Danfoss DHP-M User manual

MAKING MODERN LIVING POSSIBLE
Installation Guide
DHP-M
www.heating.danfoss.com

Danfoss A/S is not liable or bound by warranty if these
instructions are not adhered to during installation or service.
The English language is used for the original instructions.
Other languages are a translation of the original instructions.
(Directive 2006/42/EC)
© Copyright Danfoss A/S

Table of Contents
1 About documents and decals ........................................................ 4
1.1 Introduction ................................................................ 4
1.2 Symbols in documents .......................................................... 4
1.3 Symbols on decals ............................................................ 5
2Important information/Safety instructions ............................................... 6
2.1 General safety precautions ....................................................... 6
2.2 Refrigerant ................................................................. 7
2.3 Electrical connection ........................................................... 9
2.4 Water quality ................................................................ 9
3Transport, unpacking and setting-up ................................................... 10
3.1 Transporting the heat pump ...................................................... 10
3.2 Setting-up the heat pump ....................................................... 10
3.3 Dismantling the front cover ...................................................... 11
4 Heat pump data ................................................................. 12
5 Components .................................................................... 13
6 Piping installation ................................................................ 14
6.1 Safety valves ................................................................ 14
6.2 Heating system supply pipe and return pipe ............................................ 15
6.3 Noise information ............................................................. 15
6.4 Connection brine ............................................................. 16
7 Electrical installation .............................................................. 18
7.1 Electrical components .......................................................... 19
7.2 Fuse size ................................................................... 19
7.3 Estimated current for DHP-M XL, L and M .............................................. 19
7.4 Connecting external supply voltage ................................................. 20
7.5 Position and connect outdoor sensors ................................................ 21
7.6 Network connection, Online and setting up primary and secondary functionality .................... 22
7.7 Connecting bottom hot water sensor ................................................ 24
7.8 Connecting top hot water sensor ................................................... 24
7.9 Connecting system supply line sensor ............................................... 24
7.10 Connecting system pump ........................................................ 25
7.11 Connecting hot gas pump with 230 V supply ........................................... 25
7.12 Connecting exchange valve for hot water ............................................. 25
7.13 Connecting control signal (start/stop) for auxiliary heating .................................. 25
7.14 Connecting pressure sensor and/or flow sensor .......................................... 26
7.15 Connecting EVU .............................................................. 26
7.16 Connection for external sum alarm ................................................. 26
7.17 Connecting distribution circuit 1 ................................................... 26
7.18 Conversion table for sensors ...................................................... 27
8 Installation protocol and customer information ........................................... 28
8.1 Installation protocol ........................................................... 28
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1 About documents and decals
1.1 Introduction
The following documents are available for this product:
▪The Installation Quick Guide is an illustrated step-by-step guide on how to install the heat pump.
Supplied with the heat pump on delivery.
▪Installation Guide. Complements the Installation Quick Guide and gives thorough information on how to install the heat pump.
Available for download, see below.
▪The Commissioning Guide contains the required information in order to commission the heat pump and tune the heating system.
Available for download, see below.
▪The Wiring Diagrams for the heat pump intended for fault tracing and service.
Available for download, see below.
▪The User Guide is intended for the end user and must be handed over and gone through with the end user when installation and
commissioning is completed.
Supplied with the heat pump on delivery.
▪The Technical Description contains information about the heat pump’s function, fault tracing and technical data.
Available for download, see below.
▪Country specific instructions and forms are available where relevant.
Supplied with the heat pump on delivery.
▪Self-adhesive decals with translation text. Must be placed on the manufacturing plate in conjunction with installation.
Supplied with the heat pump on delivery.
Documents not delivered with the heat pump are available for download here:
www.documentation.heatpump.danfoss.com
1.2 Symbols in documents
The instructions contain different warning symbols, which, together with text, indicate to the user that there are risks involved with ac-
tions 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 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.
N
Information regarding making the handling of the installation easier
or a possible operational technical disadvantage.
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1.3 Symbols on decals
The following symbols can occur on decals on the different parts of the heat pump. Which symbols are used depends on the heat pump
model.
1.3.1 General
!
Warning, danger!
!
Read the documentation provided.
Read the documentation provided.
Warning, hazardous electrical voltage!
Warning, hot surfaces!
Warning, moving parts!
Warning, risk of crushing injury!
1.3.2 Electrical components
Explanation
Component, ordinary delivery according to proposed system solutions
Components, accessories according to proposed system solutions
1.3.3 Pipe connections
Tap water
Heating system
Brine system
Defrosting tank
Expansion tank with safety valve, brine
Air bleeding
Temperature and pressure relief valve
Outdoor unit
Water heater
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2 Important information/Safety instructions
2.1 General safety precautions
Warning This appliance can be used by children aged 8 years and above, and
by persons with reduced physical, sensory or mental capabilities or
lack of experience or knowledge, provided that they are supervised or
have been instructed in the safe use of the appliance and understand
the hazards involved. Children must not clean or carry out user main-
tenance on the appliance except under adult supervision.
Warning Ensure that children do not play with the product.
Warning The installation must only be carried out by a qualified installation en-
gineer, following applicable rules and regulations in addition to these
installation instructions.
Caution The heat pump must be located in a frost-free environment!
Caution Installation and connection should be carried out in accordance with
the instructions, in order to avoid subjecting local residents to noise
disturbance.
Caution The heating appliance should be placed on a stable surface that can
support the gross weight of the heating appliance.
Caution Before the heat pump is powered, you must ensure that the heating
system and coolant system, including the heating pump, are full and
bled; otherwise, their circulation pumps may be damaged.
Caution If the electrician wishes to test the electrical connections before the
above is carried out, this should only be done after ensuring that the
heat transfer fluid pump and coolant pump are disconnected.
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Caution When filling the coolant system the coolant pump must be operating;
you must ensure that the compressor and the heat transfer pump can-
not start.
Caution This appliance is intended for use by expert or trained users in shops,
in light industry and on farms, or for commercial use by lay people.
Caution In accordance with EN60335-2-40, this product is classified as "not
available to the general public." This means that the product is de-
signed to be handled by trained staff and installed in an engine room
or similar.
Caution Isolate the power supply to the heat pump while servicing the appli-
ance or replacing parts.
Caution Only spare parts approved by Danfoss Värmepumpar may be used for
this appliance.
N
In normal operation the heat pump generates noise and vibrations.
The appliance should be set up and connected in accordance with the
instructions in order to avoid noise being spread to noise-sensitive
areas.
2.2 Refrigerant
2.2.1 Refrigerant
Caution Work on the refrigerant circuit must only be carried out by a certified
refrigeration engineer.
Although the heat pump's cooling system (refrigerant circuit) is filled with a chlorine-free and environmentally-approved refrigerant that
will not affect the ozone layer, work on this system may only be carried out by authorised persons.
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2.2.2 Fire risk
The refrigerant is not combustible or explosive in normal conditions.
2.2.3 Toxicity
In normal use and normal conditions the refrigerant has low toxicity. Even though the toxicity of the refrigerant is low, it can cause injury
(or even death) in abnormal circumstances or if deliberately abused.
Warning Risk of personal injury! Spaces in which heavy vapor can collect below
the level of the air must be well ventilated.
Refrigerant vapour is heavier than air, and in enclosed spaces or in areas below the level of the door, for example, seepage can give rise
to high concentrations with a resultant risk of suffocation due to lack of oxygen.
Warning Risk of personal injury! Refrigerant exposed to a naked flame creates a
poisonous irritating gas. This gas can be detected by its odor even at
concentrations below its permitted levels. Evacuate the area until it
has been sufficiently ventilated.
2.2.4 Working on the refrigerant circuit
Caution When the refrigerant circuit is repaired, the refrigerant must not be re-
leased from the heat pump - it must handled appropriately.
Draining and refilling must only be carried out using new refrigerant (for the amount and type of refrigerant see manufacturer's plate)
through the service valves.
Caution All warranties will become void if a refrigerant, other than what Dan-
foss specifies, is used for refilling.
2.2.5 Scrapping
Caution When the heat pump is to be scrapped the refrigerant must be extrac-
ted for disposal. Local rules and regulations related to the disposal of
refrigerant must be followed.
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2.3 Electrical connection
Warning Hazardous electrical voltage! The terminal blocks are live and can
cause death through electric shock. All power supplies must be isola-
ted before electrical installation is started. The heat pump is connec-
ted internally at the factory, for this reason electrical installation con-
sists primarily of the connection of the power supply.
Caution Electrical installation may only be carried out by an authorized electri-
cian and must follow applicable local and national regulations.
Caution The electrical installation must be carried out using permanently rout-
ed cables and must follow applicable local and national regulations. It
must be possible to isolate the power supply using an all-pole circuit
breaker with a minimum contact gap of 3 mm.
2.4 Water quality
Caution A normal heating system always contains a certain amount of corro-
sion particulates (rust) and sludge products from calcium oxide. This
comes from acid that is naturally occurring in the fresh water that the
system is filled with. It is not good practice to have to fill the heating
system regularly which is why any leakage in the heating system
should be repaired immediately. Normal filling should occur only once
or twice a year. The water in the heating system should be as clean as
possible, always position the dirt filter on the return line from the heat-
ing system to the heat pump, as close to the heat pump as possible.
Caution Hard water; Normally it is not a problem installing a heat pump in
areas with hard water because the normal operating temperature for
the hot water does not exceed 60°C. In areas where there are excep-
tional prevailing conditions with the water one can install a softening
filter, which softens the water, cleans any impurities and prevents the
build up of calcification.
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3 Transport, unpacking and setting-up
3.1 Transporting the heat pump
Caution The heat pump must always be transported and stored upright in a
dry environment. Secure the heat pump so that it cannot tip over dur-
ing transportation.
Caution If the heat pump is laid on the incorrect side it may become seriously
damaged, as the oil in the compressor may run out into the pressure
pipe and thereby prevent normal functioning.
3.1.1 Unpacking
1. Check that there are no transportation damages.
2. Remove the packaging.
3.1.2 Delivery check
Check that the delivery includes the following items:
Name Quantity
Heat pump 1
Document set 1
Sound plate kit, 086L3375
Name Article number Quantity
Front and rear plate 086L3376 2
Left and right side plate 086L3377 2
Sensor kit, 086L3546 (in the electrical cabinet)
Name Article number Quantity
Outdoor sensor 086U3351 1
System supply line sensor 086L3356 1
3.2 Setting-up the heat pump
3.2.1 Recommended location
Positioning the heat pump
▪The heat pump should preferably be placed against an outside wall (see chapter 'Heat pump data')
▪Do not place the heat pump against walls facing noise-sensitive areas.
▪Avoid placing the heat pump in the corner of a room.
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▪If possible, choose a location where the surfaces nearest the heat pump are soft. Avoid placing the heat pump close to large plas-
tered or tiled areas.
▪The heat pump is fitted with internal vibration insulation. However, the degree of vibration insulation achieved depends on the
bearing strength of the surface the heat pump stands on. In order to achieve adequate vibration insulation, the heat pump should
be placed on a concrete floor with a thickness of at least 100 mm, or another surface with equivalent characteristics.
▪In order to minimise noise generation from the heat pump, the sound plate (included) should be fitted when the heat pump has
been put into position.
▪The heat pump must be level.
3.3 Dismantling the front cover
1 2 3
1. Turn the two locks on the top panel.
2. Push the front cover out by about 25 cm.
3. Lift the front upwards and lift off.
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4 Heat pump data
To facilitate the installation and subsequent testing and maintenance, there must be sufficient free space around the heat pump.
500 mm
500 mm
500 mm
500 mm
300 mm
756 mm
849 mm
686
543
488
178
129
245
50 10
10
166
181
321
656
702
314
134
761
900 mm
100 10 mm
1644 20, 0 mm
400 mm
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5 Components
12
13
14
15
10
16
17
18
19
20
21
22
23
24
1
2
4
6
5
3
9
8
7
11
The arrows show input to and output from the heat pump.
1. Return pipe, heating system
2. Supply pipe, heating system
3. Hot gas to water heater
4. Returning hot gas from water heater
5. Brine out
6. Brine in
7. Lead-in for incoming supply
8. Lead-ins for communication cable and sensor
9. Control panel
10. Inverter
11. Flexible hose
12. Hot gas exchanger
13. Service output, high pressure
14. High pressure transmitter
15. High pressure switch
16. Condenser pump
17. Condenser
18. Drying filter
19. Brine pump
20. Low pressure transmitter
21. Service outlet, low pressure
22. Evaporator
23. Compressor
24. Electronic expansion valve
DHP-M Connections, pipe diameter in mm
Brine Heating system Hot gas exchanger
54 42 28
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6 Piping installation
Caution To prevent leaks, ensure that there are no stresses in the connecting
lines
Caution Pipe installation must be carried out by an authorised installer
Caution Ensure that the pipe installation is carried out in accordance with the
dimensions and connection diagrams
Caution Bleed valves should be fitted if necessary
6.1 Safety valves
Warning Radiator systems with a closed expansion tank must also be equipped
with an approved manometer and safety valve. The safety valve
should be to a minimum of DN 20 and have a maximum of 6 bar open-
ing pressure, or according to country-specific requirements.
Warning The overflow pipes from the safety valve must not be closed off. The
pipes should discharge into an outlet in a frost-free area.
Warning The connecting pipe between the expansion tank and the safety valve
must slope continuously upwards. A continuous upwards slope means
that the pipe must not slope downwards from the horizontal at any
point.
Caution Cold and hot water pipes and overflow pipes from safety valves must
be made of heat-resistant and corrosion-resistant material, e.g. cop-
per.
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6.2 Heating system supply pipe and return pipe
▪Install a filter (max mesh size 0.7 mm) in the heating system's return pipe to protect the unit against foreign particles.
▪Install the supply line with all the accompanying components.
▪Ensure that the correctly dimensioned system pump is connected to the heating system's supply line, and connect the system
pump's control cables to the correct terminal block (see connection of system pump).
▪Install the return line with all the accompanying components.
▪Insulate the supply and return lines.
6.3 Noise information
To prevent disturbing noise from the heat pump the following recommendations should be observed:
▪The heat pump's pipe connections cause vibration. In order to prevent this vibration spreading to the heating system and frame,
the pipes should be connected and laid with particular care.
▪The brine and heat transfer fluid should normally be connected to the heat pump by means of a flexible hose.
▪Pipes must not be attached to walls facing noise-sensitive areas.
▪In cases where attachment of pipes to sensitive construction elements cannot be avoided, special elastic pipe attachments should
be used.
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6.4 Connection brine
6.4.1 Drill 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 be-
low 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
1
2
3
3
4
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 30 cm. 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 centered 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).
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6.4.2 Connection brine
DHP-M
▪Install a filter (max. mesh size 0.7 mm) in the incoming brine pipe to protect the unit against foreign particles.
▪Install the incoming brine pipe with all the accompanying components.
▪Install the outgoing brine pipe with all the accompanying components.
▪Fit both pipes with anti-diffusion condensation insulation.
▪The expansion tank for brine is dimensioned in accordance with the manufacturer's instructions.
▪Max. working pressure of heat source: 6 bar.
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7 Electrical installation
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to, see table, at the inter-
face point between the user´s supply and the public system.
It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if neces-
sary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to see table.
SSC M L XL
MVA 2.1 2.4 3.2
The heat pump is connected internally at the factory, for this reason electrical installation consists mainly of the connection of the power
supply.
Danger Electrical voltage!
The terminal blocks are live and can be highly dangerous.
All power supplies must be switched off before the electrical installa-
tion is started.
Warning The electrical installation may only be carried out by an authorized
electrician and must follow applicable local and national regulations.
Warning The power cable may only be connected to the terminal block inten-
ded for this purpose.
No other terminal blocks may be used!
Caution The electrical installation must be carried out using permanently rout-
ed cables and must follow applicable local and national regulations.
Isolate the power supply using an all-pole circuit breaker with a mini-
mum contact gap of 3 mm.
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7.1 Electrical components
2
4
5
7
6
1
3
1. Terminal block row X1
2. Fuse F1
3. Fuse F2
4. EMC filter
5. Transformer
6. Terminal block row X2
7. I/O card
7.2 Fuse size
DHP-M
Heat pump Unit M L XL
400 V 3-N 50 Hz heat pump A C40 C50 C63
7.3 Estimated current for DHP-M XL, L and M
Rad out Estimated current (A) for XL
65 50,8 51,0 51,2 51,4 51,8 52,3 52,7
60 50,8 51,8 52,5 53,1 53,5 54,0 54,2 1
55 46,7 47,6 48,2 48,7 49,1 49,5 49,2
50 42,9 43,7 44,2 44,7 45,0 45,4 45,7
45 39,5 40,2 40,7 41,2 41,6 42,0 42,3
40 36,6 37,3 37,9 38,3 38,8 39,3 39,7
35 34,4 35,2 35,8 36,3 36,9 37,6 38,1
30 33,1 33,9 34,6 35,3 36,0 36,9 37,5
Brine in -10 -5 0 5 10 15 20
1) Highest current
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Rad out Estimated current (A) for L
65 35,0 36,6 38,0 38,9 39,4 39,4 39,2
60 36,1 37,4 38,5 39,4 39,8 139,8 39,5
55 34,1 35,1 36,0 36,7 37,1 37,1 36,8
50 32,2 32,9 33,6 34,2 34,5 34,6 34,4
45 30,3 30,7 31,3 31,8 32,2 32,3 32,2
40 28,4 28,7 29,2 29,7 30,1 30,4 30,4
35 26,6 26,8 27,2 27,7 28,3 28,8 29,0
30 25,0 25,0 25,4 26,0 26,8 27,5 27,9
Brine in -10 -5 0 5 10 15 20
1) Highest current
Rad out Estimated current (A) for M
65 25,7 26,9 27,9 28,6 29,0 29,0 28,8
60 26,4 27,4 28,3 28,9 29,3 129,2 29,0
55 25,0 25,7 26,4 26,9 27,2 27,2 27,0
50 23,5 24,0 24,6 25,0 25,3 25,3 25,1
45 22,0 22,4 22,8 23,2 23,5 23,6 23,5
40 20,6 20,9 21,2 21,6 21,9 22,1 22,2
35 19,3 19,4 19,7 20,1 20,5 20,9 21,1
30 18,0 18,1 18,4 18,8 19,4 19,9 20,2
Brine in -10 -5 0 5 10 15 20
1) Highest current
7.4 Connecting external supply voltage
7.4.1 Connect external supply voltage
Danger Electrical voltage! The power cable may only be connected to the ter-
minal block intended for this purpose. No other terminal block may be
used.
If the heat pump is connected to mains via a residual-current circuit breaker (RCCB). The RCCB should be of type B.
1. Remove the front cover from the heat pump.
2. Route the power cable through the opening in the top panel of the heat pump to the terminal blocks.
3. Localise terminal block row X1
4. Connect the power cables as follows.
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