STIEBEL ELTRON HPG-I 04 S Premium Setup guide

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D0000095883-c
Version D0000095883-c 10.01.2022
The brine-to-water heat pump is equipped with an integrated "WPM" heat pump manager and a
control panel in the top panel of the unit.
The speed-controlled rotary piston compressor is controlled by an inverter. The heat output is adjusted
depending on the power. The circulation pumps for the heat source and heat extraction are built into the
unit. These are controlled via a PWM signal. The multi-function module "MFG" has a change-over valve
and controls the operating modes heating and hot water. Two integrated expansion vessels of 24l each
for the brine and heating circuits are located in the unit.
Refrigerant R 454 C safety class A2L (low flammability) is used in the refrigerant circuit.
The "cool" version offers the additional option of passive cooling (without a cooling circuit) by means of
an additional plate heat exchanger. This enables the temperature exchange between the heating system
and the heat source by means of a switching valve.

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D0000095883-c
Table of contents
1. General note ....................................................................................................................... 5
2. Applicable information / substitute notes ................................................................................. 5
3. Affected devices................................................................................................................... 6
4. Variants.............................................................................................................................. 6
5. Functional description ........................................................................................................... 6
5.1 Heating and hot water operation ....................................................................................... 6
5.2 Compressor control ....................................................................................................... 7
5.3 Compressor locked ........................................................................................................ 7
5.4 Passive cooling mode (variant B and D) ............................................................................ 7
6. Device description ................................................................................................................ 8
6.1 Housing ....................................................................................................................... 8
7. Circuit diagram .................................................................................................................... 8
7.1 Variant A and B (up to 9555) ........................................................................................... 9
7.2 Variant A and B (up to 9555) ........................................................................................ 10
7.3 Variant A and B (from 9556)......................................................................................... 11
7.4 Variant A and B (from 9556)......................................................................................... 12
7.5 Variant C and D (up to 9555) ........................................................................................ 13
7.6 Variant C and D (up to 9555) ........................................................................................ 14
7.7 Variant C and D (from 9556)......................................................................................... 15
7.8 Variant C and D (from 9556)......................................................................................... 16
7.9 Legend circuit diagram ................................................................................................. 17
8. Hydraulic plan.................................................................................................................... 18
9. Position of the components.................................................................................................. 18
9.1 Variant A / C .............................................................................................................. 19
9.2 Variant B / D .............................................................................................................. 20
10. Refrigeration circuit diagram ................................................................................................ 21
10.1 Refrigerant circuit / hydraulics Variant A (heating) ........................................................... 21
10.2 Refrigerant circuit / hydraulics Variant B (heating and cooling)........................................... 22
10.3 Cooling circuit / hydraulics Variant C (heating / hot water) ................................................ 23
10.4 Refrigerant circuit / hydraulics Variant D (heating / cooling / hot water) .............................. 24
10.5 Refrigerant circuit legend .............................................................................................. 25
11. Specifications and safety devices .......................................................................................... 26
11.1 Default room size ........................................................................................................ 26
11.2 Safety chain ............................................................................................................... 26
11.3 Safety temperature limiter compressor (BT51) ................................................................ 26
11.4 Safety temperature limiter Emergency/auxiliary heater (BT55) .......................................... 26
11.5 Safety concept ............................................................................................................ 27
12. Scope of delivery................................................................................................................ 27
13. Status displays .................................................................................................................. 27

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D0000095883-c
13.1 Operation................................................................................................................... 27
13.2 Malfunction................................................................................................................. 28
14. Entry list........................................................................................................................... 29
15. Further notes on troubleshooting and fault rectification ............................................................... 35
15.1 Reset control unit (FES) ............................................................................................... 35
15.2 Reset heat pump manager (WPM).................................................................................. 35
15.3 Multifunctional assembly (MFG) ..................................................................................... 36
15.3.1 Overview of the components of the multifunctional assembly (MFG)............................. 36
15.3.2 Incorrect circulation during DHW charging or heating operation ................................... 36
15.3.3 Frequent WW charging in cooling mode.................................................................... 36
15.3.4 Noise when bypassing the change-over valve............................................................ 37
15.3.5 Water leakage at the motor of the change-over valve (MA12) ..................................... 37
15.3.6 Blocking the DHC stages if the volume flow is too low ................................................ 37
15.4 Internal brine pressure switch (BP18)............................................................................. 37
15.5 Source Min ................................................................................................................. 38
15.6 Diaphragm expansion vessel (MAG) Heat source leaking .................................................... 38
15.7 Pressure monitoring Unit housing................................................................................... 38
16. Testing components ........................................................................................................... 38
16.1 Internal circulation pump ............................................................................................... 38
16.2 Internal heat source pump ............................................................................................. 39
16.3 Temperature sensor ..................................................................................................... 39
16.4 Pressure sensors ......................................................................................................... 39
16.5 Pressure socket connection Pressure monitoring............................................................... 39
17. Special repair specifications ................................................................................................. 40
17.1 Check housing tightness............................................................................................... 40
18. Software versions............................................................................................................... 41
18.1 Minimum software levels............................................................................................... 41
18.2 Software history .......................................................................................................... 41
19. Maintenance...................................................................................................................... 42
20. Technical data ................................................................................................................... 42
20.1 Performance data ........................................................................................................ 42
21. Refrigerant circuit Special features........................................................................................ 42
21.1 Evaporation temperature .............................................................................................. 43
21.2 Condensing temperature............................................................................................... 43
21.3 Evaporator overheating ................................................................................................ 43
21.4 Definition ................................................................................................................... 43
22. Application limits................................................................................................................ 44
22.1 Application limit heating ............................................................................................... 44
22.2 Application limit passive cooling..................................................................................... 44
23. Change history .................................................................................................................. 45

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D0000095883-c

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D0000095883-c
1. General note
Work on the opened unit and repairs may only be carried out by a person instructed by STIEBEL
ELTRON. The current safety instructions in the operating and installation instructions for the unit must be
observed.
The units are filled with the refrigerant R454c. The refrigerant belongs to safety group A2L and consists
of a mixture of R32 (difluoromethane) and R1234YF (2,3,3,3-tetrafluoropropene). It is non-toxic and
hardly flammable and has a very low combustion rate of 1.6 cm/sec. No explosive mixtures can be
formed on discharge.
The units are marked on the housing with the corresponding information sticker.
For maintenance and repair work, the country-specific safety data sheets for Opteon XL20 (R-454c) must
be observed.
oil in the refrigeration circuit is: DiamondFreeze MA 68
Attention!
•The refrigerant is odourless
•Do not drill or burn parts of the appliance.
•The unit should only be stored or operated in rooms without permanent sources of ignition.
•Only agents recommended by STIEBEL ELTRON may be used for cleaning.
2. Applicable information / substitute notes
Operation and installation HPG-I_04-15_(C)S Premium_en
344827
Operation and installation HPG-I_04-15_(C)S Premium_fr
344780
Operation WPM
324276
Commissioning WPM
324278
Repair instructions WPM
D0000072411
Special requirements for the use of R454C refrigerant
D0000095843
KD-Info "Leakage at MFG and MFG3"
D0000062134
KD- Info "Retrofitting edge protection"
D0000097035

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D0000095883-c
Info "Replacing the valve assembly on the MFG".
D0000050953
Special requirements for the use of R454c refrigerant
3. Affected devices
Device
Mat. no.
HP ID
Variant
HPG-I 04 S Premium
202617
A
HPG-I 06 S Premium
202618
A
HPG-I 08 S Premium
202619
A
HPG-I 11 S Premium
202620
A
HPG-I 15 S Premium
202621
A
HPG-I 04 CS Premium
202627
B
HPG-I 06 CS Premium
202628
B
HPG-I 08 CS Premium
202629
B
HPG-I 11 CS Premium
202630
B
HPG-I 15 CS Premium
202631
B
HPG-I 04 DS Premium
202622
C
HPG-I 06 DS Premium
202623
C
HPG-I 08 DS Premium
202624
C
HPG-I 12 DS Premium
202625
C
HPG-I 15 DS Premium
202626
C
HPG-I 04 DCS Premium
202632
D
HPG-I 06 DCS Premium
202633
D
HPG-I 08 DCS Premium
202634
D
HPG-I 12 DCS Premium
202635
D
HPG-I 15 DCS Premium
202636
D
4. Variants
The heat pumps are divided into four variants.
Variant A
H
Heating
Variant B
HK
Heating / Cooling
Variant C
HW
Heating / hot water
Variant D
HKW
Heating / cooling / domestic hot
water
The safety valve of the heat source must be installed externally.
5. Functional description
5.1 Heating and hot water operation
As soon as the heat pump control recognises a request for heating or DHW operation, the changeover
valve (MA12) in the multifunction module (MFG) moves to the corresponding position. The following
components are controlled depending on the output: the heat source pump (MA25) starts with flow, then
the compressor (MA01) and the circulation pump (MA10) are switched on.
The thermodynamic refrigeration circuit extracts heat from the source medium through the evaporating
refrigerant. The compressor compresses the aspirated refrigerant vapour and brings the refrigerant to a
higher temperature level. When the gaseous refrigerant is liquefied, the heat energy is transferred to the

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D0000095883-c
source medium.

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heat system. Once the set point is reached, the capacity is reduced until the compressor (MA01) and the
circulation pump (MA10) stop, the heat source pump (MA25) is switched off delay.
5.2 Compressor control
A specific heat demand is determined based on the parameterisation of the heating controller. The
Compressor is controlled in a frequency range of 20...120Hz depending on the model.
The inverter installed in the heat pump controls the compressor. A compressor speed increase requested
by the capacity controller is limited by a speed dependent on the HP type. A requested compressor speed
reduction is not limited; the compressor is switched off immediately from any speed.
When the compressor is started, the start speed (40 rpm/sec) is operated as the minimum speed for a
period of time (30 sec). Furthermore, a range control is integrated, which only allows a speed change
after the delay time.
Operating status
Slope ramp
Base speed
Duration
Compressor start
0.3 Hz/sec.
40 U/sec.
30s
Operation
0.3 Hz/sec.
Target speed
-
Shut down compressor
0
-
-
5.3 Compressor locked
If the temperature of the heating flow or heating return is below 15°C, the compressor is not started.
Until this temperature is reached, the supplementary heating switches and takes over the heating
operation.
5.4 Passive cooling mode (variant B and D)
If a room remote control (FE7 or FET) is connected to the heat pump manager (WPM), the
If the "PASSIVE COOLING" parameter and "Summer mode" are active, passive cooling is possible.
If the set temperature "ROOM SET POOL COOL" is exceeded, the cooling output and the heating circuit
pump switch on, the internal changeover valve moves into position "COOL". If the cooling temperature
exceeds "SUPPLY SET + HYSTERESIS", the source and buffer circulation pumps switch on, if the cooling
temperature falls below "SUPPLY SET" or the calculated dew point temperature +2K, both pumps stop.
If the temperature falls below the set "ROOM SETTING COOLING" -2K, all pumps stop and the cooling
output is switched off with a delay of 5 minutes. The minimum running and standstill time of the source
pump is 5 minutes each.
For surface cooling, dew point monitoring by means of room remote control (FET) is required.
•Cooling only works in conjunction with an FE7 as a minimum solution. No dew point monitoring
is available here. An extension with FET when using an FE7 is not possible.

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•If several circuits are required for cooling, this is only possible with FETs. The
cooling tank is passively cooled to the lowest setpoint temperature.
•Summer mode must be activated. The control unit must be in automatic mode.
6. Device description
6.1 Housing
The enclosure concept consists of a frame with a closed rear wall and recessed grips for transport. The
symmetrical side panels are hooked into hinges of the frame. The front wall is attached in the upper area
via sliding hooks. The hooks are secured with screws. The top cover is designed to slide and allows easy
electrical connection after removal of the rear top cover strip. The enclosure is tightly sealed by a built-in
fan with pressure monitoring. A test port is located on the rear wall of the unit.
7. Circuit diagram

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7.1 Variant A and B (up to 9555)

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7.2 Variant A and B (up to 9555)

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7.3 Variant A and B (from 9556)

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7.4 Variant A and B (from 9556)

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7.5 Variant C and D (up to 9555)

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7.6 Variant C and D (up to 9555)

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7.7 Variant C and D (from 9556)

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7.8 Variant C and D (from 9556)

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7.9 Legend circuit diagram
Component
Description
Connection
Description
AA01
Heat Pump Manager (WPM)
XE1
Earthing block
AA02
Integrated heat pump control
(IWS)
XE2
Earthing block
AA04
Inverter compressor
XE3
Support point earthing
AA06
Operating unit
XE4
Support point earthing
AA07
Multifunction group MFG 3.1
XE5
Support point earthing
AA08
Power supply fan
XE6
Support point earthing
BF01
Volume flow sensor heating
XE7
Support point earthing
BL01
Float switch
XE8
Support point earthing
BP01
High pressure sensor (42 bar)
XE9
Support point earthing
BP03
Low pressure sensor (16 bar)
BP04
High pressure switch (50 bar)
X1.1
WPM CAN IWS
BP10
Pressure sensor heating circuit
X1.2
WPM CAN control unit
BP13
Pressure sensor Heat source
X1.3
WPM Outdoor temperature sensor
BP17
Pressure box interior vacuum
X1.4
WPM Buffer sensor / HK 1
BP18
Pressure switch Heat source
X1.6
WPM HK2 Flow sensor
BT01
Temperature sensor heating
flow PT1000
X1.8
WPM Hot water sensor
BT02
Temperature sensor heating
return PT1000
X1.9
WPM VL Cooling
BT04
Hot water sensor
BT07
Temperature sensor heating
flow MFG PT1000
X1.10
WPM 2nd heat generator sensor
PT 1000
BT20
Temperature sensor
outdoor air PT1000
X1.11
WPM Collector sensor PT 1000
BT25
Temperature sensor heat source
flow PT1000
X1.12
WPM WW bottom PT1000
BT26
Temperature sensor heat source
return PT1000
X1.14
WPM Analogue input 0...10V
BT43
Temperature sensor
condenser outlet PT1000
X1.15
WPM Analogue input 0...10V
BT45
Klixon HG Compressor
X1.16
WPM Solar pump PWM
BT46
Temperature sensor compressor
inlet PT1000
X1.17
WPM 2nd heat generator PWM
BT48
Temperature sensor oil sump-
PT1000
X1.19
WPM CAN MFG
BT50
Temperature sensor hot gas
PT1000
X2.1
WPM Network
BT55
Safety temperature limiter MFG
X2.2
WPM EVU
EB02
Oil sump heating
X2.3
WPM HK pump 1
KF06
Isolating contactor inverter
KF20
Relay emergency/auxiliary
heating MFG
X2.4
WPM Mixer pump
KF21
Relay emergency/auxiliary
heating MFG
X2.10
WPM Interference output

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Component
Description
Connection
Description
KF22
Relay emergency/auxiliary
heating MFG
X2.11
WPM Solar pump
MA01
Motor Compressor
X2.14
WPM Mixer 1
MA04
Stepper motor electric expansion
valve
X11.1
IWS plug 3pin mains
control
MA07
Motor changeover valve
heating/cooling
X11.3
IWS plug 2pin - defrost valve
MA10
Circulating pump
X11.4
IWS plug 2pin - oil sump heater
MA12
Motor switch valve WW-
heating
X11.8
IWS plug 3pol - EVU lock
MA25
Motor Pump Heat Source
X12.1
IWS Plug-Rast 4pin - Fan PWM
MA26
Extractor fan housing
X12.2
IWS plug detent 12-pin -
temperature sensor 1
X12.3
IWS Plug Rast 3pol - BUS
Connection
XD1
Connection terminal external
mains WP
X12.4
IWS Plug-Rast 7pol - HD/ND-
Pressure
XD2
External connection terminal NHZ
X12.5
IWS Plug-Rast 5pol - Expansion
valve
XD3
External connection terminal
Control
X12.6
IWS Plug-Rast 5pol - Inverter
cooling valve
XD4
6x5 block Mains control
X12.7
IWS plug latch 6pin - temperature
sensor 2
X12.9
IWS Plug-Rast 7pol - Differential
pressure sensor air
X12.11
IWS Plug-Rast 4pin - Modbus
Inverter
8. Hydraulic plan
•See refrigeration circuit diagram
9. Position of the components

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9.1 Variant A / C
•For legend, see chapter "Refrigerant circuit legend".