Shoebox (O Manual)
Contents
1. KensaHeat Pumps Shoebox Heat Pum User Manual on Kensa Heat Pumps Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps Page 1 of 20 Introduction Safety information General product information Operational Instructions Fault Finding Warranty Suipuij 1 ned suonmonu sul Ieuonei do uolguuojJuli 19npoid ej u p uonewsojul Ajajes uono npodlul A3ue le AA Contents Page Section Description Page L islas asuasktaas I UPOd CtIe lluu a 12 asas Qaqaqa qes 3 2 E EA Safety Information 4 P A EEA Disposal Decommissioning n n nanas 4 DD s usss a maq al REtUPMING PRODUCES u rened aa iaaea odes res iesneanngavnenisonseacaasens vshsenseasersesase 4 e EE General Product Information 5 3 1 uqa tanata Ke sa Heat PUMPS u uu m u ua a naa qua ka EEA ENE haskasa 5 e e asya shayuqahaunai sans Product Descriptio sses iseseisana aiaa ini eanais aiaei 5 e 3 EEEIEE Kensa Shoebox Technical Details 9 e E Operational Instructions 10 4 1 uu totieniees Maximising the efficiency of the heat pump 10 AD yaya phawaq auay Display a ati Ra naa E Vasiectantncestecaevansaanewelaesatecune2. called the evaporator and a refrigerant through the other The refrigerant has a very low boiling point and by absorbing the energy in the brine this causes the refrigerant to evaporate The refrigerant gas is then passed through a compressor where its pressure is increased which in turn increases its temperature This high pressure hot gas then flows around a second heat exchanger called a condenser with the heating distribution fluid passing through the other side of the heat exchanger Energy is then transferred from the refrigerant into the heating distribution system this in turn causes the refrigerant to condense This high pressure cold refrigerant is then passed through an expansion valve or throttle and the pressure is reduced The whole cycle is then repeated GSHPs are an extremely energy efficient technology with every unit of electricity used to drive the pumps and compressor producing between 3 and 4 units of heat The Kensa shoebox heat pump is designed to provide a low cost renewable heat source for a buildings heating system It is ideally suited to multi flat developments using a communal ground borehole field In addition and if required the Kensa Shoebox can also provide domestic hot water Heat pumps can provide lower running costs and will generate significantly lower carbon emissions compared with traditional fossil fuels Shoebox lt p u mp Wy Fig 2 Ashoebox heat pump Page 6 of 2
3. o KensaHeat Pumps Introduction Safety information c S s O O me Qa oO s O lt O O Fault Finding Warranty uonewsojul Alj Jes uono npou1lul uolguuoJui 19npoid jej u p Sulpuly 1 ned Aue Pe AA 5 Fault Finding Many faults which occur on commissioning are found to be due to incorrect wiring or setting up therefore it is recommended that a thorough check is carried out should there be a problem a Blank display on software controller Compressor not running but display reading temperature near setpoint Display flashes fault code tP Display flashes fault code HP Display flashes fault code LP Display flashes fault code A1 Display flashes fault code E1 E2 E3 or E4 No power supply Controls MCB tripped There is no call from the time clock or thermostat for heat pump operation Heat pump is up to temperature Low water pressure in the ground or heating system side due to pipe relaxation or other pressure loss Overheat warning No or low flow around heating distribution circuit because of air in water pump or stuck water pump impellor or heating distribution system valves actuators closed HP can also be temporarily displayed when the heat pump reverts from DHW to space heating mode Low gas pressure in machine Can occur simultaneously with an A1 alarm Can occur temporarily on first start up when unit is new or after a lo
4. relating to any substances identified as hazardous or potentially hazardous Page 4 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps 3 General Product Information Introduction This manual explains how to operate a Kensa Shoebox ground source heat pump 3 1 Kensa Heat Pumps Kensa Heat Pumps is the leading UK manufacturer of a full range of ground source heat pumps Kensa provides exceptional levels of expertise and advice on the use design and application of heat pumps Kensa have been active in the heat pump market since 1999 and remains a well respected company not only in the industry but also with all our customers and stakeholders Since 1999 the company has manufactured and installed over two thousand heat pumps of various types throughout Europe and manufacture ranges suitable for the domestic market and specifically designed for commercial applications Safety information Kensa are ISO9001 approved for the design and manufacture of heat pumps and hold an unique status as being accredited by Microgeneration Certification Scheme for both the manufacture and installation of ground source heat pumps Kensa were also a founding member of the Ground Source Heat Pump Association and play a major role in helping to raise the profile of heat pumps and formulate Industry Standards Kensa s aim has always been to take the mystery and complexity out of heat pumps designing systems that can be easily ins
5. properly installed and commissioned in compliance with the operating instructions General installation and safety instructions for pipeline and plant construction 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 01872 862140 www kensaheatpumps com 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 Installation and Operation Instructions could cause damage to the product will invalidate the warranty and may cause injury or fatality to personnel 2 1 Disposal Decommissioning Kensa offer a life time decommissioning service for this product This is available on a return to base basis carriage at users cost Disposal of any antifreeze water mix should follow the disposal instructions as laid out on the COSH Safety Data Sheet in the Installation Manual 2 2 Returning products Customers and stockists are reminded that under EC Health Safety and Environment Law when returning products to Kensa Heat Pumps they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health safety or environmental risk This information must be provided in writing including Health and Safety data sheets
6. 0 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps Introduction Fig 3 Ashoebox single compressor heat pump Safety information wn S O 5 pan wn Cc 5 S s O Compressor Ground Array Water Pump Fault Finding Fig 4 The internals of a single compressor shoebox heat pump Warranty Page 7 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps uolnonpod1u This page is intentional left blank uolnmeguuoJu 1 Jes xe oO x o v 5 wn pal Cc Qa T n Sulpuly Ne AJUeLe AA Shoebox Heat Pump Operational Manual Version 2 1 ay er KensaHeat Pumps uoI onpou uU uoleuuojJu Ajajes x WEEN suoljonsjsu jeuoiesado Sulpul4 1 ned esu y 132e1uo2o aseajd payejnojed ase Sain3lj asay MOY UO S 1E7 p pue S UaIINI Juels JO uol1e3lJue 3 J04 duind sayem YINqu y JO UOIZdLUNSUOD i Axod y s pn oui in8lJ SIUL 4oo ju pun 0 MO 2 Bap GE punoi8 y uuo1ij 2 Bap 0 TTSYTNI Sg 0 3uljeu e uo p seq ale Aoqe saun3ly yL S AJLA 10 depy wwzz YUM e1ed dS8 v E OLEXSOPXOES l8u s GC O r L ET OE ZH OS DV SHOA OET ASEUd l8u s paljddns ull ease you Jue MHA Jeuo a s ul ease 1 JSUuEe11 SS019 jqe ju uno quasino yu uno yndino yeay uunuululuu 44319m Ajddns Sues suluuns Suluuns jeuuayL papuawwoday azis UolaUUOD suoisu uumq ssossaidwoy JeUI
7. 1 7 Replacement Parts Kensa Heat Pumps Ltd s warranty obligations with respect to replacement parts are identical to those with respect to original parts provided however in no event shall the warranty term for such replacement parts extend beyond the term established by the commencement date i e commissioning date of the warranty under which Kensa Heat Pumps Ltd was obligated to provide such replacement parts Kensa Heat Pumps Ltd shall have the right to retain possession or dispose of any parts replaced by it Page 17 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps This page is intentional left blank Shoebox Heat Pump Operational Manual Version 2 1 Page 18 of 20 KensaHeat Pumps This page is intentional left blank Shoebox Heat Pump Operational Manual Version 2 1 Page 19 of 20 KensaHeat Pumps This page is intentional left blank Shoebox Heat Pump Operational Manual Version 2 1 Page 20 of 20 KensaHeat Pumps
8. WON JaMOd JeoidAL JeoidAL xe JPeUIWON Jossaidwio aj3uis sjiejaq Ie31uu3 1 xoq ous esuay AJUee AA Kensa Heat Pumps Shoebox Heat Pump Operational Manual Version 2 1 Page 9 of 20 uolnonpod1u uonewsojul Alj Jes O oO 5 D S gej 5 Qa Q A 3 3 fes 5 Sulpuly 1 ned AJUuee AA 4 Operational Instructions Always ensure that individuals using the appliance have read and fully understood the Operation instructions Do not operate the appliance with the cover removed Do not operate the appliance in anything other than dry conditions Do not exert any strain on electrical or pipe connections to the appliance Do not put any foreign object into the appliance Do not spill water or any other substance onto the appliance 4 1 Maximising the efficiency of the heat pump In order to increase the efficiency of the heat pump and lower the overall energy costs of the building there are a number of simple steps that can be taken 1 Insulate the property as much as possible This will reduce the heat loss from the building which in turn will reduce running time of the heat pump and hence energy costs 2 The lower the flow temperature from the heat pump the higher the efficiency so consider a heating system with a large heat emitting area such as underfloor 3 If in a well insulated building with underfloor mounted in screed throughout consider running your heat pump o
9. ated on the commissioning certificate or 2 years from the date of manufacture whichever is shorter 7 1 3 Scope Kensa Heat Pumps Ltd warrants to the original purchaser and any subsequent owner of the it Buyer that all parts Parts of the Kensa Shoebox Ground Source Heat Pump excluding accessories shall be merchantable and free from defects in materials and workmanship appearing under normal working con ditions Kensa Heat Pumps Ltd will at its option and without charge to the Buyer replace or repair any Parts which cause the Kensa Shoebox Ground Source Heat Pump to be inoperable however if Kensa Heat Pumps Ltd elects to provide replacement Parts it shall not be obligated to install such replacement Parts and the Buyer shall be responsible for all other costs including but not limited to shipping fees and ex penses The warranty applies to faults originating inside the item 7 1 4 General exceptions Compensation is not provided for consequential losses damage caused by normal wear and tear inadequate maintenance or care damage caused by freezing damage of the unit due to non approved or incorrect quantities of antifreeze being used in the ground side incorrect flowrates or air in the system damage caused by power surges incorrect supply voltage or lightning strikes cost of inspecting adjusting or cleaning the item unless this relates to damage that is eligible for compensation minor damag
10. e e g scratches and marks that does not affect the operation of the item damage covered by insurance indirect damage loss or damage caused by gross negligence or intent misappropriation fraud or similar crime against property breach of trust or fraudulent conversion products that have been altered subject to misuse negligence accidental damage abnormal use or service operated or installed in a manner contrary to Kensa Heat Pumps Ltd published or written Shoebox Heat Pump Operational Manual Version 2 1 Page 16 of 20 Kensa Heat Pumps products subjected to abrasion or corrosion products operated in connection with any liquid source that contains impurities which are corrosive to copper products operated in a temperature range inconsistent with Kensa Heat Pumps Ltd s published or written recommendations 7 1 5 Care of Duty The product must be handled with normal care and attention to minimise the risk of damage or loss 7 1 6 In the event of Damage The installing contractor Contractor or if the installing Contractor is not available Kensa Heat Pumps Ltd must be notified of any damage immediately and no later than six months after you first became aware of the damage The commissioning certificate received on installation should be appended to the claim If a claim for compensation is made after the deadline specified above or if a commissioning certificate cannot be produced the guarantee shall not apply 7
11. e 10 4 2 una una manass To read flow temperatures and refrigerant pressures 12 4 22 usupa ai EET To change the heat pump return flow temperatures 12 4 3 asnapa aypasun DHW Production s e 55 12 A A E Maintenance P 13 Goseren Fault finding u n e oenen 14 O22222 saus Complaint Procedure 22 n n 55555 sarccces 15 7 sisicesansscassceventse Warranty eee n s n s s 16 Zaza ET TTS anci emaqitions_ 16 TAA cece Persemsceverecdiby the Warramiyamamanp l l 16 7 1 2 Ka Validity period of the Warranty ccccessccssecssscsssecseseessseeeeeeseaeeceeeseaeeceeeeeaeecees 16 7 1 3 Kan SGopem s A EEE u 16 7 1 4 Kan GerenallexceephjmysW U UU U U T a 16 7 1 5 ee Care OF DULY 3 3 eee Eee PEER occ 00000n00c00000000008 Eee eee 17 7 1 6 eee Inptherevent of Damage snn 5 17 7 1 7 a Replacement Parts EA s sss 17 Page 2 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps 1 Introduction a message from the Managing Director Thank you for choosing a Kensa Shoebox ground source heat pump for your project Kensa Heat Pumps has been manufacturing ground source heat pumps s
12. ff for automatic reset Refer to Kensa Technical department KensaHeat Pumps 6 Complaint Procedure The expertise of members and the assurance provided by the Renewable Energy Consumer Code make sure that micro renewable technology supplied and installed under the scheme are free from manufactur ing or installation faults Occasionally however problems can develop If you want to complain about the quality of the equipment the installation the advice given the standard of service or any other aspect of the contract between Kensa and yourself the following procedure should be used Any complaint should be notified to Kensa Heat Pumps within three months of first noticing the problem a If the complaint cannot be rectified remotely Kensa or a representative on its behalf will arrange to inspect the system within 20 working days from receiving the complaint If the complaint is about under performance you should make evidence available to Kensa C Kensa will consider the details of the complaint and report the findings clearly to the consumer within seven working days from any inspection d Kensa will try to find an agreed course of action to solve the complaint to the consumer s satisfaction e Kensa will co operate fully with local consumer advisers or any other person that you consult when making a complaint f If a complaint cannot be sorted out through the above procedure you or Kensa can use the conciliation
13. heating distribution system and work on a temperature differential of approximately 5 degrees i e if the return temperature set point is 29 C to 30 C the actual flow temperature out of the heat pump is approximately 35 C The outlet flow temperature of the heat pump determines the efficiency of the heat pump and should have been set for your particular heating system and application at commissioning This is passcode protected to avoid unauthorised changes If for any reason that the heat pump return flow needs to be changed please contact Kensa Heat Pumps s Technical Department on 01872 862140 4 3 DHW Production The most efficient way of producing Domestic Hot Water DHW is by using Solar Thermal however DHW can be provided by most heat pumps The installation and operation of a heat pump in DHW mode is more complex than space heating and needs careful design and installation To simplify the production of DHW using a heat pump Kensa has designed an industry leading and straightforward DHW option The heat pump is designed to operate at the optimum temperature that provides DHW at the maximum efficiency without using any inbuilt direct electric heaters The system does not need a tank thermostat or a software temperature setpoint Page 12 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps 4 3 1 DHW Operation To get the most cost effective production of DHW and space heating it is advised that the sys
14. ince 1999 and have significant experience in providing heat pump systems in domestic and commercial applications Your Kensa heat pump will provide you with many years of low energy bills and maintenance free running while also reducing your carbon footprint Kensa Shoebox heat pumps are designed for ease of operation and once set by your installer to provide the optimum flow temperature for your heating system should not require adjusting The purpose of this manual is to guide you through the operational aspects of living with a heat pump Finally please feel free to contact Kensa should you have any questions 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 Se Simon Lomax Managing director Kensa Heat Pumps Ltd kensaheatpumps Welcome to Kensa For further information on ground source heat pumps and their application please refer to www kensaheatpumps com Shoebox Heat Pump Operational Manual Version 2 1 AT KensaHeat Pumps x 2 gt D amp oO v Fault Finding Operational Instructions General product information Warranty uolnonpod1u O 2 5 e s gej i ox o zA 3 3 ie Suipuij 1 ned suonmonu sul Ieuoneij do AJUeLe AA 2 Safety information Safe operation of this unit can only be guaranteed if it is
15. n off peak electricity tariffs such as Economy 10 4 With underfloor systems avoid the use of insulative coverings such as thick carpets and wooden floors 5 Consider the use of Solar Thermal for the production of the majority of DHW 4 2 Display Each heat pump has a dedicated display which can be interrogated to view various parameters alter the heat pump outlet flow temperature and indicate faults alarms 2 Heating 3 Compressor symbol number 1 Floor return temperature 3 Compressor run symbol n b the numbers above refer to the points below Fig 5 Heat Pump Display Shoebox Heat Pump Operational Manual Version 2 1 sun so KensaHeat Pumps The display normally reads the temperature of the water returning from the heating distribution system The controller will turn the heat pump off once a pre set temperature of water returning from the heating system has been achieved This setting is normally 30 C for underfloor applications which is a typical re turn temperature for an underfloor application In twin compressor units the left hand controller is set at 30 C the right hand at 31 C For radiators this is generally set during commissioning at 45 C for standard units and 55 C for high temperature models The display normally reads the temperature of the water returning from the heating distribution system The controller will turn the heat pump off once a pre set temperature of water returning from the heating s
16. ng period out of use Insufficient antifreeze added and heat pump frozen Freeze protection system activated Low or no water flow on the ground cold side of the machine Can also occur after many months of running in very cold weather Loss of contact with probes inside heat pump E4 could be loss of contact with weather compensation sensor Shoebox Heat Pump Operational Manual Version 2 1 Page 14 of 20 Check Fuse in plug and replace if necessary Check wall mounted electrical isolator switch or call electrician Call electrician to investigate cause Programme time clock according to manu facturer s instructions No fault The pressures should be between 1 and 2 bar If below this the pressure needs to be increased above 1 8 bar To increase the pressure in either circuit the cold fill valve will need to be opened Check that the water pumps are operational and spin the impellors See section 6 3 No action Check that the water pump is operational and spin the impellors see section 6 3 If symptom persists outside of the two listed circumstances contact Kensa Technical de partment No action Allow heat pump to defrost and add the correct antifreeze quantity Check antifreeze has been added and unit commissioned correctly Check that the water pump is operational and spin the impellors see section 6 3 Ensure no flow restrictions and wait approxi mately 4 hours with the machine turned o
17. rational Manual Version 2 1 Kensa Heat Pumps Introduction Safety information c S S x O me Qa oO s O lt O O Fault Finding Warranty uolnonpod1u uonewsojul Alj Jes G oO 3 oO pej i Qa c Q aa 3 o 3 Sulpuly Ned hyuene M 4 2 1 To read flow temperatures and refrigerant pressures Using the display it is possible to interrogate the heat pump to read flow temperatures and refrigerant pressures To read flow temperatures and refrigerant pressures 1 Press and hold SEL until is displayed 2 Press the UP arrow until b is displayed 3 Press SEL and b01 is displayed 4 Press SEL 5 Temperature of water returning from the underfloor is displayed b01 6 Press SEL 7 Press the UP arrow once until b02 is displayed 8 Press SEL 9 Temperature of water returning from ground arrays is displayed b02 10 Press SEL 11 Press the UP arrow once until b03 is displayed 12 Press SEL 13 Temperature of water going out to the ground arrays is displayed b03 14 Press SEL 15 Press the UP arrow once until b04 is displayed 16 Press SEL 17 Refrigerant pressure in Bar is displayed b04 18 Press SEL 19 Press PRG twice until S P is displayed 20 Press and hold PRG until the display returns to normal 4 2 2 To change the heat pump return flow temperatures Heat pumps are generally controlled on the return temperature from the
18. service offered by the Renewable Energy Consumer Code Please see www recc org uk Page 15 of 20 Shoebox Heat Pump Operational Manual Version 2 1 Kensa Heat Pumps Introduction Safety information General product information wn S S O 5 N lt 3 Cc S oO O Qa O Warranty uolguuojJul 19npoid ej u p uonewsojul Ajajes uono npod1lul suonmonu sul Ieuonei do R ov T 5 5 oa 7 Warranty The Kensa Shoebox Ground Source heat pump is designed and built to the highest standard and as such is guaranteed for 5 years for parts from the date of commissioning or 5 years from the date of manufacture excluding the internal water pumps and electrical components whichever is shorter Internal water pumps ground side and electrical components are guaranteed for 2 years for parts from the date of commissioning or 2 years from the date of manufacturer whichever is shorter 7 1 Terms and Conditions 7 1 1 Persons covered by the Warranty The Warranty applies to the original purchaser and any subsequent owner of the item 7 1 2 Validity period of the Warranty The guarantee period excluding the water pumps and electrical components is five years calculated from the commissioning date stated on the commissioning certificate or 5 years from the date of manufacture whichever is shorter For the water pumps and electrical components it is 2 years from the commissioning date st
19. talled without any specialist training making the product available to a larger market and helping to reduce CO2 emissions while reducing client s energy bills 3 2 Product description Heat pumps basically extract solar energy stored in the ground water courses and in the air and convert this to a higher temperature to use in a building s heating distribution system They work in a similar manner to a fridge in reverse where the inside of the fridge is the heat source and the grill at the back of the fridge is the heating system Electrical Power Compressor Underfloor Heating Distribution System wn S a O 5 N lt 5 S _ O Q O Electrical Power Electrical Power Fault Finding FF Z Z Z Z Low Grade Heat From Ground Fig 1 Heat pump Schematic Warranty Shoebox Heat Pump Operational Manual Version 2 1 ese Pe KensaHeat Pumps uonmo npoulu uolnmguuojJu 13 Jes O gej oO x ow 2 5 141 3 Cc Qa rt n Sulpuld 3ne4 AJUeLe AA A ground source heat pump GSHP extracts heat from the ground by circulating a cold solution of water and antifreeze brine around pipes buried in the ground As these pipes are buried below 1m in depth where the temperature of the ground remains pretty constant 8 to 10 C heat is absorbed from the ground into the fluid approximately 5 C This brine is then passed through one side of a heat exchanger
20. tem is used in conjunction with an off peak electricity tariff for example Economy 10 Economy 10 will provide three periods of off peak electricity throughout a 24 hour period The majority of the off peak period should be used for space heating and the settings on the DHW timeclock should reflect this DHW production takes priority over the space heating so it is important that sufficient time is allocated to the space heating to ensure that the building is warm Using the in built controls the heat pump will continue to produce DHW until the timeclock ceases to call for DHW or the controls automatically stop the heat pump If the controls stop the production of DHW the heat pump will not restart for a period of approximately two hours as the number of compressor starts are limited in DHW mode for a given period of time Shoebox heat pumps are designed to provide higher outlet temperatures so will produce DHW at 60 65 C however as with all heat pumps increasing the outlet temperature decreases the efficiency 4 4 Maintenance No routine maintenance is required to Kensa Shoebox Heat Pumps and there are no user serviceable components inside If further help is required then telephone our helpline on 01872 862140 or send an email to technical kensaheatpumps com Before cleaning always switch off the appliance at the electrical isolator Use only soap and a damp cloth do not use solvents Shoebox Heat Pump Operational Manual Version 2 1
21. ystem has been achieved This setting is normally 30 Deg C which is a typical return temperature for an underfloor application The Kensa Shoebox Range of heat pumps are delivered with the software pre configured for a typical underfloor mounted in screed application 1 The display on the controller indicates the return temperature of the underfloor circuit 2 The left hand symbols sun indicate heating The shoebox is only available for heating applications 3 A number 1 and or 2 will appear in the top right of the controller this is to indicate the compres sor number If the number 1 and or 2 is flashing the internal timer is activated and the com pressor is waiting to run When the compressors are running the number 1 and or 2 and the compressor run symbol will be on V Sunsymbol heating mode Compressor running A flashing error code may appear if there is a fault with the heat pump the most common will be Am D Low water pressure ground or heating distribution OB High gas pressure caused by low or no flow on the heating distribution circuit LP Low gas pressure fault can occur temporarily on first start up Call Kensa Technical Department Anti freeze alarm ground getting to cold insufficient anti freeze unit not commissioned correctly low flow around ground arrays See Fault Finding Section 5 for further details Page 11 of 20 Shoebox Heat Pump Ope
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