Kensa Heat Pumps Q80 Series Guide

Q80 Series Range Heat Pump Manual Version 1
Page 1 of 40
Q80 Series Heat Pumps
Installaon and Commissioning Manual
Warranty Fault Finding Commissioning Installaon
electrical
Installaon
mechanical
Installaon
schemacs
Installaon General product
informaon
Safety
informaon
Introducon
Heat Pump
sengs sheet
Copyright ©2022 Kensa Heat Pumps Ltd

Q80 Series Range Heat Pump Manual Version 1
Page 2 of 40
Contents Page
Secon Descripon Page
1....................... Introducon .................................................................................. 4
2....................... Safety Informaon ........................................................................ 5
2.1........................... Access ...................................................................................................................... 5
2.2........................... Lighng .................................................................................................................... 5
2.3........................... Tools and consumables ........................................................................................... 5
2.4........................... Handling ................................................................................................................... 5
2.5........................... Residual hazards ...................................................................................................... 5
2.6........................... Freezing ................................................................................................................... 5
2.7........................... Disposal/decommissioning ...................................................................................... 5
3....................... General product informaon ........................................................ 6
3.1........................... Equipment delivery and handling ............................................................................ 6
3.2........................... Kensa Q80 Series Range technical data ................................................................ 9
4....................... Installaon.................................................................................... 10
4.1........................... The golden rules of installing a heat pump ............................................................ 10
4.2 .......................... Q80 Series heang schemacs ................................................................................ 10
4.3........................... Q80 Series heang and cooling schemacs ............................................................. 14
4.3.1…………………….. Acve or Passive Cooling……………………………………………………………………………………… 14
4.4........................... Secondary boiler back up systems (bivalent alternave systems) Fig 7……………….. 16
4.5……………………….. Secondary boiler back up systems (bivalent parallel systems) Fig 8……………………… 16
4.6........................... Mechanical installaon ........................................................................................... 19
4.6.1........................ Locang the heat pump .......................................................................................... 19
4.6.2........................ Recommended clearances ...................................................................................... 19
4.6.3........................ Installaon of the heat pump .................................................................................. 20
4.7........................... Electrical installaon ............................................................................................... 21
4.7.1........................ Three phase power supplies .................................................................................... 22
4.7.2…………………….. Main PCB Terminal Descripon……………………………………………………………………………. 23
5....................... Seng to Work ............................................................................. 28
5.1........................... Purging the ground array of air ............................................................................... 28
5.1.1........................ Purging procedure .................................................................................................. 28
5.1.2........................ Purging the headers ................................................................................................ 30
5.1.3........................ Adding anfreeze / inhibitors ...................................... ........................................... 30
Safety
informaon
General product
informaon
Installaon Installaon
schemacs
Installaon
mechanical
Installaon
electrical
Commissioning Fault Finding Warranty Heat Pump
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Introducon

Q80 Series Range Heat Pump Manual Version 1
Page 3 of 40
Contents Page
Secon Descripon Page
5.1.4........................ Pressure Tesng in accordance to BS805 Secon 11.3.3.4 .................................... 30
5.1.5........................ Tesng of anfreeze concentraon ....................................................................... 31
6....................... Controller .................................................................................... 32
7…………………….. Fault Finding………………………………………………………………………………. 33
8....................... Warranty...................................................................................... 34
8.1........................... Terms and Condions............................................................................................. 34
8.1.1........................ Persons covered by the Warranty........................................................................... 34
8.1.2........................ Validity period of the Warranty.............................................................................. 34
8.1.3........................ Scope....................................................................................................................... 34
8.1.4........................ General excepons ................................................................................................. 34
8.1.5........................ Care of Duty ............................................................................................................ 35
8.1.6........................ In the event of Damage .......................................................................................... 35
8.1.7........................ Replacement Parts.................................................................................................. 35
9....................... Heat pump and system sengs sheet .......................................... 36
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Q80 Series Range Heat Pump Manual Version 1
Page 4 of 40
1. Introducon—a message from the CEO
Kensa Heat Pumps has been manufacturing ground source heat pumps since
1999. In the early days, it was dicult to nd contractors willing to consider the
technology. As a consequence, Kensa made considerable eorts to simplify the
installaon process to allow any competent contractor to perform the work. The
company is now reaping its rewards as heat pumps become mainstream heang
appliances.
The purpose of this manual is to guide you through the installaon process. It is
expected that all the required informaon has been provided to allow you to connect the heat pump.
Crical instrucons, aimed at ensuring you do not experience any dicules, are highlighted on the
‘Golden Rules’ in the installaon secon.
Please note you will need to speak to the Technical Support Team on 01872 862140 to arrange a
commissioning visit. Opening hours are 8.00am to 5.00pm .
Finally, please feel free to contact Kensa should you have any quesons, wish to consider ground source
heat pumps for any future projects or even just to share your experiences of using a ground source heat
pump with us.
Ma Trewhella
CEO
Kensa Group Ltd
For further informaon on
ground source heat pumps and
their applicaon, please refer to
www.kensaheatpumps.com
Safety
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Installaon Installaon
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Installaon
mechanical
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Commissioning Fault Finding Warranty Heat Pump
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Introducon

Q80 Series Range Heat Pump Manual Version 1
Page 5 of 40
2. Safety informaon
Safe operaon of this unit can only be warranted if it is properly installed and commissioned in
compliance with the manufacturer’s requirements. General installaon and safety instrucons for pipeline
and plant construcon, as well as the proper use of tools and safety equipment must also be complied
with.
Manufacturer:-
Kensa Heat Pumps
Mount Wellington
Chacewater
Truro
Cornwall
TR4 8RJ
Tel [phone]
www.kensaheatpumps.com
2.1 Access and Egress
Ensure safe access and egress before aempng to work on the product. Arrange suitable liing gear if
required.
2.2 Lighng
Ensure adequate lighng, parcularly where detailed or intricate work is required.
2.3 Tools and consumables
Before starng work ensure that you have suitable tools and / or consumables available.
2.4 Handling
Manual handling of large and /or heavy products may present a risk of injury. Liing, pushing, pulling,
carrying or supporng a load by bodily force can cause injury parcularly to the back. You are advised to
assess the risks taking into account the task, the individual, the load and the working environment and use
the appropriate handling method depending on the circumstances of the work being done.
2.5 Residual hazards
Many products are not self-draining. Take due care when dismantling or removing the product from an
installaon.
2.6 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
2.7 Disposal/Decommissioning
Kensa oer a life me decommissioning service for this product. This is available on a return to base basis
(carriage at users’ cost). Disposal of any anfreeze water mix should follow the disposal instrucons as laid
out on the COSH Safety Data Sheet available on request.
This symbol on the product indicates that this product must not be disposed of with your
other household waste. Instead, it is your responsibility to dispose of your waste equip-
ment by handing it over to a designated collecon point for the recycling of waste elec-
trical equipment. The separate collecon and recycling of your waste equipment at the
me of disposal will help to conserve natural resources and ensure that it is recycled in a
manner that protects human health and the environment. For more informaon about
where you can drop o your waste equipment for recycling, please contact your local city
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The product is designed and constructed to withstand the
forces encountered during normal use. Use of the product
for any other purpose, or failure to install the product in
accordance with these Installaon and Commissioning
Instrucons, could damage the product, will invalidate the
warranty, and may cause injury or fatality to personnel.

Q80 Series Range Heat Pump Manual Version 1
Page 6 of 40
3. General Product Informaon
This manual explains how to install a Kensa ground source Q80 Series heat pump.
The Kensa Q80 Series Heat Pump is designed to provide a low cost renewable heat source for a buildings
heang system. Heat pumps can provide lower running costs and will generate signicantly lower carbon
emissions compared with tradional fossil fuels.
The Kensa Q80 Series Heat Pump is designed for straighorward installaon and integraon into a
buildings heang system. The installaon must conform to all relevant construcon and electrical codes.
3.1 Equipment delivery and handling.
Factory shipment
Prior to shipment, the Kensa Q80 Series Heat Pump is tested, calibrated and inspected to ensure proper
operaon.
Receipt of shipment
Each pallet should be inspected at the me of delivery for possible external damage. Any visible damage
should be recorded immediately on the carrier’s copy of the delivery slip.
Each pallet should be unpacked carefully and its contents checked for damage.
If it is found that some items have been damaged or are missing, nofy Kensa immediately and provide full
details. In addion, damage must be reported to the carrier with a request for their on-site inspecon of
the damaged item and its shipping pallet. The Q80 Series Heat Pump should be moved indoors immediate-
ly when received as the unit is not rated for external condions and storage.
Storage
If a Kensa Heat Pump is to be stored prior to installaon, the environmental storage condions should be
at a temperature between 0°C and 50°C (32°F and 122°F), and between 10% and 80% relave humidity
(non-condensing). The Q80 Series Heat Pump should be moved indoors immediately when received as the
unit is not rated for external condions and storage.
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Fig 1. Q80 Series Heat Pump

Q80 Series Range Heat Pump Manual Version 1
Page 7 of 40
Fig 2. The internals of a heat pump (side view)
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Fig 3. The internals of a heat pump. (door open)
Plate Heat Exchangers
Compressors
Controller Wiring
Enclosure

Q80 Series Range Heat Pump Manual Version 1
Page 8 of 40
Fig 4. Contoller Wiring Enclosure (cover removed)
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Introducon
Controller main PCB
Terminals
MCBs
Smart Starts
Ground pump volt free
relay

Q80 Series Range Heat Pump Manual Version 1
Page 9 of 40
3.2 Kensa Q80 Series Technical Details— Compressor—3 Phase 400 Volts Only
Nomi-
nal
Thermal
Output
Ground Design
Flow Rate
Ground
Design
Flow
Rate
Ground
Design
Flow
Rate
Ground
pressure
drop at
design
Output
Design
Flow Rate
Output Design
Flow Rate
Output
Design
Flow Rate
Output pres-
sure drop at
design
Design owrates are
based on ground tem-
peratures of 0oC in and –
4oC out of the heat
pump and 30oC and 35oC
for the load side.
Max rated
current
Sound
Power Level
kW l/s l/m m3/h kPa l/s l/m m3/h kPa Amp
dB A
83 5.98 359 21.53 46.3 4240 14.4 27.6 64
72.3
The gures above are based on a rang to BS EN14511, 0 deg C from the ground, 35 deg C ow to underoor.
For claricaon of starng currents and details on how these gures are calculated please contact Kensa.
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Q80 Series Range Heat Pump Manual Version 1
Page 10 of 40
4. Installaon
Note: Before aconing any installaon observe the 'Safety informaon' in Secon 2.
It is essenal that the following installaon guidelines are followed carefully.
Any electrical work required to install or maintain this appliance should be carried out by a suitably
qualied electrician in accordance with current IEE regulaons.
Any plumbing work should be carried out to local water authority and WRC regulaons.
Kensa Q80 Series heat pumps do not come with any water circulang pumps for either the load or ground
side. These should be specied by the M and E consultant and will depend on site condions.
Important
The following secon includes typical schemacs of how a heat pump can be connected. It is important to
note that the schemacs are only general arrangements and hence do not illustrate all required valves or
ngs. System designs are also very site specic and should be provided by the M and E consultant. The
following is a guide only.
4.1 The golden rules of installing a Q80 Series heat pump
1. A ‘D’ Type MCB should be used for the heat pumps power supply.
2. All pipe connecons to the heat pump must be vibraon isolated using bellows or equivalent.
3. Use a suitably sized purge pump for purging the ground arrays and heat pump.
4. Pipe lengths to the ground arrays should be kept equal to maintain equal ow and connected
reverse return.
5. Flow switches should be installed to prevent operaon in non-ow situaons.
6. Read this manual fully before commencing installaon
4.2 Q80 Series heang schemacs
The key to obtaining low CO2 emissions and running costs for any heat pump is to maintain the ow
output at as low a temperature as possible. Any increase in outlet temperature will result in a drop in
eciency and systems should be designed to reect this.
The following schemac details how a heang system for a Q80 Series property can be designed.
The modular design of Kensa Q80 Series heat pumps enables the system to closely match the required
heang load. Each unit should be congured via the BMS to operate sequenally to allow part operaon
to match the heat demand of the building. The mulple unit approach also oers a degree of redundancy
in the unlikely event of a problem with one if the units.
Depending on the system design it might be necessary to incorporate a buer vessel to avoid short cycling
problems and it is recommended, to improve overall eciency of the system, that this is a twin
connecon buer vessel. The vessel should be sized for 10 litres per kW of the smallest heat pump
module. For example as the twin compressors are run in tandam, for a 120kW heang load using 2 x
80kW heat pumps the buer vessel should be approx 80 (compressor size) x 10 = 800 litres.
Kensa heat pumps can work equally as well with horizontal, vercal or lake arrays as the energy source.
Although for large Q80 Series projects it can be more usual to use a borehole eld design due to space
consideraons.
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Introducon

Q80 Series Range Heat Pump Manual Version 1
Page 11 of 40
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Fig 5 Typical Q80 Series heang only schemac

Q80 Series Range Heat Pump Manual Version 1
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Fig 6 Typical Q80 Series DHW heang only schemac

Q80 Series Range Heat Pump Manual Version 1
Page 13 of 40
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This page is intenonal le blank.

Q80 Series Range Heat Pump Manual Version 1
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4.3 Q80 Series heang and cooling schemacs
In many modern Q80 Series buildings, with the improvement in energy saving measures such as In-
sulaon, the requirement for cooling is now almost as great (if not greater) than the requirement for
heang. This cooling requirement is generally being driven by the use of heat eming devices such as
computers and printers and even the sta themselves.
When ground source heat pumps run they always produce heat and cold, just like other heat pumps such
as refrigerators or air condioners. This means it is simple to use a ground source heat pump for cooling.
The steady temperature of a ground array gives a ground source heat pump even more potenal for
cooling.
Kensa’s Q80 Series range of heat pumps can provide cooling externally. This has the advantage of a lower
cost system, higher eciency and can be installed at a later date by the M&E contractor. Kensa’s
approach is to maintain stored volumes of hot and cold uid to be used by the building when and where
its needed, if there is a large cooling load the system will dump the excess heat to the boreholes via an
HEX and vice versa.
4.3.1 Acve and passive cooling
At the end of a heang season the ground temperature is at its lowest—typically 0-5°C. This temperature
is cool enough without modicaon to be used in various cooling distribuons to provide cost eecve
passive cooling. During passive cooling the uid from the ground array provides cooling without the
compressor needing to run. Only a small amount of energy is used by the water pumps.
For a heat pump to acvely cool, the compressor does run and the hot and cold side inputs are simply
switched. The ground source heat pump is now acvely pumping heat from inside the room to the
ground, thus cooling the room (and heang the ground). Acve cooling has wider applicaons than
passive cooling and can be used more eecvely with higher ground temperatures but also has a higher
running cost.
It is important that a sucient quanty of glycol anfreeze (minimum 22%, Refracve index 1.356) is
added to the cooling and heang circuit uid to avoid freezing of the uid in cooling mode. Failure to do
this will invalidate the warranty.

Q80 Series Range Heat Pump Manual Version 1
Page 15 of 40
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Fig 7 Typical Q80 Series heang, DHW and cooling schemac

Q80 Series Range Heat Pump Manual Version 1
Page 16 of 40
4.4 Secondary boiler back up systems (bivalent alternave systems) Fig 8
This type of system can be used where the heat emiers require a higher temperature than the heat
pump can output, when it is cold outside. This set up would require thermostac control on the boiler as
well as external bivalent controls to switch between the heat pumps and the boiler.
Care must be taken when seng up the BMS, as it may take some me for the system to come up to tem-
perature.
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For all systems it is recommended that the BMS/Instrumentaon Engineer contact Kensa if unsure on
any aspects of the control of the system, i.e. Regarding:-
• Time delays
• Expected temperatures
• Compressor run-mes
• Compressor starts per hour.
• etc
4.5 Secondary boiler back up systems (bivalent parallel systems) Fig 9
Bivalent Parallel systems can be when the heat pump output cannot meet the full building load in cold
climates. This can be controlled either externally or by the heat pumps. The boiler will require a blending
valve to match the target ow temperature to the buer tank. Please contact Kensa for further infor-
maon.
Again care must be taken when seng up the BMS, as it may take some me for the system to come up
to temperature.

Q80 Series Range Heat Pump Manual Version 1
Page 17 of 40
Fig 8 Secondary boiler back up (bivalent alternave)
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Q80 Series Range Heat Pump Manual Version 1
Page 18 of 40
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informaon
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Installaon
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Installaon
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Fig 9 Secondary boiler back up (bivalent parallel)

Q80 Series Range Heat Pump Manual Version 1
Page 19 of 40
4.6 Mechanical Installaon
4.6.1 Locang the heat pump
Decide on a suitable locaon for the Heat Pump. This should be in a plant room which isolates any
occupied spaces from the noise and vibraon of the heat pumps. It should not be placed near, under, or
above, any inhabited space. Take into account the “Recommended Clearances” when nalising the
locaon and future requirements for access and removal. It is important that an-vibraon mounngs or
“bellows” are used.
Check the appliance for transport damage. Under no circumstances should a damaged appliance be
operated or installed without prior agreement.
Posion the appliance on a rm, level and substanal concrete base that will absorb vibraon well away
from any occupied rooms
Ensure all pipes and wires are adequately supported where necessary, pipes are properly insulated and
concentraons of inhibitor/anfreeze (where added) are correct. Connecons should be vibraon isolated
by the use of bellows and have appropriate air vents and isolaon valves. The appliance and any metal
pipes should also be properly earthed.
A water treatment device should be provided in hard water areas.
Do not use the appliance as a shelf.
4.6.2 Recommend clearances
Fig 10 Heat Pump clearances
If mulple units are used then
these should have a clearance
of approximately 675 mm
between them to enable access.
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Remember to consider any
future maintenance or removal
requirements as a return to
base might be required if an on
-site repair is not feasible.
Refer to g 10 or secon 3.2
for dimensions of the unit
If a concrete pad is used in front
of the unit, ensure that this is
extended by 1450mm forwards
to allow complete removal of
the heat pump. If access to the
whole of the unit is via
withdrawing the unit the
clearance between the units can
be 30-50mm

Q80 Series Range Heat Pump Manual Version 1
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4.6.3 Installaon of the heat pump
The heat pump is designed for internal use only. Ideally the heat pump should be placed next to an
external wall allowing easy access to the externally mounted ground array manifold. Any pipes internal to
the building must be insulated with vapour barrier insulaon such as Armaex. It is not recommended
that the ground or header array manifold is installed within a building due to condensaon and diculty
in lagging the manifold to overcome this.
It is possible to place manifolds in underground chambers and Kensa can supply suitable chambers on
request. If an underground manifold is used all joints must be electro-fusion type.
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Installaon
mechanical
Installaon
electrical
Commissioning Fault Finding Warranty Heat Pump
sengs sheet
Introducon
i. Using specialist liing equipment, place the Heat Pump into posion.
ii. Ensure the heang distribuon system has been thoroughly purged of any debris and any lters are
clean.
iii. All pipe connecons to the heat pump must be vibraon isolated using bellows or
equivalent. Connect the ground feed & return pipes from the ground array/header manifold, and
the feed and return pipes from the heang distribuon manifold (which must be connected the
correct way round), according to Fig 12. The reason for using exible connecons is that the heat
pump is suspended on an-vibraon mounts, so the connecons must also be exible. For
mulple plant room modules the ows and returns should be manifolded together and balanced
ideally in a reverse return arrangement if possible.
iv. Open the access panel.
v. Using the correct knock outs in the top of the unit, thread the power supply and BMS wires from
external to the unit into the control box and connect them to the terminals required, ( see electrical
installaon secon ).
vi. Check and recfy any leaks that may be in the plumbing system. It is advisable that a pressure test
is carried out to ensure the system is leak free.
vii. The appliance should be le for 12 hours aer installaon before it is turned on, to allow the
refrigerant to sele. The area where the heat pump is installed must be dry and rodent free.
viii. Phone Kensa to arrange for the commissioning of the unit. Do not switch the unit on without talking
to Kensa rst.
Fig 11 Q80 Series heat pumps