Air Source Heat Pump Installation and Maintenance Manual · 2018-12-04 · 4 5 Underfloor Heating...

Air Source Heat PumpInstallation and Maintenance Manual

Model NumbersRASM Monoblocs

RWM Splits RWD Combi (pre-plumbed)

RWH High temp

2 3

Contents Freedom Heat Pumps

Who are Freedom Heat Pumps?Freedom Heat Pumps are a wholesale distribution company for the Samsung EHS and the Hitachi Yutaki range of heat pumps and underfloor heating systems. We offer technical support, training, design and consultancy services and operate the www.samsungehs.co.uk and www.freedomhp.co.uk web sites and freedom heat pumps and Hitachi Yutaki Facebook pages.

We launched Samsung’s eco heating systems in the UK in 2010 and have been market leaders in this sector with over 5000 units out in the field. In 2016 we started distributing Hitachi’s Yutaki range of units to expand our heat pump portfolio and market influence.

How we workOur approach is very straightforward. If you have a set of plans or an outline of the requirements for a project, send them to [email protected]. From there, we will produce a heat loss calculation in line with today’s standards, and put together a list of the kit required at your cost price.

Alternatively, if you don’t currently have a heat pump project, but would like to become a heat pump installer, and don’t know where to start, contact us on 02380 274833 or email us at [email protected] and we can set you on the correct course.

Homeowners If you are the homeowner please ask your installer for the pdf homeowner manual or download it at www.freedomhp.co.uk. Scroll to the bottom and click the link for end user manual. It shows how the unit should be used and how to get the best from it.

Freedom Heat Pumps 3

Underfloor Heating 4

Hitachi Warranty Registration 7 Year 5

Handover of the System 7

Maintenance 12

Installation 13

Monobloc Installation 14

High Temperature S80 Installation 18

Combi Installation 23

Split Installation 28

Start-up procedure 33

Remote controller set up first time 34

What the Unit Comes With and What You Will Need 38

Wiring and Power Supply Information, All systems 40

How To Wire The Electric Meters 42

Special systems and extra settings 43

4 5

Hitachi Warranty Registration 7 YearUnderfloor Heating

If you are looking for an underfloor design which we guarantee will have the heat pump at the centre of the system design, instead of as an add on, come and talk to us at Freedom HP.

All Hitachi heat pumps can now be registered for a 7-year parts warranty, covering only the Hitachi components. Any labour charges for replacing faulty parts are not covered. The Hitachi warranty does not cover, radiators, cylinders, UFH, valves, pumps etc. It is the role of the installer to offer a warranty to the end user covering the heating system including the heat pump. Your installer may offer you their own full parts labour and call out warranty as part of their maintenance agreement, but you need to discuss this with the installer / maintenance company. The warranty will be held by the end user at the address the unit is installed. It is important that a qualified engineer services the unit annually to maintain the warranty . It does not have to be the installer who does this, we can recommend engineers to do this if the installer does not want to do this work.

Your unit is not automatically registered for warranty, your installer needs to fill in a form Online at www.freedomhp.co.uk.

Once this is done a certificate and a maintenance book will be emailed to the applicant, please make sure you have a copy of this certificate, and proof of maintenance. Hitachi may ask for this when a warranty claim is made.

Installation Details

Your Name

Your email address

Outdoor model number

Outdoor serial number

You will find this on the side of the heat pump

Indoor unit model number

Date commissioned / /

Name of Homeowner

End user email address

This is where the warranty certificate will be sent by Samsung

Installation address

Post code

Installation Details

Company name

Engineers name

Office telephone number

Is this your first Hitachi install? YES / NO

Date commissioned

Will you or your company be maintaining the Unit? YES / NO

If No, Freedom Heat Pumps will advise of an engineer who can do this

Install PhotosPlease take at least 6 photos showing the outdoor unit, control box and cylinder cupboardPipe

We supply a high quality 16x2mm multilayer pipe, consisting of 5 layers of polyethylene, adhesive and aluminium. Typically rated at 95°C at 10bar, this strong flexible pipe is well suited to underfloor heating, and is manufactured within the EU.

ControlsAt Freedom we provide a wide range of controls manufactured by leading brands such as Heatmiser, Danfoss and Reliance. On offer are basic dial thermostats to the latest digital phone app controlled products.

ManifoldsOur brass manifolds are made in Germany, and are supplied to us by Watts Industries. This premium product has individual flow meters, isolation ball valves, and is fitted with an auto air vent and pressure gauge to aid testing.

Plate SystemsOur plate system is generally used for a suspended floor. Insulation should be fixed flush with the top of the existing joists to prevent downward heat loss. Battens are fixed at 400mm centres at 90° to the existing joists. Aluminium trays are then laid and stapled into position and the underfloor heating pipe is pressed into the grooves within the trays.

The pipe warms the trays and the heat is spread across the floor. Chipboard or plywood can then be laid and fixed to the battens.

Overlay SystemsOverlay panels provide many advantages over other insulation products when used with warm water underfloor heating systems.

Our panel dimensions are 1250mm in length by 350mm in width and either 20mm or 25mm high.

Screed SystemsA Screed System is where the underfloor heating pipes are incorporated within the solid floor structure. Staples, interlocking cliprail or castellation mats are fixed directly on to the floor insulation. At Freedom Heat Pumps, we can provide everything from staples to cliprail through to castellation mats in order to suit your project.

Quotations are provided without obligation, and a fully insured BS1264 compliant AutoCAD pipe layout can be prepared prior to delivery and installation. This affords the client an opportunity to approve our suggestions prior to final acceptance.

Do you have a project which you would like us to provide a competitive underfloor heating quotation for? If so, please email [email protected] or call 02380 274 833

6 7

Header, Buffer or

Heat Exchanger

Pump Z1Z1

Z2

The 3 port valve MUST go A to DHW and B to Heating

Flow & Return at Heat Pump

Return from Header

Return from Heating

Flow out of Header

Flow into Header

Handover of the SystemHitachi Warranty Registration 7 Year

Heating Mode Commissioning DataIt is useful to take these measurements at commissioning and testing. They are for your own records, they are not needed to register the unit for warranty.

What type of system do you have? Pre-plumbed / Separate Cylinder

Is there a Header, Buffer or Heat Exchanger installed?

Measure the following and record the data:

Flow temperature at Heat Pump Measure with pipe thermometer

Return temperature at Heat Pump

Flow temp into header / plate

Return from header / plate

Flow temp out of header / plate to heating

Return from Heating into header / plate

Flow rate from flow meter

Air temp at the back of the unit

Ambient air temperature Measure from the garden

Hot water cylinder model No.

Cylinder water temp at start-up Measure from the remote controller

Cylinder water temp after 30mins Measure from the remote controller

Water flow temp at cylinder Measure with pipe thermometer

Water return temp at cylinder Measure with pipe thermometer

Flow Rate Measure from the flow meter

Hot Water Mode Commissioning DataYou must be running the heat pump in hot water mode for this section

Leave these 5 pages with the Homeowner.

Search Freedom heat pumps, Handover video for Hitachi heat pump on YouTube

Thank you for buying an Hitachi heat pump system, your Hitachi heat pump heats the house and hot water cylinder much like a normal fossil fuel boiler, however there are a couple of differences which you should take notice of.

Your installer should have provided you with a room thermostat if you have radiators or a thermostat in every room if you have under floor heating. They will tell you how to use these stats. The heat pump will run when it gets a run signal from the thermostat. It is not controlled by the Hitachi remote controller.

To turn on the heating all you need to do is turn up the thermostats, to turn it off you need to turn them down. The thermostat sends a run signal to the heat pump. Once the unit starts up it will take time to get to temperature, it is not instant. Within 10 minutes you should feel the radiators beginning to warm up

Weather compensationThe radiator temperatures will be lower than you are used to with a gas or oil boiler. To add to this, we run them in a weather compensation mode, this means that the unit measures the outside temperature and adjusts the radiator temperature to suit.

The colder it is outside the warmer the rads will be and vice versa. This function is automatic and is designed to save you money. In very cold weather the radiator will be at their hottest, they will reach 50°C, its possible to get to 80°C if you have an HT system.

Running your machine efficientlyIt is very expensive to heat the house up from cold, with a heat pump the best advice is to maintain the house at as close to constant temperature as possible all the time.

Please DON’T set the room temperature too low when you leave the house, ideally drop it 2 degrees below your normal set temperature when you go out or it will take a long time and a lot of money to recover.

To switch off the heating in summer set the thermostats down to 16°C to avoid the heating starting up.

Your radiators will have thermostatic valves on them, you can adjust each room’s temperature with these.

Water temp in weather comp mode

Ambient temperature °C

Flow

tem

pera

ture

°C

-535

55

50

45

40

0 5 10 15

8 9

Handover of the System Handover of the System

General AdviceThe heat pump comes with a controller which looks like this, you should not use this or press the buttons, it is used for commissioning and fault diagnosing the system.

On you tube (search for freedom heat pumps) there are videos showing how to use the controller, faults etc.

If the system goes into fault, the screen will show a number at the bottom starting with A, for example A020. The green light will go out and a red light will flash. The engineer will want to know this number when you call.

Please avoid turning the unit off at the power supply especially in cold weather. If the unit is off and the weather is very cold, it cannot protect itself and your warranty will be at risk.

Hot Water

Scroll right highlight DHW, press power to turn DHW on. Press up to set the temperature of the cylinder typically 55°C for a low temp and 70°C for a high temp unit

The unit it set up to maintain the water between 43 and 50°C all the time.

As you use the water the heat pump will constantly top up the cylinder. The hot water cylinder has priority over the heating, if the cylinder temperature falls 5 degrees below its set point the unit will automatically switch to heating the cylinder. This should take less than an hour.

Once set temperature is achieved the unit will go back to heating the house. The hot water cylinder loses almost no heat (1/3 a degree an hour) if no hot water is used.

An anti-legionella / disinfection operation will be completed at a 3am every Wednesday morning. The unit will heat the cylinder with the immersion to 60°C, the hot water will be hotter on a Wednesday morning than the rest of the week.

If you don’t require 24/7 hot water It is possible to time clock the hot water to reduce costs, the timer video on you tube will show you how to do this.

Location Function

1Liquid Crystal Display Screen where controller software is displayed.

2OK button To select the variables to be edited and to confirm the selected values.

3Arrow Keys It helps the user to move through the menus and views.

4Run/Stop button It works for all zones if none of the zones is selected or only for one zone when that zone is selected.

5Menu button It shows the different configuration options of the user controller.

6Return button To return to the previous screen.

7Favourite button When this button is pressed, the selected favourite action (ECO/Comfort, Holiday, Simple timer or DHW boost) is directly executed.

OK

2

1

3

4

5

7

6

10 11

Common Icons Icons for the comprehensive view

Icon Name Values Explanation

OFF

Status for circuit 1, 2, DHW and swimming pool.

Circuit I or II is in Demand-OFF

Circuit I or II is on Thermo-OFF

Circuit I or II is working between 0 < X ≤ 33% of the desired water outlet temperature



Mode

Heating

Cooling

Auto

88 Setting TemperaturesValue Displays the setting temperature of the circuit 1, circuit 2, DHW and

swimming pool

OFF Circuit 1, Circuit 2, DHW or Swimming Pool are stopped by button or timer

Alarm Existing alarm. This icon appears with the alarm code

TimerSimple timer

Weekly timer

Derogation When there is a derogation from the configured timer

Installer Mode Informs that user controller is logged on the installer mode which has special privileges

Menu Lock It appears when menu is blocked from a central control. When indoor communication is lost, this icon disappears

Outdoor Temperature The ambient temperature is indicated at the right side of this button

Icon Name Values Explanation

Pump

This icon informs about pump operation. There are three available pumps on the system. Each one is numbered, and its corresponding number is displayed below to the pump icon when it is operating

Heater step Indicates which of the 3 possible heater steps is applied on space heating

DHW Heater Informs about DHW Heater operation. (If it is enabled)

Solar Combination with solar energy

CompressorCompressor enabled (For YUTAKI S, S COMBI and M)

Compressors enabled. 1: R410A / 2: R-134a (For YUTAKI S80)

Boiler Auxiliary boiler is working

Tariff Tariff signal informs about some cost conditions of the consumption of the system

Defrost Defrost function is active

Central/Local- No icon means local mode

Central mode (Three types of control: Water, Air or Full)

Forced OFFWhen forced off Input is configured and its signal is received, all the configured items on the comprehensive view (C1, C2, DHW, and/or SWP) are shown in OFF, with this small icon below

Auto ON/OFF When daily average is over auto summer switch-off temperature, circuits 1 and 2 are forced to OFF (Only if Auto ON/OFF enabled)

Test Run Informs about the activation of the “Test Run” function

Anti-Legionella Activation of the Anti-Legionella operation

DHW boost It activates the DHW heater for an immediate DHW operation

ECO/Comfort mode for circuits 1 and 2

- No icon means Comfort mode

ECO mode

Handover of the System Handover of the System

12 13

InstallationMaintenance

The Hitachi heat pump should be maintained at least once a year to comply with warranty and RHI. You must log your maintenance at www.freedomhp.co.uk for the 7-year warranty.

Installing the Outdoor Unit (Boiler)Position the outdoor unit so that the air flows into an open area, where there are no plants and animals

Install the outdoor unit on a flat, stable surface, the unit needs to be securely mounted at least 100mm off the ground on rubber feet. The unit must be bolted down for security using 10mm bolts and Zebedee’s.

The unit must have adequate drainage away from the unit; it can produce up to 6 L / hour of condensate. If you are installing the unit at height you can install a drain pan under the unit but its best to let the unit drain into the ground.

There is an optional draining kit, see picture, which you can use but we recommend draining straight into the ground.

Dimensions Split:

Size 2 - 600mm (h) 792mm (w) 300mm (d) 46kg


Size 4, 6, 8 and 10 - 1380mm (h) 950mm (w) 370mm (d) 116kg

Dimensions Monobloc:




The space around the unit is very important, allow:

300mm to the left hand side (facing the front of the unit), 600mm to the right of the unit, 300mm to the rear of the unit and 1500mm to the front of the unit.

300 or more

300

or m

ore

1500

or m

ore

600 or more

Hot Water CylinderCheck electrical connections & check the tank temperature sensor is above the immersion heater and fixed properly and the overheat thermostat is set to 70°C. On a Telford cylinder set the stat to 5.

Maintenance procedureStop the unit, clean the water strainer in the unit you need a spanner and circlip pliers for this.

On Monoblocs 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 glycol tester / refractometer can be bought from your heat pump supplier or online.

Refill the unit, pressure should be 1.5 bar,

We need to test the operation of the unit against the hot water cylinder. So first we need to draw off 50 liters of water, run a couple of taps for 5 mins to achieve this. The unit should start up automatically in hot water mode, if it doesn’t on front screen scroll left highlight Heating press power to turn this off.

Scroll right highlight DHW press power turn DHW on. The unit should now run in DHW and open the 3 port to the cylinder,

To test cylinder and flow temp press menu, operational information ok, select DHW ok all temperatures are listed. Log the temperature of the flow, the flow rate, the temperature of the air as it enters the coil and the temperature of the air in the garden.

The heat pump should be able to achieve 50°C cylinder temperature without using the immersion heater. While running, check the outdoor unit for damage & debris, the coil needs washing, we recommend you use an approved heat pump cleaning chemical, your distributor will stock this. Instructions are given on the bottle. You also need to clean and polish the outside casing we recommend car wax to do this

OUTLET OUTLETINLET INLET

Ball in closed position Ball in cleaning position

Ball ready to clean-cutwith flush. An extra 22º isneeded to rotate the ball.At this position, the mesh

can be removed from thefilter ball for maintenance

tasks

Drain Pipe

Extruded Portion

Drain Boss

Rubber Cap

Drain hole of Base

14 15

Monobloc Installation Monobloc Installation

Installing the indoor (mirror) boxThe tank sensor and controller come as accessories

Install the control unit indoors, it’s not waterproof. It needs to be sited within 75m of the hot water cylinder, less than 100m from the outdoor unit.

The box is 360mm wide, 490mm high, 100mm deep.

Note the pump in the Monobloc can only manage a run of 10m at 28mm diameter copper each way to the header or cylinder.

Hea

der,

Buffe

r or

Hea

t Ex

chan

ger

Pum

p Z1

Z1Z2

The

3 po

rt v

alve

MUS

T go

A

to D

HW

and

B to

Hea

ting

Flow

& R

etur

n at

Hea

t Pum

p

Retu

rn fr

om

Hea

der

Retu

rn fr

om

Hea

ting

Flow

out

of

Hea

der

Flow

into

H

eade

r

Hea

ting

and

Hot

Wat

er S

yste

ms M

onob

loc

360

490

16 17

Pump Z1

Remote

ControllerH

eating run signal from

stat or ufh

3 port Monobloc

split and ht only

Comm

s to O

utdoor Unit

Power

16 Amps

Imm

ersion Heater 13A

Cylinder sensor up to 75m

long

2 Core flex0.75m

m

Monobloc InstallationMonobloc Installation

Wiring Diagram

Monobloc ( PCB in the M

irror Box )

Power the H

itachi system needs 2 pow

er supplies Im

mersion heater is connected to 31 Live and 30 N

eutral; Com

munication cable connect to the control box, term

inals 1 and 2. Rem

ote controller connect to 3 and 4. Cylinder sensor connect this using 5 and 6

Run signal, 13 is permanently 240V ac. The run signal goes into 14. Rem

ove the link. Pum

p Z1 Live 14 and Neutral 34 on a com

bi wire live to 36

3 port connect live to 32 and Neutral to 34 the orange and grey w

ires are not used. If a low

loss header or buffer is used you can connect a buffer sensor in 8 and 9

Before power up

Monobloc Dip Switches when using mirror box

In the outdoor unit on the right hand pcb, set DSW 4 Pin 1 up to activate indoor unit wiring box. You also need to set SSW1 to Local push it down (Instead of remote)

On the Monobloc, mirror box / indoor unit make sure DSW2 switches in the indoor switch box match the setting for the outdoor unit selected, this tells the unit its size.

Details of the disp switches in the mirror box and how you have to set them. If you get fault 011 or fault 31 on a Monobloc with mirror box (indoor wiring box) you have not set these switches correctly

Now power it up, it will say AUoP on the outdoor unit if you heave set this up right.

Now turn to page 33.

2.0 HP 2.5 HP 3.0 HP 4.0 HP 5.0 HP 6.0 HP 8.0 HP 10.0 HP

18 19

High Temperature S80 Installation High Temperature S80 Installation

Installing the High temp indoor box The HT box contains, the high temp refrigeration system including a compressor, water to refrigerant heat exchanger, filter ball, flow meter, flow switch, expansion vessel, an 8m pump, cylinder sensor and the remote controller.

Note that the HT box makes a noise as it has a compressor in it, you need to think about sighting this out of hearing range, don’t put it in the lounge.

It might be an idea to mount it on rubber feet and fit flexi hoses if it’s going in the house. The fittings are 1 ¼ bsp female.

Install the unit indoors, it’s not waterproof and it sounds like a dishwasher so keep it out of ear shot. It needs to be sited within 75m of the hot water cylinder, and less than 75m from the outdoor unit.

The box is 600mm wide, 751mm high, 623mm deep.

Note the pump in the HT can only manage a run of 10m at 28mm diameter copper each way to the header or cylinder.

HT units need a drain connection for the Robokit and condensation

Refrigeration pipework HT Your fridge engineer will need to pipe between the indoor and outdoor units with refrigeration pipework.

Pipe Sizes

Outdoor Unit & Yutaki M Indoor Unit

ModelPipe Size

ModelPipe Size

Gas Pipe Liquid Pipe Gas Pipe Liquid Pipe

( 3 - 6 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”) ( 3.0 - 6.0 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”)

Pipe Limits

Outdoor Unit (HP) 4 5 6

Maximum piping length between outdoor unit and indoor unit (Lmax)

Actual piping length (L) 75m

Equivalent piping length 95m

Minimum piping length between outdoor unit and indoor unit (Lmin) Actual piping length (L) 5m

Maximum height difference between indoor and outdoor unit (H)

Outdoor unit higher than indoor unit 30m

Indoor unit higher than outdoor unit 20m

All units have enough refrigerant R410a for 15m of pipework (each way).

The additional refrigerant charge required is:

• Size 4 add 60g/m after 15m• Size 6 add 60g/m after 15m

If the pipe length is under 5m set DSW2 pin 1 up to on. If the pipe length is over 30M set DSW2 pin 2 to up on

When delivered the indoor unit expansion valves are fully closed. To open the valve you must apply power to the unit and make sure dip switch DSW4 pin 2 to up .

You MUST pressure test, vac and charge using both service valves at all times.

When you finish vaccing and charging switch power off the unit, set DSW4 pin 2 to off and then power up again or the unit wont start.

+H

20 21

Pum

p Z1

Rem

ote

Cont

rolle

rH

eatin

g ru

n si

gnal

from

st

at o

r ufh

3 po

rt M

onob

loc

split

and

ht o

nly

Com

ms t

o O

utdo

or U

nit

Pow

er

32 A

mps

Imm

ersi

on H

eate

r 13A

Cylin

der s

enso

r up

to 7

5m lo

ng

2 Co

re fl

ex0.

75m

m

Heating and H

ot Water System

s HT

Wiri

ng D

iagr

am H

eatin

g an

d H

ot W

ater

HT

High Temperature S80 Installation High Temperature S80 Installation

Header,

Buffer or H

eat Exchanger

Pump Z1

Flow and return

1 1/4” female

If unit is in the house you might

want to use flexi hoses and

rubber feet under the unit

Z1 Z2

Flow & Return

at Heat Pum

p

Return from

Header

Return from

Heating

Flow out of

Header

Flow into

Header

The 3 port valve MUST go

A to DHW

and B to Heating

Pow

er th

e H

itach

i sys

tem

nee

ds 2

pow

er su

pplie

sIm

mer

sion

hea

ter i

s con

nect

ed to

31

Live

and

30

Neu

tral

;Co

mm

unic

atio

n ca

ble

conn

ect t

o th

e co

ntro

l box

, ter

min

als 1

and

2.

Rem

ote

cont

rolle

r con

nect

to 3

and

4.

Cylin

der s

enso

r con

nect

this

usi

ng 5

and

6

Run

sign

al, 1

3 is

per

man

ently

240

V ac

. The

run

sign

al g

oes i

nto

14. R

emov

e th

e lin

k.Pu

mp

Z1 L

ive

14 a

nd N

eutr

al 3

4 on

a c

ombi

wire

live

to 3

63

port

con

nect

live

to 3

2 an

d N

eutr

al to

34

the

oran

ge a

nd g

rey

wire

s are

not

use

d.If

a lo

w lo

ss h

eade

r or b

uffe

r is u

sed

you

can

conn

ect a

buf

fer s

enso

r in

8 an

d 9

22 23

High Temperature S80 Installation Combi Installation

Installing the indoor box CombiThe box contains, hot water cylinder 3 port valve, water to refrigerant heat exchanger, filter ball, flow meter, flow switch, expansion vessel, an 8m pump, cylinder sensor and the remote controller.

Install the unit indoors, it’s not waterproof. It needs to be sited less than 30m from the outdoor unit if size 2 and 3 and 75m if its size 4-5-6.

The box is 1816 high, 600mm wide, 733mm deep. It weighs 135kg empty and up to 400kg full

Note the pump in the combi can only manage a run of 10m at 28mm diameter copper each way to the header.

You need a g3 drain from the unit in 15mm, the fitting on the unit is 16mm so needs chopping off.

Combi units need a drain connection for the Robokit and condensation

Refrigeration pipework Combi Your fridge engineer will need to pipe between the indoor and outdoor units with refrigeration pipework.

Pipe Sizes


ModelPipe Size

ModelPipe Size


2 HPØ 12.7 (1/2”) (*)

Ø 6.35 (1/4”) 2.0 HPØ 15.88 (5/8”) (*)

Ø 6.35 (1/4”)

2.5 HP Ø 6.35 (1/4”) (*) 2.5 HP Ø 9.52 (3/8”) (*)

( 3 - 6 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”) ( 3.0 - 6.0 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”)

Note on the 2 and 2.5HP units run the pipes as per outdoor unit, the indoor comes with adaptors to suit the pipework.

+H

Before power upOn the indoor circuit board set the following switches

DSW 4, Pin 5 needs to set pushed up

DSW 4 Pin 3 push to up to enable immersion heater

Note before the unit will run the expansion valve dip switch needs to be set by the fridge engineer.


Vaccing and ChargingWhen delivered the indoor unit expansion valves are fully closed. To open the valve you must apply power to the unit and make sure dis switch DSW4 pin 2 to up .




24 25

Hea

der,

Buffe

r or

Hea

t Ex

chan

ger

Pum

p 3

Hea

ting

flow

and

retu

rn2.

0-3.

0HP:

G 1

” fem

ale

4.0-

6.0H

P: G

1 1/

4” fe

mal

e

Cold

feed

and

DH

W o

ut

3/4”

fem

ale

Pres

sure

Re

lief 1

5mm

Z1Z2

Flow

& R

etur

n at

Hea

t Pum

p

Retu

rn fr

om

Hea

der

Retu

rn fr

om

Hea

ting

Flow

out

of

Hea

der

Flow

into

H

eade

r

Pipe Limits

Outdoor Unit (HP) 2 2.5 3 4 5 6


Actual piping length (L) 50m 75m

Equivalent piping length 70m 95m







• Size 2 add 30g/m after 15m• Size 3 add 40g/m after 15m• Size 4 add 60g/m after 15m• Size 6 add 60g/m after 15m





Combi Installation Combi Installation

Not

e th

ere

is a

pre

ssur

e re

lief a

t the

bac

k of

the

unit

G3, i

t com

es o

ut in

16m

m, y

ou

need

to re

mov

e th

is a

nd re

plac

e th

e pi

pe w

ith 1

5mm

copp

er a

nd d

on’t

forg

et d

rain

fo

r ind

oor u

nit

Hea

ting

and

Hot

Wat

er S

yste

ms C

ombi

26 27

Pump 3

Remote

ControllerH

eating run signal from

stat or ufh

Note if you w

ant to use the heating backup heater in the Com

bi you need a bigger power supply.

Another 13 Amps for the 2 and 3H

P model and 26

Amps for the 4-5 and 6 kW

Comm

s to O

utdoor Unit

Power

16 Amps

2 Core flex0.75m

m

Power the H

itachi system needs 2 pow

er supplies Com

munication cable connect to the control box, term

inals 1 and 2. Run signal, 13 is perm

anently 240V ac. The run signal goes into 14. Remove the link.

Pump 3 Live 14 and N

eutral 34 on a combi w

ire live to 36 If a low

loss header or buffer is used you can connect a buffer sensor in 8 and 9

Wiring Diagram

Heating and H

ot Water Com

bi

Combi Installation Combi Installation






Vaccing and ChargingWhen delivered the indoor unit expansion valves are fully closed. To open the valve you must apply power to the unit and make sure dis switch DSW4 pin 2 to up .




28 29

Split Installation Split Installation

Installing the indoor box SplitThe Hydro box contains, electric backup heater, water to refrigerant heat exchanger, filter ball, flow meter, flow switch, expansion vessel, an 8m pump, cylinder sensor (blue) and the remote controller.

Install the unit indoors, it’s not waterproof.

It needs to be sited within 75m of the hot water cylinder, less than 75 or 30m m from the outdoor unit.

The box is:

• 2-3hp 450mm wide, 820mm high, 275mm deep. It weighs 45kg• 4-6hp 520mm wide, 940mm high, 360mm deep. It weighs 48kg• 8-10hp 670mm wide, 990mm high, 360mm deep. It weighs 62kg

Note the pump in the split can only manage a run of 10m at 28mm diameter copper each way to the header or cylinder.

Split units need a drain connection for the Robokit and condensation

Refrigeration pipework Combi Your fridge engineer will need to pipe between the indoor and outdoor units with refrigeration pipework.

Pipe Sizes


ModelPipe Size

ModelPipe Size


2 HPØ 12.7 (1/2”) (*)

Ø 6.35 (1/4”) 2.0 HPØ 15.88 (5/8”) (*)

Ø 6.35 (1/4”)

2.5 HP Ø 6.35 (1/4”) (*) 2.5 HP Ø 9.52 (3/8”) (*)

( 3 - 6 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”) ( 3.0 - 6.0 ) HP Ø 15.88 (5/8”) Ø 9.52 (3/8”)

8 HPØ 25.4 (1” 1/18)

Ø 9.52 (3/8”) 8 HPØ 25.4 (1” 1/18)

Ø 9.52 (3/8”)

10 HP Ø 12.7 (1/2”) 10 HP Ø 12.7 (1/2”)

Note on the 2 and 2.5HP units run the pipes as per outdoor unit, the indoor comes with adaptors to suit the pipework.

Pipe Limits

Outdoor Unit (HP) 2 2.5 3 4 5 6 8 10


Actual piping length (L) 50m 75m 70m

Equivalent piping length 70m 95m 90m







• Size 2 add 30g/m after 15m• Size 3 add 40g/m after 15m• Size 4 add 60g/m after 15m• Size 6 add 60g/m after 15m• Size 8 add 65g/m after 15m• Size 10 add 65g/m after 15m





+H

30 31

Heating and H

ot Water System

s Split

Header,

Buffer or H

eat Exchanger

Pump Z1

Flow and return

1 1/4” female

Z1 Z2

The 3 port valve MUST go

A to DHW

and B to Heating

Split Installation Split Installation

Pow

er th

e H

itach

i sys

tem

nee

ds 2

pow

er su

pplie

s Im

mer

sion

hea

ter i

s con

nect

ed to

31

Live

and

30

Neu

tral

; Co

mm

unic

atio

n ca

ble

conn

ect t

o th

e co

ntro

l box

, ter

min

als 1

and

2.

Rem

ote

cont

rolle

r con

nect

to 3

and

4.

Cylin

der s

enso

r con

nect

this

usi

ng 5

and

6

Run

sign

al, 1

3 is

per

man

ently

240

V ac

. The

run

sign

al g

oes i

nto

14. R

emov

e th

e lin

k.

Pum

p Z1

Liv

e 14

and

Neu

tral

34

on a

com

bi w

ire li

ve to

36

3 po

rt c

onne

ct li

ve to

32

and

Neu

tral

to 3

4 th

e or

ange

and

gre

y w

ires a

re n

ot u

sed.

If

a lo

w lo

ss h

eade

r or b

uffe

r is u

sed

you

can

conn

ect a

buf

fer s

enso

r in

8 an

d 9

Wiri

ng D

iagr

am H

eatin

g an

d H

ot W

ater

Spl

it

Pum

p Z1

Rem

ote

Cont

rolle

rH

eatin

g ru

n si

gnal

from

st

at o

r ufh

3 po

rt M

onob

loc

split

and

ht o

nly

Com

ms t

o O

utdo

or U

nit

Pow

er

20 A

mps

Imm

ersi

on H

eate

r 13A

Cylin

der s

enso

r up

to 7

5m lo

ng

2 Co

re fl

ex0.

75m

m

Not

e if

you

wan

t to

use

the

heat

ing

back

up h

eate

r in

the

Split

yo

u ne

ed a

big

ger p

ower

supp

ly. A

noth

er 1

3 Am

ps fo

r the

2

and

3HP

mod

el a

nd 2

6 Am

ps fo

r the

4-5

and

6 k

W

32 33






First make sure the dip switches are set, see the settings for your unit.

Before filling the unit with water remove cap from auto vent in unit, on the combi its top left inside the indoor unit.

Please make sure all fittings are tight before filling the unit with water

Filling and flushing, when installing any Heat pump, we insist on a thorough system flush prior to connection in line with the Building Regulations for England and Wales, Part L, 2006. Using the power flusher fill the system with water, there is a pressure sensor in the unit so we can operate from 1.5 -3 bar maximum.

In Monobloc units only Using the power fill the system with water and 25% Propylene Glycol

Setting up the cylinder immersion heater To avoid the immersion heater cutting out before the legionella function is complete you have to set the stat in the immersion heater to 65°C minimum, on a Telford cylinder set it to 5.

Powering UpMakes sure all your room thermostats are off and all underfloor run signals are off.

Apply power to outdoor unit first. Now power the indoor unit, you should see a display on the indoor and outdoor pcb.

Vaccing and ChargingAll split units are delivered with a refrigerant charge in the outdoor unit and all expansion valves in the indoor unit in the fully open position.

If you power the unit up the expansion valves DO NOT close.

You can vac the system powered or unpowered.

Once you have released the refrigerant into the system and added any additional charge you need to be set the unit back to normal operation.

Power off the units (indoor and outdoor for 5 mins.

Flick DSW4 pin 2 to down (Off).

If you don’t do this the unit will never run.


Split Installation Start-up procedure

34 35

Remote controller set up first time Remote controller set up first time

When you first power up the unit the remote controller will ask you a few questions please follow as directed below:

1. Select language, English, press OK2. Date and Time, use left and right to select 12 or 24-hour format, press

down, 3. Year will highlight, use up and down to change, press right, set month

using up and down, 4. Press right, set day using up and down, 5. Press right, set hours and minutes. Then press ok.6. Configuration assistant, press ok7. Is this device attached to unit? Select yes using right, press ok8. Is this device used as a room thermostat? Select no, press ok9. How many circuits do you have? Select 1, press ok10. What are the heat emitters on the circuit? Select to suit (Radiators or

UFH), press ok11. If you have rads AND UFH select rads.12. Do you have a domestic hot water tank installed? If you have a

cylinder select yes, press ok. 13. Do you have a swimming pool? No, press ok.14. Do you have a boiler installed? No, press ok. (If you have a hybrid

system or Backup boiler, select yes, it will then ask what the bi-valent point is, set to 3 degrees or you’re your design temp)

15. Do you have electric backup heater? Select no on Monobloc and HT units, select yes in Split and Combi units, press ok.

16. How many thermostats are installed? Select 0 (This is asking how many HITACHI thermostats are installed on the system, so we select 0, even though your system will be controlled by an external run signal), press ok.

17. Completed shows, press ok.

On all units Activate Anti Legionella

1. Scroll up to DHW – OK2. Scroll down to Anti Legionella – OK3. Status press right to change to enabled4. Press down, to operation day, press left to Tuesday5. Down to start time to right to 3 am6. Press down setting temperature 60°C7. Press return x 2

On all units Stop Pumps running when there is no demand.

1. DSW 4, Pin 5 needs to set- pushed up (already done)2. Scroll to Heat Pump – OK3. Water Pump Configuration – OK4. Minimum off time – Change to 0 mins5. Minimum on time – change to 0 mins6. Overrun time – change to 0 mins7. Press return x2

On all units Adjust the weather comp

8. In system configuration, ok9. Space heating, ok10. Circuit 1, ok11. Water calculation mode, ok12. OTC gradient shows go left to points.13. In points graph, pressing down highlights the water temp at low

ambient, set this using left or right arrows to 45°C for UFH or 50°C for radiators. On HT units set this to 70°C

14. Pressing down highlights water temp at low ambient temperatures, set this using right or left to 37°C. On HT units set this to 50°C

15. Press down to set the low ambient temp set this to -2 with the right button,

16. Press down to set the high ambient temperature, use the left arrow button to set this to 15°C.

17. Press return 3 times until you get back to the menu.

IMPORTANT do this: Air Purge Procedure

18. Scroll down to Commissioning – OK19. Air Purge Procedure – OK20. Set duration – 30 mins use left or right, Down Select start air purge –

OK21. Do you want to continue Select Yes – OK22. Let the unit cycle the pumps and get the air out the system, it will

take it up to 30 mins. Press down Select Cancel – OK to stop Air Purge procedure.

23. Once finished press return 3 times to menu screen, scroll down to return to user mode, press ok. Do you want to continue right ok.

Accessing the Installer MenuTo get into the installer menu to start the commissioning process, hold the Back/Return and the OK button together for three seconds. It was ask for a passcode, the passcode is: Right, Down, Left, Right. “Passcode Correct” shows, press ok. You will now see a picture of a Spanner in the bottom, right hand corner. Press the Menu button and you will see more options in the menu than when in user mode.

On a Combi unit, only If you are using a buffer, plate heat exchanger or a low loss header with pump 3.

1. Press Menu2. System Configuration – OK3. Optional Functions – OK4. System – OK5. Hydraulic Separator Status – press right change to enabled6. Press return x 2

This setting activates the pump on the heating side of the header.

36 37

Cylinder Timer, if you are heating a hot water cylinderFrom the home screen

1. Push right arrow to select DHW – OK2. Select Timer – OK3. If Simple Timer is Selected:4. Frequency – Never / Once / Everyday / Weekends / Work day (Monday

– Friday) change to suit5. Starting Time – change to suit6. Setting Temperature – Change to suit.7. Stop Time – change to suit

Starting the unit in heating modeWith everything off the display on the PCB shows oF

On the controller Scroll to highlight heating C1, press power button to turn heating on.

You will see the target temp displayed and off written underneath. The indoor PCB shows hESt its in heating standby waiting for a run signal.

Now turn up your heating thermostats the unit will operate. The display will show hE0f. Note on the remote controller the pumps 1 (in the unit) and 3 after the header are running and the off signal goes, When the compressor starts the display will show hEon

If alarm A.70 shows

If the flow rate is too low, you need to fix this before moving on. Remove any air, clean the filter in the unit and if it’s still not enough you need bigger pumps. To clear the fault code, switch off both heating and hot water then switch them on again.

To test flow rates and temperatures

1. Hold back / return and OK together for 3 seconds. 2. Enter Password shows, Enter Password as right down, left right, 3. Password is correct press OK4. Press Menu, Scroll to Heat Pump – OK, Water Pump Configuration –

OK, 5. Overrun time – change to 5 mins, Press return x26. Go to Operational information, OK, select Heat pump details, OK flow

rates is listed.

Flow must be 7l/min or 0.4m3/hr on size 2 and 3 units. 14l/min 0.8m3/hr on size 4,5 and 6 units and 25l/min or 1.5m3/hr on size 8 and 10 units. A.70 also shows on the PCB

Starting the System in hot water modeOn the controller scroll left highlight Heating C1, press power to turn this off.

With everything off the indoor PCB will say oF.

Scroll right highlight DHW, press power to turn DHW on. Press up to set the temperature of the cylinder typically 55°C for a low temp and 70°C for a high temp unit.

The PCB will show hSoF, it will change to hSon when it opens the 3 port to the cylinder and starts pump 1

When its running check the flow rate again.

1. Press Menu2. Operational Information – Ok3. Scroll down to Heat Pump Details – OK4. Water Flow Level – will show current water flow rate (m3/hr)

Run test in hot water modeOnce the unit has got going you can view the temperatures and record them on the warranty card at the front of the book.

To test cylinder and flow temp:

1. Press menu, 2. Operational information ok, 3. Select DHW ok 4. All temperatures are listed.

On LT units the water storage temperature is lower (50°C) than a normal cylinder. It’s important to check that any shower or bath mixers do not further reduce the water temperature. Using your thermometer check that the hot water comes out the tap at the same temperature it leaves the cylinder. If it doesn’t you might need to make adjustments to taps mixers etc. DON’T raise the cylinder temperature to compensate.

Remote controller set up first time Remote controller set up first time

Now handover the system to the end user and fill in the warranty card at the front of the book. Your system is now fully commissioned, congratulations.

38 39

What the Unit Comes With and What You Will NeedWhat the Unit Comes With and What You Will Need

Diverter valves Hitachi use a 3-port valve to convert from heating to hot water

Heat meters If you are using more than one heat source, heat pump + boiler you MUST measure the heat produced by the heat pump and the electricity used. This is essential for RHI. The heat meter goes in the return to the heat pump with a sensor in the flow. The electricity meter must measure only the power consumed by heat pump. See hybrid drawings.

The Cylinder If you want to heat water with a heat pump you need a dedicated heat pump cylinder. These are 600mm diameter and are pre-insulated and can store water at up to 3 bar pressures. Note the size and weight of the cylinder. Full installation instructions will be included with the cylinder.

Ideally Cylinders should only be used IF the coil area is more than 2.5m2. Smaller coils give very long recovery times and increase usage of the immersion heater. Cylinders can be pressurised or open vented. We can work out the run cost for you if you tell us the coil size.

Below is a list of the components you will need to buy for each of the systems:

Flexible hoses we recommend flexi hoses are used on Monobloc systems, they are not required on the split systems. The water connections to all units are 1 inch BSP female up to size 4 and 1 1/4 on the 5 and 6 units. We recommend connecting the water pipework with flexible hoses for ease of maintenance and to avoid any vibration from the unit going into the house. All external pipework has to be insulated to meet MCS standards.

Mounting feet the outdoor units need to be mounted 100mm above the ground, we recommend using rubber feet with unistrut channel. These come with mounting bolts included. Splits have 2 feet, monos have 3 feet

An expansion vessel, pressure gauge, pressure relief valve and filling loop All Hitachi units have an expansion vessel inside.

Pump The Hitachi units have a 7.5m pump installed inside.

Assuming you use a low loss header for heating, 1x 3 port zone valves and 6 elbows, you can run, measuring from the header to the heat pump

• 30 m separation on 22mm copper for the 2HP• 30 m separation on 28mm copper for the 3HP• 20 m separation on 28mm copper for the 4-6HP• Call for the 8 and 10HP

If your runs exceed this give us a call as you might need extra pumps.

Water Filter The Hitachi units have a filter inside the units, if the unit is running on a dirty system an additional filter might be a good idea.

Glycol / anti-freeze In Monobloc heat pumps the water goes outside the building. The unit can protect itself from freezing up, but if the power goes off there is a risk that the unit will freeze causing damage. To prevent this, we recommend putting propylene glycol mixture in the system. It is important that the glycol concentration is adequate to protect the unit, if the unit freezes up there will be no warranty. Manufacturer dependant, a mix of 25% is normal for UK conditions.

Adding too much glycol is not a good idea as it increases the water pump power and slightly reduces the capacity of your system.

Flow switch and flow meter The Hitachi units have a flow meter and switch installed in the units.

40 41

Wiring and Power Supply Information, All systems Wiring and Power Supply Information, All systems

The Hitachi system needs 2 power supplies:

Outdoor unit, you need a power supply to the outdoor unit. 20 Amp for the 2 and 3 HP, 32 Amp for the 4, 5 and 6HP and 25 Amp 3 phase for the 8 and 10HP units.

The indoor unit for, Split low temp and mono bloc a 20 Amp supply, this wires into power terminals at the bottom of the electrics box.

On a Combi unit, the power terminals look like 3 phase, if you’re using single phase power supplies you put your live into the 1ˢᵗ Phase and use the top terminal as neutral as normal.

On High temp units, you need 32 Amp supply to power for the unit and the immersion heater combined. This wires into power terminals in the top-left corner of the electrics box

The Immersion heater is connected into the control box terminals 31 Live and 30 Neutral; the control box controls the operation of the immersion heater. If a fused spur is used it must be labelled “do not turn off” as switching it off will cause an error.

Communication cable must be run from the outdoor unit terminals 1 and 2 to the control box, terminals 1 and 2. Use 2 core screened 0.75mm (its 16V ac). It must not have any breaks in it or switches.

Remote controller is normally installed next to the control box out of easy reach, it is mainly used for commissioning. You need to supply a 2 core 0.75mm 2 core flex from 3 and 4 in the remote controller to 3 and 4 in the control box. Maximum distance is 100m.

The cylinder sensor is 1m long, you need to connect this using 0.75mm flex 2 core to terminals 5 and 6 in the control box and into the cylinder in the top ½ of the cylinder. It must install above the immersion heater. You must fix it so it can’t be pulled out of the cylinder. Keep it well away from any mains cables.

The Buffer sensor is 1m long, you need to connect this using 0.75mm flex 2 core to terminals 7 and 8 in the control box and into the buffer or header at the top. You must fix it so it can’t be pulled out. Keep it well away from any mains cables.

3 port valve needs to be connected to terminals 32 live and 34 Neutral the orange and grey wires are not used.

When using multi zone heating systems on a header, buffer or HEXWhen the stat is made, it will drive its zone valve open, inside the zone valve a switch links the orange to the grey wire when the valve is open. We connect the grey to 14 the run signal and the orange to 13 permanent live, so when the valves open the heat pump will run. Hot water production is not affected and will always take priority.

Pump Z1 is connected live to 14 Live and Neutral to 34

Thermostats/ timers and under floor heating manifolds, the heating is controlled with a field supplied room stat / setback stat, time clock or a run signal from an under-floor manifold. 13 is permanently 240V ac. The run signal goes into 14.

Valve Z2Power In

Valve Z1

Pump Z1

Run Signal to Heat Pump

14

14

34

13Power In

42 43

How To Wire The Electric Meters

It is now a requirement to measure the electricity being used by the heat pump so the end user can see what the unit costs to run. We provide a Smart Process electric meter with every unit. Ideally it should measure the total draw for the heat pump (outdoor and indoor unit combined). The outdoor unit takes most of the current so in many installations it will only be used to measure the outdoor unit.

Neutral fom mains and out to heat pump

Live to heat pump

Live from mains

Special systems and extra settings

Backup boilers and HybridsThe Hitachi unit can send a run signal to an external boiler if required.

A relay links terminals 37 and 38 to run the boiler.

Take a live from the boiler into 37 and the run to the boiler in 38.

If no live is available link 33 (permanent live) to 37.

On Hybrid systems, Set up boiler parameters :

1. Menu2. System configuration, press OK.3. Complimentary heating, press OK.4. Automatically populates Heating source (Monobloc will say

“HP+Boiler”, Splits and combi will say “HP+EH+Boiler”) 5. Boiler combination, press OK.6. Adjust Bivalent point to your desired bivalent point or 3°C7. Combination mode: Parallel8. Waiting time: 5 min

In this config, the boiler will run IF the ambient is below the Bi Valent point, the heat pump will not run below the bi valent point. The boiler can run at high temperatures.

On boiler backup systems, Set up boiler parameters:

1. Menu2. System configuration, press ok.3. Complimentary heating, press ok.4. Automatically populates Heating source (Monobloc will say

“HP+Boiler”, Splits and combi will say “HP+EH+Boiler”) 5. Boiler combination, ok6. Adjust Bivalent point to your desired bivalent point 3°C7. Combination mode: Serial8. Waiting time: 5 min

In this config, the boiler will only run IF the ambient is below the Bi Valent point, and the heat pump is struggling, Both the heat pump and boiler will run together. You must set the boiler to run at only 55°C.

Freedom Heat Pumps Ltd Unit 2 Warrior Park, Eagle Close Chandlers Ford, Hampshire SO53 4NF Tel: 02380 274 833 Email: [email protected]

Copyright © 2018 Freedom Heat Pumps Ltd. All rights reserved. Specifications and designs are subject to change without notice. Non-metric weights and measurements are approximate. All data were deemed correct at time of creation. All brand, product, service names and logos are trademarks and/or registered trademarks of their respective owners and are hereby recognized and acknowledged. v031218

Date post:	17-Jun-2020
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

Air Source Heat Pump Installation and Maintenance Manual · 2018-12-04 · 4 5 Underfloor Heating...

Documents