from the heat pump your system volume will be adequate. When utilizing multiple units, a buffer or low loss header is required to hydraulically join the units.
Water Filter
In all cases a filter with strainer needs to be installed in the return to the heat pump. A magnetic filter should also be installed in the return to the unit. The filters ensure that debris/foreign materials do not cause damage to the heat exchanger in the unit voiding warranties.
Glycol
A propylene glycol mixture must be utilized to prevent freezing of the water within the system. It is important that the glycol concentration is adequate to protect the unit in case of power failure in very cold conditions. If the unit freezes up there will be no warranty. Manufacturer dependant, a mix of around 25% should suffice.
Cylinder
Cylinder
Information taken from;
The cylinder needs to be installed less than 15m from the control box to allow for the temperature sensor cable. Note the size and weight of the cylinder. Full installation instructions are included with the cylinder. We only recommend using Gledhill heat pump stainless steel cylinders however other cylinders can be used IF the coil area is more than 2.5m^2. Smaller coils are not acceptable and cannot be used. Please do not attempt to utilize a standard central heating, non-heat pump optimized cylinder. Cylinders can be pressurised or open vented. When using Gledhill cylinders both the heat pump (top) coil and the solar (bottom) coil should be used. If no solar thermal is being used the heat pump should connect to both coils as per the recommendations in the Gledhill installation instructions, and oversized by 30% to take into account 0kW input from solar thermal in winter.
G3
The G3 regulations state in section 3.13a “for all indirect heat sources an overheat cut out to disconnect the supply to the stored vessel in the event of the stored water overheating must be employed so that the temperature of the stored water does not exceed 100C”. For this reason the heat pump cylinder comes with a 2 port valve and tank stat. The valve can be installed in the flow as per the diagram. However as the refrigerant used in the Samsung EHS is R410A it is not able to physically heat above its critical temperature of 72.8C. Many heating engineers do not install this valve.
Wiring
Wiring
Filling and Flushing
Filling and Flushing
Always follow the manufacturer's instructions for different models, for isolation of cooling function.
Filling and flushing:
The Building Regulations for England and Wales, Part L, 2006, now require a central heating system to be cleaned and inhibited chemically whenever the boiler is changed or any major works are carried out to the system. When installing any Heat pump we insist on a thorough system flush prior to connection of the new equipment, your warranty will be at risk if a suitable flush is not carried out and the system becomes blocked during normal operation.
Power flushing
The recommended procedure is to power flush the system in both forward and reverse directions at 110% of the normal flow rate and to use a chemical flushing agent where required.
Filling
Using the power flusher fill the system with water and 25% Propylene Glycol to more than 1 bar. It’s a good idea to note what the flow rate is through the system on the inline flow meter. DON’T fill the unit with a hose expecting no air locks, the heat pump is prone to air locking at the outdoor unit, there is no auto air vent here. Don’t pour neat glycol into the unit; there is no chance of the heating pump moving neat glycol around the system.
Starting/Powering up
Each manufacturer will have their own procedures to power up the unit and run the circuits, always follow the instructions accordingly.
Maintenance
Maintenance
All Heat Pump's should be maintained at least once a year to comply with warranty and RHI.
Example maintenance procedure;
Stop the unit, clean the strainer or magnetic filter in accordance with manufacturer’s recommendations and replace it.
Test the concentration of the Anti-freeze (glycol) in the system using a Glycol tester the level should be 25%. If you don’t have a glycol tester a Samsung glycol tester can be bought from your heat pump supplier or online.
Refill the unit, pressure should be 1 -2 bar,
Test the operation of the unit against the hot water cylinder. So first we need to draw off 20 liters of water, run a couple of taps for 5 mins to achieve this.
Check the controller is working appropriately
The heat pump should be able to achieve 48C cylinder temperature without using the immersion heater.
While running, check the coil on the heat pump for damage & debris, the coil needs washing we recommend you use Pro-universal heat pump cleaner, this is available online or from your heat pump supplier, one bottle will do up to 3 units. Instructions are given on the bottle.
Check electrical connections & sensor are fixed properly and the overheat thermostat is set to 70C.
Check immersion heater works properly, Measure the current drawn by the heater; it should be 12-13 Amps.
Measure the temperature of the flow using the remote controller.
Measure the flow rate from the flow meter.
With the unit running flat out measure the temperature of the air as it enters the coil and the temperature of the air in the garden. They should be the same check cold air is not recirculating.
Manufacturers documentation
Manufacturers documentation
A2W-Installation-Guide-2020-Final-Draft.pdfERGA-EV_ERGA06-08EVH_ERGA04-08EVA_Installation manual_4PEN629079-1C_English.pdfERGA-EV_EVH_EVH7_ERGA04-08EVA_EHVH-UE6V_Installer reference guide_4PEN629090-1C_English.pdfPage updated
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