commissioning manual v4 - kensa heat pumps€¦ · · 2014-12-19compact heat pump commissioning...

Compact Heat Pump Commissioning Manual Version 4 of 35

Compact Heat Pump

Commissioning Manual

Copyright ©2012 Kensa Engineering Ltd


Contents

Section Description Page

1....................... Introduction .................................................................................. 3

2....................... Safety Information ........................................................................ 4

2.1........................... Access ...................................................................................................................... 4

2.2........................... Lighting .................................................................................................................... 4

2.3........................... Tools and Consumables ........................................................................................... 4

2.4........................... Handling ................................................................................................................... 4

2.5........................... Residual Hazards ...................................................................................................... 4

2.6........................... Freezing ................................................................................................................... 4

2.7........................... Disposal/Decommissioning ..................................................................................... 4

3....................... General Product Information ........................................................ 5

4....................... Client and Heat Pump Data ........................................................... 6

5....................... Heating System Data ..................................................................... 8

6....................... Ground Arrays ............................................................................... 10

7....................... Switching the Heat Pump On ......................................................... 12

8....................... Checking for Air in the Water Pump .............................................. 14

9....................... Changing the Antifreeze Alarm Point ............................................ 16

10..................... Changing the Return Water Set Point ............................................ 17

11..................... Taking the ‘B’ Readings ................................................................. 18

12..................... Weather Compensation ................................................................ 20

13..................... Commissioning Sign Off ................................................................. 21

14..................... Faults That Can Occur During Commissioning ................................ 22

14.1......................... Carel Controller Seems Dead ................................................................................... 22

14.2......................... Carel Display is Operational But Remote Display is Dead ........................................ 23

14.3......................... LP Alarm Displayed and Red Light Flashes ............................................................... 25

14.4......................... A1 Alarm Displayed and Red Light Flashes .............................................................. 26

14.5......................... E1,E2 and E3 Alarms ................................................................................................ 28

14.6......................... E4 Alarm .................................................................................................................. 29

14.7......................... HP Alarm (High Pressure Gas) ................................................................................. 31

14.8......................... Tp Alarm—Low Pressure Underfloor or Groundside ............................................... 33

14.9......................... Compressor Sounds Noisy ....................................................................................... 34

15..................... Fault Finding Summary .................................................................. 35


Kensa Engineering has been manufacturing ground source heat pumps since

1999. In the early days, it was difficult to find contractors willing to consider the

technology. As a consequence, Kensa made considerable efforts to simplify the

installation process. With the advent of the Microgeneration Certification

Scheme the number of certified installers is increasing and the company is now

reaping its rewards as heat pumps become mainstream heating appliances.

The purpose of this manual is to guide you as an MCS installer, through the commissioning process. It is

expected that all the required information has been provided to allow you to connect the heat pump

correctly and that the commissioning will be a simple process.

Please note if you experience any problems please feel free will to speak to the Technical Support Team

on 01872 862140. Opening hours are 8.00am to 5.00pm .

Finally, please 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.

Simon Lomax

Managing director

Kensa Engineering Ltd

1. Introduction—A message from the Managing Director


2. Safety information Safe operation of this unit can only be guaranteed if it is properly installed and commissioned in

compliance with the manufacturer’s requirements. 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 Engineering

Mount Wellington

Chacewater

Truro

Cornwall

TR4 8RJ

Tel 01872 862140

www.kensaengineering.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 Commissioning Instructions, could damage the product, will invalidate the warranty, and may cause

injury or fatality to personnel.

2.1 Access

Ensure safe access before attempting to work on the product. Arrange suitable lifting gear if required.

2.2 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

2.3 Tools and Consumables

Before starting 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. Lifting, pushing, pulling,

carrying or supporting a load by bodily force can cause injury particularly 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

installation.

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 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 and Commissioning Manual.


3. General Product Information

This manual gives guidance on how to commission a Kensa ground source heat pump. The manual is

designed for use by MCS approved installers who undertake commissioning of a Kensa Heat pump as part

of the service and grant process for their clients.

The Kensa Compact Single Compressor Heat Pump is designed to provide a low cost renewable heat

source for a buildings heating system. In addition, and if required, the Kensa Compact 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.

The Kensa Compact Single Compressor Heat Pump is designed for straightforward installation and the

installation must conform to all relevant construction and electrical codes and comply with the

requirements of the Microgeneration Certification Scheme (MCS) MIS3005 ’Requirements for Contractors

undertaking the Supply, Design, Installation, Set to Work Commissioning and Handover of Microgeneration

Heat Pump Systems’.

The following sections detail the steps to be taken for the final commissioning of the unit. It advises the

steps and possible errors that could occur during commissioning. The idea of the manual is to work

through each section in turn while referring to the fault section as and when required. Many faults found

with heat pumps generally occur due to wiring faults or in setting the unit up. Therefore it is recommend

that initially a detailed check is carried out should there be a problem.

The manual can be used as a record of the commissioning or simply as a guide through the commissioning

process.

Information taken during the commissioning can help with any future fault finding and also provide

information to satisfy the requirements for the commissioning certificate from the Low Carbon Buildings

Programme.


4. Client and Unit Data

Commissioning Engineer

Date

Client Name

Address

Postcode

Telephone Number

Site Telephone Number

Installation Address

(If different)

Installation Postcode

Type of Property (Flat, Bungalow,

House)

Style of Property (mid-terraced, end-

terraced, semi, detached)

Number of Bedrooms


Product

Note : Check for initial wiring faults on three phase systems

Serial Number

Heating or Cooling

Note : For Cooling Applications please contact Kensa Technical

Department

kW rating

kWh per annum

Note : This figure can be obtained from the clients SAP report

Fuel displaced

Ensure all MCB’s are turned off


Type of Heating System

Note: If Radiators then the return flow temperature might need to be set

higher. See Changing the Return Water Set Point - Section 10

Make of underfloor

Type of underfloor system Ground floor

First floor

Second floor

Note: This will affect the final running temperature of the heat pump.

Screed will be 35oC, suspended floors will need to set at 40 to 45

oC. See

Changing the Return Water Set Point - Section 10.

Number of underfloor heating

manifolds

Does each manifold have its own

pump?

Note: This only applies for systems 4kW +

Have all the mixing valves been

removed?

Are 25% of the zones left open or is a

buffer vessel fitted?

Note: When switching a heat pump on for the fist time and the weather

is very cold (below 3 deg C), the best way is to open one underfloor zone

at a time. This puts less demand on the ground arrays. This is called a

flat battery syndrome.

5. Heating System Data


Control Philosophy

Note: How is the underfloor controlled i.e. Underfloor control unit,

thermostat, time clock, linked terminals

Is the heat pump able to receive a call

for heat

Note: This is required to ensure that power can be supplied to the unit

during the commissioning. This can be done via the control unit or in its

simplest form linking terminals 1 and 2 on the wiring block.

Link between terminals one and two


Type of Ground Arrays

Number

Length

Horizontal or vertical trench

Trench separation distance

Note : For slinkies this should be 5m, for straight pipe 1m

Has the array been purged in both

directions with a Clarke SPE1200SS

purge pump

Note: If No, the ground arrays need to be purged using the Clarke Purge

Pump SPE1200SS available from Machine Mart. Air might be in the sys-

tem if purged incorrectly.

Antifreeze (quantity added)

Antifreeze concentration (checked

with two random samples)

Sample 1 Sample 2

Note: If the consistency of antifreeze to water is not 20% or protected to

-10oC the heat pump will more than likely go out on an A1 alarm which

means that ice can form in the heat exchanger. The system MUST have

the right amount of antifreeze protection. If low additional antifreeze

must be added and the system repurged. Following this commissioning

can continue. Concentration should be checked via a refractometer.

Pipe visually inspected before

backfilling (kinks and nicks)

Pipe leak tested to BS805 Section

11.3.3.4

Pressure

A B C

Note : The ground array pressure will drop over the first year due to the

pipe relaxing within the ground, hence the fill loop needs to be

connected if the pressure needs increasing at a later date. Any short

term drop generally indicates a leak.

6. Ground Arrays


Pressure gauge readings on heat

pump.

Load

Gauges are below the water pumps

within the heat pump.

Ground

Note : The pressure should be between 2 and 6 barg. The pressure

switch activates at 0.3 barg and resets at 1.8. If the pressure to low top

up using the ground fill loop or underfloor fill loop to at least 2 barg. If

pressure to high release pressure using schrader valves.

Have the flow arrows been added to

the manifolds?

Note : Flow direction arrows need to be placed on the manifold to

indicate flow and return for future reference. This is a requirement of

MCS.

Have the water pumps impellors been

spun?

Note: See directions within the installation manual. This is to ensure

pumps are free to spin. The 30/10 pump (16kW and above) does not

have a bleed screw

Has the antifreeze been circulated

thoroughly through the arrays and

heat pump?

Note: The antifreeze must be mixed thoroughly otherwise any unmixed

solution will ice and freeze within the heat exchanger resulting in an A1

alarm. If not done this can be achieved by running the ground water

pump (DO NOT SWITCH THE 25AMP MCB ON ONLY THE 4AMP). On twin

compressors both the 4amps need to be turned on. It can take about

45min to completely mix.

Load side gauge Ground side gauge

4amp mcb, should be marked on the

mcb. Usually for single phase 2nd

mcb

in (check on twin), three phase 4th

mcb

in (check on twin)


Visual check of heat pump installation

Note : Check to make sure no leaks, no obvious damage to the unit.

Unit level?

Front cover removed

Note: Ensure power to the unit is isolated

Visual inspection of wiring

Note: If any visual damage halt the commissioning and call an electrician.

Type of Consumer unit MCB fitted Amps

Rating

Note: Type D's are preferred, however type 'C' is acceptable for single

phase heat pumps with smart starts.

Power turned on to the unit

Note: Power turned on via the main MCB in the consumer unit

Turn only the 4amp MCBs on.

Note: On a twin both 4amp MCBs need to be turned on. DO NOT TURN

ANY 25AMP MCBs ON

7. Switching the Heat Pump On

4amp mcb, should be marked on

the mcb. Usually for single phase

2nd

mcb in (check on twin), three

phase 4th

mcb in (check on twin)


Reading on display Carel controller dead (see section 14.1)

Carel is working but remote display is not (see section 14.2)

LP alarm flashes with red light (see section 14.3)

A1 alarm flashes with red light (see section 14.4)

E1, E2 or E3 flashes with red light (see section 14.5)

E4 alarm flashes with red light (see section 14.6)

Any software errors?

Heat pump comes to life and the

return flow temperature is displayed


If not already on, switch only the 4

amp mcbs on (two on a twin). Do not

switch any 25 amp mcbs on.

The underfloor pump should switch

on and the underfloor pressure gauge

should register approx 1/2 bar drop in

pressure

Note: If no movement see section below

Repeat three times

Around 5 seconds later the contactor

should operate (large clunk) and the

ground pressure should increase

about 1/2 bar

Note: If no movement see section below

Repeat three times

No movement in gauges.

If the ground or load side pressure

gauges do not show a change in

pressure this generally means that air

is around the pump. Turn the 4 amp

MCBs off and bleed the pipe at the

top of the pipe into the heat

exchanger via the Schrader valve.

Note : If no fluid is around the impeller the pump generally gets very hot

8. Checking for Air in the Water Pumps

4amp mcb, should be

marked on the mcb.

Usually for single phase

2nd

mcb in (check on

twin), three phase 4th

mcb

in (check on twin)

Load side gauge Ground side

gauge


Check pump is not stuck and spin

pump

Note: See directions within manual. This is to ensure pumps are free to

spin. The 30/10 pump (16kW and above) does not have a bleed screw

Check all valves on manifolds open

Check flow direction arrows on

manifold pumps correct.

Note : Pumps will be pumping against each another if flow direction is

the same.

Check power supply to pumps

Note : Pumps might be faulty if power supply ok. Check if running. If

pump faulty then contact Kensa Technical Department

Was the system purged correctly?

Note : If not repurge

Load side bleed point

Ground side

bleed point


The antifreeze alarm is factory set at 0oC. This needs to be reset during commissioning to -5

oC. Failure to

do this (or lack of antifreeze) could cause the heat pump to display an A1 alarm and turn itself off during

cold weather. The antifreeze alarm point should only be changed once the correct antifreeze quantities

have been added and confirmed.

1 For the upper external controller, press and hold

SET until 0 is displayed. For the lower controller

within the heat pump, press and hold SEL and PRG

together.

2 Press and hold the UP button, and release when

66 is displayed

3 Press SEL

4 Display will now read S-P (which means "Set

Parameter")

5 Press SEL, and -/- is displayed

6 Press SEL

7 Press the UP arrow until -/04- is displayed

8 Press SEL

9 Press the DOWN arrow to change from 3 to 0

10 Press SEL

11 Press PRG

12 Press the UP arrow until -d- is displayed

13 Press SEL

14 Press the UP arrow until d03 is displayed

15 Press SEL and the Antifreeze Setpoint is displayed

16 Press and hold the DOWN arrow to change from

0.0 to -5.0

17 Press SEL

18 Press PRG

19 Press the DOWN arrow until -/- is displayed

20 Press SEL


22 Press SEL

23 Press the UP arrow to change from 00 to 03

24 Press SEL

25 Press PRG twice until S-P is displayed

26 Press and hold PRG until the display returns to

normal

Note: Heat pumps are shipped with the antifreeze

alarm set at 0C, this needs to be reset to -5oC at

commissioning. This needs to be done for both sides

if it is a twin compressor model.

9. Changing the Antifreeze Alarm Point

External Controller

Internal Controller


Return water set point is factory set at 30oC to provide water into the underfloor at 35

oC. For underfloor

in joisted systems this will possible need to be increased to 40-45oC depending on floor coverings.

Radiators require a higher flow temperature and hence the temperature should be set at 45oC. A mix of

underfloor and radiators will also require 45oC.

1 For the upper external controller, press and hold SET until 0 is displayed. For the lower

controller within the heat pump, press and hold SEL and PRG together.

2 Using the up arrow go to 11

3 Press SEL

4 Display will now read S-P (which means "Set Parameter")

5 Press and hold SEL until -/- is displayed

6 Press the DOWN arrow until -r- is displayed

7 Press SEL and r01 is displayed

8 Press the UP arrow until r03 is displayed

9 Press SEL

10 The return water temperature setpoint is displayed

11 Press the UP or DOWN arrows to change the setpoint

12 Press SEL


14 Press and hold PRG until the display returns to normal

For twin compressor units both controllers i.e. both internal or both external controllers will

need to be set with new return flow temperatures. The right hand controller generally has a

return set temperature one degree higher than the left hand controller.

Return set points

Single compressor

Twin compressor

10. Changing the Return Water Set Point

Left compressor Right compressor


The ‘B’ readings are measurements of the temperatures and pressures within the heat pump. They give

an indication of how well the heat pump is working and will help with any diagnostics.

Turn the 25amp MCB for the

compressor on

Compressor noisy?

Note: If yes, see section 14.9

Run compressor for 5-10 mins and

then record any errors.

A1 alarm see section 14.4

LP alarm see section 14.3

Tp alarm see section 14.8

E1 to E3 alarm see section 14.5

E4 alarm see section 14.6

Reading the ‘B’ temperatures and

pressures

Note : For twins readings have to be taken and recorded from both

controllers

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 The temperature of water

returning from the underfloor is

displayed

b01 single twin

Note: Return flow temperature should read between 0 and 30oC. If

above 30oC check that the return flow temp hasn’t been changed. If

the flow temperature is set correctly and reading above 30oC then

check sensors are connected and call the Kensa Technical

Department

When taking the b01 reading you can check for no flow by watching

how fast the heat is dissipated when the compressor is not running.

This will confirm that flow is present.

11. Taking the B Readings

25amp mcb, should be

marked on the mcb and

for single phase the first

mcb. On three phase all

three mcb's should be

turned on.


6 Press SEL

7 Press the UP arrow once until b02

is displayed

8 Press SEL

9 The temperature of water return-

ing from ground arrays is displayed

b02 single twin

Note: Return ground temperature should read between 15 and

-5oC. If the b02 temperature is around room temperature, the

probe could have come lose. Trace the wiring back to yellow probe

on heat exchanger to confirm ok. If problem persists contact Kensa

Technical Department.

10 Press SEL


is displayed

12 Press SEL

13 The temperature of water going

out to the ground arrays is

displayed

b03 single twin

Note: b03 is the temperature leaving the ground side of the heat

pump. If b03 is below the antifreeze set point and it has not gone to

alarm, A1, then check the antifreeze alarm set point. This should be

set to -5oC. See Section 9.

14 Press SEL


is displayed

16 Press SEL

17 The refrigerant pressure in Barg is

displayed

b04 single twin

Note: Take b04 when compressor running. b04 is the gas pressure

and this should be between 4.6 and 2.2. If weather compensator is

fitted then you will not be able to read the gas pressures. If b04 is

reading below 2 then the heat pump might be low of gas.

Note: When the ground is very cold the heat pump can go out on LP

alarm and b04 is very low. This can happen when a heat pump is

switched on for the first time and the building is cold. The building

needs to be heated up one zone at a time (flat battery)

Note: If b04 is to high, the expansion valve may need adjusting.

Contact Kensa Technical Department.

Note: Check sensor wiring as could be a bad connection. Call the

Kensa Technical Department if problem still present

18 Press PRG twice until S-P is

displayed

19 Press and hold PRG until the display

returns to normal

Check the b readings are logical, ie, that the load return temperature is below the outlet temperature and that the

ground outlet is below the inlet. If not this could indicate that the sensors are incorrectly positioned.


It is advised that weather compensation is not enabled for underfloor systems operating on off-peak

tariffs and is only used on radiators. Even then Kensa recommend the system is left without weather

compensation for at least 12 months. The heat pump must be fully commissioned before weather

compensation is enabled and the b04 probe is removed.

To read b04 the weather compensator from the bottom of the carel needs to be unplugged and the carel

pressure probe plugged back in. The -/04– parameter needs to be reset to 1 following the same procedure

as outlined below. Once the b04 reading is taken the weather compensator can be plugged back in and

-/04- enabled as below.

1 Unplug the pressure transducer from the rear of the Carel (or for older grey units bottom right

hand side of Carel)

2 Plug the weather compensation sensor into the rear of the Carel (or for older grey units bot-

tom right hand side of Carel)

3 Press and hold SET, and release when 0 is displayed

4 Press and hold the UP button, and release when 66 is displayed

5 Press SEL

6 Display will now read S-P (which means "Set Parameter")

7 Press SEL, and -/- is displayed

8 Press SEL


10 Press SEL

11 Press the DOWN arrow to change from 1 to 3

12 Press SEL


14 Press and hold PRG until the display returns to normal

12. Weather Compensation

Carel pressure probe connection

New panel mounted Carel Old Din rail mounted Carel


13. Commissioning Sign Off

The unit should now be commissioned and operating correctly.

The user manuals should be left with the client and the data collected within this commissioning process

can be used to complete any grant forms.

Comments

Commissioning Engineer Signature

Print

Date

Company

MCS Accreditation Number

Telephone


14. Faults that can occur during Commissioning

14.1 Carel controller Seems Dead

Check that power to the Heat pump is

on

Check that there is a live enable signal

over terminals one and two

Note: If a live enable signal can not be obtained from the heating control

signal, disconnect and link terminals 1 and 2

Check Carel fuse inside electric box

Note: If the fuse has blown a spare fuse is taped to the HP sensor

Check wiring is correct

Faulty Carel

Note: Contact Kensa Technical Department

Link between terminals one and two

Carel fuse


Check that the remote cable is

connected correctly

For older din-rail mounted units check

that the RS485 'chip' is present and in

position on the Carel main unit

14.2 Carel Display is Operational but Remote Display is Dead

RS485 chip


Check the wiring to the Carel,

transformer and remote display

power supply

Note: Push and hold the plug in the back of the remote display. If

the display then works, the connection on the remote display is

damaged

.

Remote display maybe faulty

Note: Contact Kensa Technical Department

Blue

Grey

Brown Remote Display Connec-

tion from the Carel

Back of the remote display

Old Din Rail

mounted Carel

New panel

mounted Carel


Check that LP switch wiring (on refrigerant) is

correct

Check b04 reading

Press and hold SEL until -/- is displayed

Press the UP arrow until -b- is displayed

Press SEL and b01 is displayed

Press the UP arrow once until b04 is displayed

Press SEL

The refrigerant pressure in Bar is displayed b04 single twin

Note: If b04 can't be read the weather compensation

might be fitted. See Section 12

Note: If b04 is below 2 barg contact Kensa Technical

Department

Press PRG twice until S-P is displayed

Press and hold PRG until the display returns to

normal

14.3 LP Alarm Displayed and Red Light Flashes

1

2

3

4

5

6

7

8

LP pressure switch

Pressure transducer

(b04)


14.4 A1 Alarm Displayed and Red Light Flashes

An A1 alarm generally indicates no flow or that the compressor has run with air in the ground arrays and

that the heat exchanger has frozen. Also check the pump impeller is not stuck.

Note : If no fluid is around the impeller the pump generally gets very

hot. See Section 8

Check the b readings from the unit

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 The temperature of water returning

from the underfloor is displayed

b01 single twin

6 Press SEL

7 Press the UP arrow once until b02 is

displayed

8 Press SEL

9 The temperature of water returning

from ground arrays is displayed

b02 single twin

Note: b02 is the ground return temperature

10 Press SEL


displayed

12 Press SEL

13 The temperature of water going out

to the ground arrays is displayed

b03 single twin

Note: b03 is the ground flow temperature, if this is below -5oC then

the unit will not operate and needs to be switched of until b03 is

above 0oC. If b03 is above -5

oC and below 0 the A1 alarm needs to

be set to -5oC to allow commissioning.

14 Press SEL


displayed

16 Press SEL

17 The refrigerant pressure in Barg is

displayed

b04 single twin

18 Press PRG twice until S-P is

displayed

19 Press and hold PRG until the display

returns to normal


Check to ensure flow around ground

arrays

Note: Check the pump. See Section 8

Double check antifreeze quantities

and concentration.

Note: Check the antifreeze quantities and concentration using a

refractometer. Reconfirm purging. All antifreeze supplied must be added

to the system.


14.5 E1,E2 and E3 Alarms

E alarms generally mean a loss of contact with a sensor used to measure b0 temperatures.

Note: any damage contact Kensa Technical Department

Check that the temperature probes

leading to the Carel are fitted properly

and not loose.

Note: The sensors mounted within the heat exchanger are not

accessible. Loose connections cannot be easily rectified and if any

damage contact Kensa Technical Department.

Note: E1 fault can also indicate a problem with the DHW relay

Sensor connector

Old Din Rail mounted Carel Controller

New panel mounted Carel

Controller


14.6 E4 Alarm

Check for a damaged external

weather compensation sensor

Note : If damaged contact Kensa Engineering to organise a replacement.

Has the heat pump been

commissioned with weather

compensation

Note: See section 12

Check for damaged external tempera-

ture probe wires

Note : Check connections. If not easily rectified contact Kensa Technical

Department

Check refrigerant pressure transducer

is ok

Note : If not easily rectified contact Kensa Technical Department

E4 alarms are generally a result of a faulty weather compensation sensor or incorrect commissioning.

Pressure transducer

(b04)

Green Terminal

connection

block.

Sensor

Main Terminal Block


Check the temperature probe wiring

is correct

Note : Check connections. If not easily rectified contact Kensa Technical

Department

Temperature

probe connections Carel pressure probe

connection

Old Din Rail mounted

Carel controller

New panel mounted Carel controller


14.7 HP alarm. (High Pressure Gas)

HP alarms indicate the heat pump is over heating and is generally an indication of 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.

No flow on underfloor system. Check

all manifolds are open and underfloor

manifold pumps are not fighting each

another.

Flow?

Note: 90% of the time Hp fault is due to no flow on the distribution side.

Note: When taking the b01 reading you can check for no flow by

watching how fast the heat is dissipated when the compressor is not

running. This will confirm that flow is present.

Note: b04 reading needs to be taken when the compressor is running.

All valves open?

Air in underfloor system?

Pumps fighting each another?

Check 3 way diverter valves

Underfloor pump running?

Note: Circulation pump might be stuck. Spin pump etc.


Check wiring to HP switch

If HP alarm still showing then possible

faults might be

1) HP switch might be faulty

2) To much gas

3) Blocked gas system.

Note : Contact Kensa Technical Department

HP Pressure Switch


14.8 tp Alarm - Low Pressure Underfloor or Ground Side

‘tp’ alarms occur due to low pressure in either the ground or the load side. This could be due to an

insufficient initial pressure, pipe relaxation or leaks.

Low pressure on underfloor or ground

arrays, try topping the pressure up.

Note: Ground arrays are topped up by using the fill loop on the heat

pump. The load side (heating) system should have it’s own individual

top up . On the load side there should be an expansion vessel to keep

the pressure stable due to the temperature changes from the Heat

pump.

Note: The low pressure switch operates (for both sides) at 0.3 barg, but

the pressure needs to be increased to above 1.8 barg to reset.

Check connectors back to LP ground

and load switch

If pressure continues to drop, this

indicates a possible leak in the system.

Pressure test the problem side.

If tP alarm still present possible causes are:

1) LP switch and pressure gauges

might be faulty

Note : Contact Kensa Technical Department

Heat pump ground array fill

Low load water

pressure switch

Low ground water pressure

switch


14.9 Compressor sounds noisy

Contactor chattering on or off

Contactor might need changing, check contacts. Contact Kensa Technical

Department.

Compressor makes a loud shrieking

noise

hp switch is faulty or access valve not depressing. Contact Kensa

Technical Department

Compressor sounds like its trying to

run backwards

Mainly 3 phase - incorrect wiring on the phases. Check wiring and rewire.

If rewiring doesn't solve the problem then call Kensa Technical

Department

Check compressor is not rubbing on

casing


15. Fault Finding Summary

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.

Symptom Possible Cause Action

Blank display on software controller No power supply Check wall mounted electrical isolator switch

or call electrician

Controls MCB tripped Call electrician to investigate cause

There is no call from the time-clock or thermostat for heat pump operation

Programme time-clock according to manu-

facturer’s instructions

Compressor not running but display reading temperature near setpoint

Heat pump is up to temperature No fault

Display flashes fault code tP Low water pressure in the ground or heating

system side due to pipe relaxation or other

pressure loss.

Check the pressure gauges below the two

water pumps. The pressures should be be-

tween 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. The

Ground cold fill is provided with every Kensa

heat pump, and is found on the right hand

side of the heat pump, underneath. The heating distribution system should have

it’s own fill point.

Display flashes fault code HP 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.

Bleed the heating distribution system pump

within the heat pump, using the schrader

valve above the pump.

Check that the water pumps are operational

and spin the impellors (see the Installation

Manual)

No action

Display flashes fault code LP 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 long period out of use.



Manual)

If symptom persists outside of the two listed

circumstances, contact Kensa Technical de-

partment.

No action

Display flashes fault code A1 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.

Check antifreeze has been added and unit

commissioned correctly.



Manual)

Ensure no flow restrictions and wait approxi-

mately 4 hours (with the machine turned off)

for automatic reset.

Display flashes fault code E1, E2, E3 or E4 Loss of contact with probes inside heat

pump. E4 could be loss of contact with

weather compensation sensor

Refer to Kensa Technical Department

commissioning manual v4 - kensa heat pumps€¦ · · 2014-12-19compact heat pump commissioning...

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