Q80 Series Heat Pumps Installation and Commissioning Manual

Page 1 of 40
Q80 Series Range Heat Pump Manual Version 1

Copyright ©2022 Kensa Heat Pumps Ltd
Q80 Series Heat Pumps
Installation and Commissioning Manual
Heat Pump Warranty Fault Finding Commissioning Installation Installation Installation Installation General product Safety Introduction
settings sheet electrical mechanical schematics information information
Introduction
Contents Page
information
Section Description Page

Safety
1....................... Introduction .................................................................................. 4

2....................... Safety Information ........................................................................ 5
General product
2.1........................... Access ...................................................................................................................... 5

information
2.2........................... Lighting .................................................................................................................... 5

2.3........................... Tools and consumables ........................................................................................... 5
2.4........................... Handling ................................................................................................................... 5
2.5........................... Residual hazards ...................................................................................................... 5
Installation
2.6........................... Freezing ................................................................................................................... 5

2.7........................... Disposal/decommissioning ...................................................................................... 5
3....................... General product information ........................................................ 6
3.1........................... Equipment delivery and handling ............................................................................ 6
Installation
schematics
3.2........................... Kensa Q80 Series Range technical data ................................................................ 9
4....................... Installation.................................................................................... 10
4.1........................... The golden rules of installing a heat pump ............................................................ 10
mechanical
Installation
4.2 .......................... Q80 Series heating schematics ................................................................................ 10

4.3........................... Q80 Series heating and cooling schematics ............................................................. 14
4.3.1…………………….. Active or Passive Cooling……………………………………………………………………………………… 14
4.4........................... Secondary boiler back up systems (bivalent alternative systems) Fig 7……………….. 16
Installation
electrical
4.5……………………….. Secondary boiler back up systems (bivalent parallel systems) Fig 8……………………… 16
4.6........................... Mechanical installation ........................................................................................... 19
4.6.1........................ Locating the heat pump .......................................................................................... 19
4.6.2........................ Recommended clearances ...................................................................................... 19
Commissioning
4.6.3........................ Installation of the heat pump .................................................................................. 20

4.7........................... Electrical installation ............................................................................................... 21
4.7.1........................ Three phase power supplies .................................................................................... 22
4.7.2…………………….. Main PCB Terminal Description……………………………………………………………………………. 23
Fault Finding
5....................... Setting 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
Warranty
5.1.3........................ Adding antifreeze / inhibitors ...................................... ........................................... 30

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Heat Pump

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Introduction
Contents Page
information
Section Description Page
Safety
5.1.4........................ Pressure Testing in accordance to BS805 Section 11.3.3.4 .................................... 30
5.1.5........................ Testing of antifreeze concentration ....................................................................... 31
General product
6....................... Controller .................................................................................... 32
information
7…………………….. Fault Finding………………………………………………………………………………. 33
8....................... Warranty...................................................................................... 34
8.1........................... Terms and Conditions............................................................................................. 34
Installation
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 exceptions ................................................................................................. 34
Installation
schematics
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 settings sheet .......................................... 36
mechanical
Installation
Installation
electrical
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

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Introduction
1. Introduction—a message from the CEO

information
Kensa Heat Pumps has been manufacturing ground source heat pumps since
Safety
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 to allow any competent contractor to perform the work. The
General product
company is now reaping its rewards as heat pumps become mainstream heating
information
appliances.
The purpose of this manual is to guide you through the installation process. It is
expected that all the required information has been provided to allow you to connect the heat pump.
Critical instructions, aimed at ensuring you do not experience any difficulties, are highlighted on the
Installation
‘Golden Rules’ in the installation section.
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 questions, wish to consider ground source
Installation
schematics
heat pumps for any future projects or even just to share your experiences of using a ground source heat
pump with us.
mechanical
Installation
Matt Trewhella
CEO
Kensa Group Ltd
Installation
electrical
Commissioning
For further information on

Fault Finding
ground source heat pumps and

their application, please refer to
www.kensaheatpumps.com
Warranty
settings sheet
Heat Pump

Page 4 of 40
Introduction
2. Safety information
information
Safe operation of this unit can only be warranted if it is properly installed and commissioned in
Safety
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.
General product
information
Manufacturer:- The product is designed and constructed to withstand the
Kensa Heat Pumps forces encountered during normal use. Use of the product
Mount Wellington for any other purpose, or failure to install the product in
Chacewater accordance with these Installation and Commissioning
Truro Instructions, could damage the product, will invalidate the
Installation
Cornwall warranty, and may cause injury or fatality to personnel.
TR4 8RJ
Tel 01872 862140
www.kensaheatpumps.com
2.1 Access and Egress
Installation
schematics
Ensure safe access and egress 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.
mechanical
Installation
2.3 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available.
2.4 Handling
Installation
electrical
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.
Commissioning
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
Fault Finding
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
Warranty
(carriage at users’ cost). Disposal of any antifreeze water mix should follow the disposal instructions 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 collection point for the recycling of waste elec-
trical equipment. The separate collection and recycling of your waste equipment at the
time 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 information about
where you can drop off your waste equipment for recycling, please contact your local city
settings sheet
Heat Pump

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Introduction
3. General Product Information

information
This manual explains how to install a Kensa ground source Q80 Series heat pump.
Safety
The Kensa Q80 Series Heat Pump is designed to provide a low cost renewable heat source for a buildings
heating system. Heat pumps can provide lower running costs and will generate significantly lower carbon
General product
emissions compared with traditional fossil fuels.

information
The Kensa Q80 Series Heat Pump is designed for straightforward installation and integration into a
buildings heating system. The installation must conform to all relevant construction and electrical codes.
3.1 Equipment delivery and handling.

Installation
Factory shipment
Prior to shipment, the Kensa Q80 Series Heat Pump is tested, calibrated and inspected to ensure proper
operation.
Installation
schematics
Receipt of shipment
Each pallet should be inspected at the time 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, notify Kensa immediately and provide full
details. In addition, damage must be reported to the carrier with a request for their on-site inspection of
mechanical
Installation
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 conditions and storage.
Storage
If a Kensa Heat Pump is to be stored prior to installation, the environmental storage conditions should be
Installation
electrical
at a temperature between 0°C and 50°C (32°F and 122°F), and between 10% and 80% relative humidity
(non-condensing). The Q80 Series Heat Pump should be moved indoors immediately when received as the
unit is not rated for external conditions and storage.
Commissioning
Fault Finding
Fig 1. Q80 Series Heat Pump

Warranty
settings sheet
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Introduction
information
Safety
Plate Heat Exchangers
General product
information
Installation
Installation
schematics
Compressors
mechanical
Installation
Fig 2. The internals of a heat pump (side view)
Installation
electrical
Controller Wiring
Enclosure
Commissioning
Fault Finding
Warranty
Fig 3. The internals of a heat pump. (door open)

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Heat Pump

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Fig 4. Contoller Wiring Enclosure (cover removed)

Ground pump volt free
Controller main PCB
Smart Starts
Page 8 of 40
Terminals
MCBs
relay
Introduction Safety General product Installation Installation Installation Installation Commissioning Fault Finding Warranty Heat Pump
information information schematics mechanical electrical settings sheet
3.2 Kensa Q80 Series Technical Details— Compressor—3 Phase 400 Volts Only
Nomi- Ground Design Ground Ground Ground Output Output Design Output Output pres- Sound Max rated Design flowrates are
nal Flow Rate Design Design pressure Design Flow Rate Design sure drop at Power Level current based on ground tem-
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Thermal Flow Flow drop at Flow Rate Flow Rate design peratures of 0oC in and –
Output Rate Rate design 4oC out of the heat
pump and 30oC and 35oC
for the load side.
kW l/s l/m m3/h kPa l/s l/m m3/h kPa dB A Amp
83 5.98 359 21.53 46.3 4 240 14.4 27.6 72.3 64

The figures above are based on a rating to BS EN14511, 0 deg C from the ground, 35 deg C flow to underfloor.
For clarification of starting currents and details on how these figures are calculated please contact Kensa.
Introduction
4. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 2.
information
Safety
It is essential that the following installation guidelines are followed carefully.
Any electrical work required to install or maintain this appliance should be carried out by a suitably
General product
qualified electrician in accordance with current IEE regulations.

information
Any plumbing work should be carried out to local water authority and WRC regulations.
Kensa Q80 Series heat pumps do not come with any water circulating pumps for either the load or ground
side. These should be specified by the M and E consultant and will depend on site conditions.
Installation
Important
The following section includes typical schematics of how a heat pump can be connected. It is important to
note that the schematics are only general arrangements and hence do not illustrate all required valves or
fittings. System designs are also very site specific and should be provided by the M and E consultant. The
following is a guide only.
Installation
schematics
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 connections to the heat pump must be vibration isolated using bellows or equivalent.
mechanical
Installation
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 flow and connected
reverse return.
5. Flow switches should be installed to prevent operation in non-flow situations.
6. Read this manual fully before commencing installation
Installation
electrical
4.2 Q80 Series heating schematics
The key to obtaining low CO2 emissions and running costs for any heat pump is to maintain the flow
output at as low a temperature as possible. Any increase in outlet temperature will result in a drop in
Commissioning
efficiency and systems should be designed to reflect this.
The following schematic details how a heating 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
Fault Finding
heating load. Each unit should be configured via the BMS to operate sequentially to allow part operation
to match the heat demand of the building. The multiple unit approach also offers 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 buffer vessel to avoid short cycling
problems and it is recommended, to improve overall efficiency of the system, that this is a twin
Warranty
connection buffer 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 heating load using 2 x
80kW heat pumps the buffer vessel should be approx 80 (compressor size) x 10 = 800 litres.
Kensa heat pumps can work equally as well with horizontal, vertical or lake arrays as the energy source.
Although for large Q80 Series projects it can be more usual to use a borehole field design due to space
considerations.
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Heat Pump

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Fig 5 Typical Q80 Series heating only schematic
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Fig 6 Typical Q80 Series DHW heating only schematic
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This page is intentional left blank.
Introduction
4.3 Q80 Series heating and cooling schematics

information
In many modern Q80 Series buildings, with the improvement in energy saving measures such as In-
Safety
sulation, the requirement for cooling is now almost as great (if not greater) than the requirement for
heating. This cooling requirement is generally being driven by the use of heat emitting devices such as
computers and printers and even the staff themselves.
General product
information
When ground source heat pumps run they always produce heat and cold, just like other heat pumps such
as refrigerators or air conditioners. 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 potential for
cooling.
Installation
Kensa’s Q80 Series range of heat pumps can provide cooling externally. This has the advantage of a lower
cost system, higher efficiency 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 fluid 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.
Installation
schematics
4.3.1 Active and passive cooling

At the end of a heating season the ground temperature is at its lowest—typically 0-5°C. This temperature
is cool enough without modification to be used in various cooling distributions to provide cost effective
passive cooling. During passive cooling the fluid from the ground array provides cooling without the
compressor needing to run. Only a small amount of energy is used by the water pumps.
mechanical
Installation
For a heat pump to actively cool, the compressor does run and the hot and cold side inputs are simply
switched. The ground source heat pump is now actively pumping heat from inside the room to the
ground, thus cooling the room (and heating the ground). Active cooling has wider applications than
passive cooling and can be used more effectively with higher ground temperatures but also has a higher
Installation
electrical
running cost.
It is important that a sufficient quantity of glycol antifreeze (minimum 22%, Refractive index 1.356) is
added to the cooling and heating circuit fluid to avoid freezing of the fluid in cooling mode. Failure to do
Commissioning
this will invalidate the warranty.

Fault Finding
Warranty
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Fig 7 Typical Q80 Series heating, DHW and cooling schematic
Introduction
4.4 Secondary boiler back up systems (bivalent alternative systems) Fig 8

information
This type of system can be used where the heat emitters require a higher temperature than the heat
Safety
pump can output, when it is cold outside. This set up would require thermostatic control on the boiler as
well as external bivalent controls to switch between the heat pumps and the boiler.
Care must be taken when setting up the BMS, as it may take some time for the system to come up to tem-
General product
perature.
information
4.5 Secondary boiler back up systems (bivalent parallel systems) Fig 9

Installation
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 flow temperature to the buffer tank. Please contact Kensa for further infor-
mation.
Installation
schematics
Again care must be taken when setting up the BMS, as it may take some time for the system to come up
to temperature.
mechanical
Installation
Installation
electrical
Commissioning
Fault Finding
For all systems it is recommended that the BMS/Instrumentation Engineer contact Kensa if unsure on
Warranty
any aspects of the control of the system, i.e. Regarding:-
• Time delays
• Expected temperatures
• Compressor run-times
• Compressor starts per hour.
• etc
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Heat Pump

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Fig 8 Secondary boiler back up (bivalent alternative)
Page 18 of 40
Fig 9 Secondary boiler back up (bivalent parallel)
Introduction
4.6 Mechanical Installation
information
4.6.1 Locating the heat pump
Safety
Decide on a suitable location for the Heat Pump. This should be in a plant room which isolates any
occupied spaces from the noise and vibration of the heat pumps. It should not be placed near, under, or
above, any inhabited space. Take into account the “Recommended Clearances” when finalising the
General product
location and future requirements for access and removal. It is important that anti-vibration mountings or
information
“bellows” are used.
Check the appliance for transport damage. Under no circumstances should a damaged appliance be
operated or installed without prior agreement.
Installation
Position the appliance on a firm, level and substantial concrete base that will absorb vibration well away
from any occupied rooms
Ensure all pipes and wires are adequately supported where necessary, pipes are properly insulated and
concentrations of inhibitor/antifreeze (where added) are correct. Connections should be vibration isolated
Installation
schematics
by the use of bellows and have appropriate air vents and isolation 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.
mechanical
Installation
4.6.2 Recommend clearances
Remember to consider any
Installation
future maintenance or removal
electrical
requirements as a return to
base might be required if an on
-site repair is not feasible.
Commissioning
Refer to fig 10 or section 3.2
for dimensions of the unit
If multiple units are used then Fault Finding
these should have a clearance

of approximately 675 mm
between them to enable access.
If a concrete pad is used in front

of the unit, ensure that this is
Warranty
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
Fig 10 Heat Pump clearances

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Introduction
4.6.3 Installation of the heat pump

information
The heat pump is designed for internal use only. Ideally the heat pump should be placed next to an
Safety
external wall allowing easy access to the externally mounted ground array manifold. Any pipes internal to
the building must be insulated with vapour barrier insulation such as Armaflex. It is not recommended
that the ground or header array manifold is installed within a building due to condensation and difficulty
in lagging the manifold to overcome this.
General product
information
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.
Installation
Installation
schematics
mechanical
Installation
Fig 11 Q80 Series heat pumps
i. Using specialist lifting equipment, place the Heat Pump into position.
Installation
electrical
ii. Ensure the heating distribution system has been thoroughly purged of any debris and any filters are
clean.
iii. All pipe connections to the heat pump must be vibration 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 heating distribution manifold (which must be connected the
Commissioning
correct way round), according to Fig 12. The reason for using flexible connections is that the heat
pump is suspended on anti-vibration mounts, so the connections must also be flexible. For
multiple plant room modules the flows and returns should be manifolded together and balanced
ideally in a reverse return arrangement if possible.
iv. Open the access panel.
Fault Finding
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
installation section ).
vi. Check and rectify 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 left for 12 hours after installation before it is turned on, to allow the
Warranty
refrigerant to settle. 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 first.
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Heat Pump

Page 20 of 40
Introduction
information
Safety
General product
information
Installation
Flange sizes are DN50 PN10/16.
Warning: This unit must not be run without a minimum of 22% glycol and inhibitor in the chilled water
Installation
schematics
circuit or the warranty will be invalidated.
Fig 12 Q80 Series heat pump connections (from the front of the unit.)
4.7 Electrical installation
mechanical
Installation
Any electrical connections must be in accordance with current IEE regulations and carried out by a suitably
qualified person. Any cable used must be adequately sized for the load.
The Kensa Q80 Series heat pump range is available in three phase power supply versions only (415V 60
Hz).
Installation
electrical
Any electrical work required to install or maintain this appliance should be carried out by a suitably
qualified electrician in accordance with current IEE regulations
To access the mains power wiring terminals :-
Commissioning
i. Open the access panel
ii. Remove the mains power cover by unscrewing the six cross head screws on the mains power enclo-
sure.
Location of mains
power terminal
Fault Finding
Warranty
Mains power
terminals with
cover removed
Fig 13 Position of the mains power enclosure

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Page 21 of 40
Introduction
4.7.1 Three phase power supplies

The power should be connected via a junction box, connected to the supplied connected lead. The lead
information
Safety
follows the ISO colour standards for three phase power supplies ie L1 - Brown, L2 - Black, L3 - Grey,
Neutral - Blue + Earth - Green/Yellow.
If the phases are connected wrong the compressor will not start but no permeant damage is caused.
General product
The supply must be connected to an isolator with all pole disconnections of minimum 3mm .
information
Fig 14 Heat pump wiring—Three phase power supplies

Installation
Installation
schematics
Cables should enter the unit from above using the knock out cable entry ports provided in the top of the
mechanical
Installation
unit. Suitable cable glands are supplied with the unit. An external isolation switch should be wired into the
circuit to provide local isolation of the electrical supply as required.
The following sections detail the standard controller wiring connections. The heat pump should be set up
in conjunction with the BMS on commissioning.
Installation
electrical
Fig 15 Location of main PCB terminals

Commissioning
Fault Finding
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Introduction
4.7.2 Main PCB terminals description
Terminal Block 1 Terminal Block 2 Terminal Block 4
information
Safety
Terminal Block 3
E N L DI1 DI4 DI3 E N L DI2 E N DO5 L NC L NO L NO L NO D17 D18 D19 0V T9 0V

DO5a DO6 DO8 DO9
General product
information
Neutral
Live 240V AC,2.5A
DI3 Cooling Signal
T9 Weather Compensation and 0V

Live 240V AC,1A
Earth
Earth
DI1 On Signal
DI4 2nd Heating Signal
Neutral
Neutral
DI2 Hot Water Signal
DO6 Fault Signal, (Max 240V AC,1A)
DO8 Hot Water Immersion Signal, ( Max240V
DO9 Configurable Relay, (Max 240V

normally open volt free relay
DO5a Underfloor Pump Cut Out,(Max 240V
Earth
0V
DI7 Pulse Input
DI8 Pulse Input
DI9 Pulse Input
AC,1A) normally open volt free relay
AC,1A) normally open volt free relay

DO5 Power out to Hot Water Valve
AC,2.5A) normally closed volt free relay

240V AC,1A
Installation
* if the load from the underfloor control is likely to be
near or exceed 2.5A, live should be taken from the out-
Installation
schematics
put side of the 6A MCB instead
Heat Pump Enable Signal

No Call 0-50V
mechanical
Installation
Call >120V
Fig 16*Main PCB terminals description 50V < Call voltages < 120V are not permitted
Terminal Block 1—Space heating/Cooling
Installation
Earth—Earth connection for space heating timeclocks/ control devices connected and powered by the
electrical
Heat Pump such as underfloor control units, heating timeclocks and thermostats.
Neutral—Neutral connection for space heating timeclocks/ control devices connected and powered by
the Heat Pump such as underfloor control units, heating timeclocks and thermostats.
Live- 240V AC, 1A Live connection for space heating timeclocks/ control devices connected and powered
Commissioning
by the Heat Pump such as underfloor control units, heating timeclocks and thermostats. If the load from
the underfloor control is likely to be near or exceed 2.5A, live should be taken from the output side of the
6A MCB instead.
DI1—Live return 240V AC, 1A (On signal) call for heating returned from space heating timeclocks/ control
devices connected to the Heat Pump. Fault Finding
DI4– 2nd Heating Signal—Live return 240V AC, 1A (On signal) call for a second heating set point returned
from space heating timeclocks/ control devices connected to the heat pump. This allows a heating zone to
be controlled which requires a higher temperature than other zones. For example a zone of underfloor
which requires a lower flow temperature can be controlled by a timeclock connected to DI1 and DI4 can
be used to control a zone of radiators requiring a higher flow temperature by a second timeclock. If both
call signals occur simultaneously the higher temperature will have priority. In this type of system archi-
Warranty
tecture the underfloor manifolds must be fitted with thermostatic mixing valves.
DI3—Cooling call signal 240V AC, 1A. This is the enable signal to the heat to provide cooling. The heat
pump and heating distribution system needs to be configured / specified for cooling applications.
Simultaneous calls for heating and cooling will result in the unit returning an error code. Cooling
applications can also affect eligibility for grant schemes.
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Introduction
Terminal Block 2—DHW
Earth—Earth connection for domestic hot water timeclock, powered by the Heat Pump.
information
Safety
Neutral—Neutral connection for domestic hot water timeclock, powered by the Heat Pump.
Live- 240V AC, 1A Live connection for domestic hot water timeclock, powered by the Heat Pump.
DI2—Live return 240V AC, 1A (On signal) call for domestic hot water heating returned from the domestic
hot water heating timeclock connected to the Heat Pump.
General product
information
Terminal Block 3 - DHW 3 Port valve connection
Earth—Earth connection for domestic hot water valve, powered by the Heat Pump.
Neutral—Neutral connection for domestic hot water valve, powered by the Heat Pump.
DO5- Live out to domestic hot water valve 240V AC 1A rated.
Installation
Terminal Block 4— Additional Inputs and Outputs
DO5a—Underfloor Pump Cut Out. Normally closed volt free relay (240V, 2.5A) which opens when the
DHW valve operates. The relay can be wired directly to the supplementary underfloor manifold water
Installation
schematics
pumps (up to a maximum of 2.5A). When the heat pump is producing domestic hot water if wired this
relay will turn all the supplementary underfloor water pumps off increasing the systems efficiency. If the
current is greater than 2.5A an external relay must be used.
DO6– Fault Signal. Normally open volt free relay (240V, 1A). Can be used as a general fault indication.
DO8– Hot water immersion heater signal. Volt free relay (240V, 1A). Can be used in conjunction with an
mechanical
Installation
external relay to operate the immersion heater (settable via the controller). The immersion heater must
be powered by a separate external power supply.
DO9– Supplementary Heat Signal. Normally open volt free relay (240v, 1A). This relay can be used to sig-
nal to an external supplementary heat source to operate when the controller detects that the heat pump
cannot maintain temperature. Configuration of this is via the controller. The supplementary heater must
be powered by a separate external power supply.
Installation
electrical
DI7, DI8, DI9 and 0V– Digital inputs from devices such as electricity meters, heat meters, etc. The
controller only shows the number of pulses detected, for example if a single pulse was an indication of
100 units, it would only register 1 pulse and to get the true reading the number of pulses needs to be mul-
tiplied by 100 (or whatever the single pulse is meant to represent).
Commissioning
Terminal Block 5—Weather Compensation T9
All Kensa Heat Pumps are supplied with Weather Compensation as standard. This facility will reduce the
return water set-point against a schedule of external ambient temperatures. In more simple terms, the
temperature of water flowing into the building’s radiators or underfloor heating is reduced in mild weath-
Fault Finding
er, which allows the heat pump to run more efficiently. This is particularly important with radiators, as
much higher temperatures are required. In cold weather, many people already turn up the tem-
perature of water flowing from their boiler by hand and are therefore weather compensating their
heating system manually.
To enable weather compensation (if required) on your heat pump the sensor should be installed and
Warranty
weather compensation enabled within the controller .

This sensor is best fixed to a North-facing wall, and connected with 2 core 0.5 mm cable, unshielded, to
the heat pump. The cable should be routed inside the heat pump case and connected to the main pcb
terminals. The weather compensation should then be left disabled. If weather compensation is required
this should then be enabled within the controller.
Note :- DI4, DO6, DO8, DO9, DI7,DI9 and T9 are all optional.
settings sheet
Heat Pump

Page 24 of 40
Fig 17 Generic Heat Pump Wiring Diagram
Page 25 of 40
Note: If DHW option is enabled after commissioning and
connection to DHW time clock, remove DHW enable link.
Introduction
DI3 is only for use with cooling models

DI2, DO5 and DO5a only for use with DHW enabled models.
information
Safety
Ground Pump Control Relay
It is important that the ground pump is controlled via an external volt free relay due to the low current
General product
ratings of the relays on the pcb i.e. DO9. This external relay is provided within the controller wiring
information
enclosure. (see Fig 4 and Fig 17 for location).
It is also important that there is an interlock on the ground pump flow linked to the run signal for the heat
pump, particularly if the control of the unit is via a BMS system.
There are two common types of control to interlock the run enable signal to the ground pump flow:-
Installation
• A flow sensor, of which there are two common types the first being an internal sprung switch, and
the second an ultrasonic sensor type.
• The differential between two pressure sensors, one before the ground circulation pump and one
after.
Installation
schematics
Ground Pump Control

(Signal only)
mechanical
Installation
Fig 18 Ground Pump

Control relay
Installation
electrical
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 26 of 40
Page 27 of 40
This page is intentional left blank.
Introduction
5. Setting to Work
information
After all mechanical and electrical work has been completed, the following instructions should be
Safety
followed.
5.1 Purging the ground array of air.

General product
It is important for correct operation that all the air is removed from the ground arrays including the
information
header pipework.
For large systems a large pump maybe required and advice can be sought from Kensa. A suitable pump for
most applications has the following specification, however it should be checked against the installation
Installation
requirements.
Outlet size = 50mm

Max output (no lift) = 600l/min
Max suction lift = 8m
Installation
schematics
Max total lift = 27m

Fig 19 purge pump Fuel = unleaded
mechanical
Installation
It is important that the right fittings are used on the pump (these will be extra to the pump), it is clean and
all joints are air tight.
5.1.1 Purging procedure for ground arrays.

Installation
electrical
It is important that all the air is removed from the ground arrays and header pipework prior to commissioning.
Failure to do this could result in damage to the units.
When purging good engineering procedures should be followed and all high points should have air bleed points
installed.
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 28 of 40
Fig 20 Header Arrangement
Page 29 of 40
Introduction
5.1.2 Purging the headers

information
Once the ground arrays have been purged of air it is important that the header pipe is also purged. This
Safety
should be done by connecting the purge points together on each array manifold in turn using suitable
pipe to create a loop. The purging should then be carried out from the header manifold following the
same purging procedure as for the ground arrays.
General product
To ensure all the air is removed it is advised that when the headers have been purged the ground arrays
information
are purged again and automatic air vents are connected at high points where air can collect. After the air
has been removed it is advisable that before the antifreeze is added the system is leak tested to BS805
Section 11.3.3.4. (See 5.1.3), if this didn’t occur when the ground arrays were installed.
Installation
5.1.3 Adding antifreeze /inhibitors
The antifreeze provides protection to the heat pump (and contains an inhibitor and anti-bacterial agents)
by preventing the circulating ground fluid from freezing in the heat exchanger. If not added in sufficient
quantities the heat pump can freeze and cease working. All antifreeze provided with the order should be
added and it is recommended that the quantity is roughly divided between the number of arrays. This
Installation
schematics
amount of antifreeze is the minimum required for a standard system (at least 22% concentration by vol-
ume , Refractive index 1.356). If the heat pump and manifold are a distance apart and header manifolds
are present this quantity of antifreeze provided may need to be increased. Please contact Kensa for further
details.
mechanical
Installation
It is very important to purge all the air from the system before adding the antifreeze as it is very difficult
to remove the air with the antifreeze in the system due to the higher viscosity of the mixture.
Once the purging of all the air within the arrays and heat pump has been completed the antifreeze needs
to be added.
Installation
electrical
Once added, to mix the antifreeze around the ground arrays thoroughly, it is advised that the ground array
circulation pump is turned on before the compressor is turned on. This ground array circulation pump
should be left running for two to three hours to ensure the antifreeze is mixed in all the ground arrays and
the heat pump.
Commissioning
Water should not be left in the ground array without biocide or antifreeze.
5.1.4 Pressure Testing in accordance to BS805 Section 11.3.3.4

Fault Finding
In accordance with the GSHPA guidance, leak tightness (pressure) testing has to follow the EN 805
prescriptions in section 11.3.3.4. This test should be carried out after the ground arrays have been purged
but before the antifreeze is added. For polyethylene (PE) tubes, the pressure testing has to be carried out
as a ‘compression test’. An overpressure (inside-outside) is applied to the pipe over the whole length. This
step inflates slightly the PE pipe over its whole length. Then a sudden pressure drop of around 10% of the
Warranty
testing pressure is applied. This pressure drop allows the pipe to compress again. If the pipe is tight, a
pressure increase is measured. This test should only be carried out on the ground arrays with the heat
pump isolated from the test.
settings sheet
Heat Pump

Page 30 of 40
Introduction
5.1.5 Testing of antifreeze concentration
information
It is important that the concentration of the antifreeze within the ground arrays should be a minimum of
Safety
22% or a protection level of –10oC (Refractive index 1.356). Concentrations below this could cause an A1
alarm and the heat pump to cease operation during severe prolonged cold weather.
General product
The antifreeze concentration should be tested with a refractometer. If required a sample can be sent to
information
Kensa for testing.
The concentration of antifreeze is required for the commissioning certificate and it is advised that this
figure is noted in the settings table.
Installation
The drain cocks on the heat exchangers can be used to obtain a sample of thermal transfer fluid.
Installation
schematics
mechanical
Installation
Installation
electrical
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 31 of 40
Introduction
6. Controller
information
Safety
The heat pump controller fitted to the heat pump has been especially designed for the application. It uses
clear and concise language to indicate faults and uses a logical and intuitive menu structure providing
trouble free commissioning. For the Q80 Series Q heat pump the controller and heat pump settings are
accessed via the display on the Q80 Series Heat Pump .
General product
information
For directions on how to commission the controller please refer to the Genesis Commissioning manual
which is available using the QR code below or direct from Kensa.
QR Code for Genesis

QR Code for Q Operational
Commissioning Manual
Manual
Installation
Installation
schematics
Before attempting Commissioning please refer to the Genesis Commissioning Manual.
6.1 Linking the Q80 Series heat pump to an existing Wi-Fi network.
It is possible to link the heat pump to an existing Wi-Fi network enabling remote diagnostics with Kensa.
mechanical
Installation
The heat pump will periodically upload performance data to a Kensa server allowing Kensa to interrogate
any issues.
I. Navigate to the Wi-Fi connection page (menu\settings\wifi)

II. Select the name of the network, from the drop down list, you wish the shoebox to connect to.
Installation
III. Enter the password for the wi-fi network chosen.

electrical
IV. The heat pump will automatically connect to the chosen network once .
See section 4.8.3 of the Genesis Commissioning Manual.

Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 32 of 40
Introduction
7. Fault Finding
information
Many faults which occur on commissioning are found to be due to incorrect wiring or setting up, therefore
Safety
it is recommended that a thorough check is carried out should there be a problem.
It is recommended the Genesis Installation Manual is consulted if there are any problems with the control-
ler/display.
General product
information
Installation
Installation
schematics
mechanical
Installation
Installation
electrical
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 33 of 40
Introduction
8 Warranty
information
The Kensa Q80 Series Ground Source heat pump is designed and built to the highest standard and as such
Safety
is warranted for 5 years for parts from the date of commissioning or 5 ½ years from the date of
manufacture (excluding the electrical components), whichever is shorter. Electrical components are
warranted for 2 years for parts from the date of commissioning or 2 ½ years from the date of
manufacturer, whichever is shorter.
General product
information
8.1 Terms and Conditions.
8.1.1 Persons covered by the Warranty
The Warranty applies to the original purchaser and any subsequent owner of the item.
Installation
8.1.2 Validity period of the Warranty
The warranty period (excluding electrical components) is five years calculated from the commissioning
date stated on the commissioning certificate or 5 ½ years from the date of manufacture, whichever is
Installation
schematics
shorter. For the electrical components it is 2 years from the commissioning date stated on the commis-
sioning certificate or 2 ½ years from the date of manufacture, whichever is shorter.
8.1.3 Scope
mechanical
Installation
Kensa Heat Pumps Ltd warrants to the original purchaser (“Buyer”) that all parts (“Parts”) of the Kensa
Q80 Series Ground Source Heat Pump, excluding accessories, shall be merchantable and free from de-
fects in materials and workmanship appearing under normal working conditions.
Kensa Heat Pumps Ltd will, at its option and without charge to the Buyer, replace or repair any Parts
which cause the Kensa Q80 Series 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
Installation
electrical
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.
Units installed not in line with the O&M required clearances are return to base repair only.
Commissioning
8.1.4 General exceptions

Compensation is not provided for:
- consequential losses
- damage caused by normal wear and tear, inadequate maintenance or care
- damage caused by freezing
Fault Finding
- 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
Warranty
-minor damage (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
instructions.
-products subjected to abrasion or corrosion
settings sheet
Heat Pump

Page 34 of 40
Introduction
-products operated in connection with any liquid source that contains impurities which are corrosive to
information
copper
Safety
-products operated in a temperature range inconsistent with Kensa Heat Pumps Ltd’s published or written
recommendations
8.1.5 Care of Duty
General product
information
The product must be handled with normal care and attention to minimise the risk of damage or loss.
8.1.6 In the event of Damage
Installation
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 warranty shall not apply.
Installation
schematics
8.1.7 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
mechanical
Installation
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.
Installation
electrical
Commissioning
Fault Finding
Warranty
settings sheet
Heat Pump

Page 35 of 40
Introduction
9. Heat Pump and System Settings Sheet

information
Date
Safety
KR Reference
General product
Clients Name / End User

information
Post Code
Address
Installation Company
Installer
Installation
Installers phone number
Controls Company
Controls Engineer
Controls Engineer's phone number
Installation
schematics
Main Contractor
Main Contractor contact name
Main Contractor contact number
mechanical
Installation
Electrician Company
Electrician's Name
Electrician's number
Installation
electrical
Heat pump location confirmed & connected

Transit Bolts Removed
Load side flushed and pressurised
Ground side flushed and antifreeze added
Commissioning
Antifreeze circulated
warning triangle visible
Flap Type Non Return Valves Installed
Filters fitted to system with isolation valves
Manual Air vents fitted at highest points
Fault Finding
Monovalent or Bivalent
Bivalent Heat Source

Heat Source Function
Bivalent Point Control
Bivalent set point
Warranty
settings sheet
Heat Pump

Page 36 of 40
Introduction
Load Side Flow Meter Installed
Ground Side Flow Meter Installed
information
Open Loop Flow Meter Installed
Safety
Open Loop Flow Meter Readings
Commissioning Sets Installed
Auto top up installed
General product
Interlocked with Controls
information
Concentration of Antifreeze
Sample 1
Sample 2
Installation
Buffer Vessel
Buffer vessel Fitted
Buffer connection
Buffer Size L
Installation
schematics
25% of heating system as open flow
Heating System
Type of emitters
Number of UFH Manifolds
mechanical
Installation
blending valves on manifold
Pumps on Manifold
Total pumps on HTG system
Heating Controls
Installation
electrical
Swimming Pool
Swimming Pool Provided by Heat Pump?
Heat Pump Production
Commissioning
Ground Array
Type of ground array
Proven flow or area from survey form (Water
Source Only) Fault Finding
Closed Loop
Details of ground array
Quantity
Borehole Depth / Horizontal coil length
Trench Depth & Width
Warranty
Trench Centres / Distance between Boreholes

Pipe size
Total length of Closed loop pipe
settings sheet
Heat Pump

Page 37 of 40
Introduction
Open Loop
Open Loop Pump Control via D09
information
Discharge Pipe Depth / Length

Safety
Pipe Size
Extraction Pipe Depth / Length
Pipe Size
General product
Distance Between Extraction & Discharge

information
HX Size checked by Kensa
Header pipe length

Header pipe size
Installation
Expansion vessel Fitted
Communal Array
Installation
schematics
Drums of antifreeze added
Product
mechanical
Installation
Serial Number
Product Code
Heat pump function

DHW System
Installation
electrical
Electrical
Amp Rating & Type
Input voltage
Commissioning
Load Side Flow Meter Reading l/min

Ground Side Flow Meter Reading l/min
No Flow Pump test interface correct
Fault Finding
Load Return Temperature °C

Load Flow Temperature °C
Ground Return Temperature °C
Ground Flow Temperature °C
Warranty
Discharge Pipe Temperature °C
Weather comp enabled

T9 Weather Compensation Set Point °C
Weather Compensation Multiplier
Weather Compensation Maximum Variation
settings sheet
Heat Pump

Page 38 of 40
Introduction
Pressures
Load Water Pressure Bar
information
Ground Water Pressure Bar
Safety
Suction Gas Pressure Bar
Discharge Gas Pressure Bar
General product
Set Points
information
Heating set point 1 °C
Heating set point 2 °C
Antifreeze set point °C
Compressor delay set point (Seconds)
Installation
Time & Date Set
DHW end pressure Bar

Min Stopping Time (Hours)
Installation
schematics
Excessive DHW Warning Enabled
Excessive Running Time (Hours)
External Immersion / Boiler Controlled Via Heat

pump
mechanical
Installation
Run time After DHW Cycle (Hours)
Pasteurisation enabled
Time Schedule (Days)
Duration (Hours)
Installation
electrical
Configurable Relay
DO9 Functionality
Time Delay (Hours)
Cut-in Diff °C
Commissioning
Cut-Out Diff °C
Passive Cooling Active

cooling set point °C
Fault Finding
Factory Settings
Load Side Operational Speed %

Ground Side Operational Speed %
Load Side Set Back Speed %
Ground Side Set Back Speed %
Warranty
Exercise Mode
Load Side ∆T °C
Ground Side ∆T °C
settings sheet
Heat Pump

Page 39 of 40
Introduction
Ground Side Bar

Ground Side Bar
information
Load Side Bar

Safety
Load Side Bar

General product
Total cylinder volume

information
Port A towards DHW

Is the Cylinder the last return
Cylinder control Philosophy
Secondary return installed
Is external heating element fitted
Installation
Type of Secondary return Heater

Secondary return heater temperature °C
How does the secondary return terminate
Installation
schematics
External Immersion / Boiler Control

Duration
Time set
Cylinder stat set point
Cylinder Immersion Set Point °C
mechanical
Installation
Cylinder Immersion Control
DHW End Reading

T2 at pressure stop
T1 at pressure stop
Installation
electrical
P5 Pressure Switch
Point of use temperature
Commissioning
Comments:
Fault Finding
Installed by:-
Warranty
Date:- Tel:-
settings sheet
Heat Pump

Page 40 of 40

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Page 1 of 40

Q80 Series Range Heat Pump Manual Version 1

Section Description Page

1....................... Introduction .................................................................................. 4

2.1........................... Access ...................................................................................................................... 5

2.2........................... Lighting .................................................................................................................... 5

2.6........................... Freezing ................................................................................................................... 5

3.2........................... Kensa Q80 Series Range technical data ................................................................ 9

4.2 .......................... Q80 Series heating schematics ................................................................................ 10

4.6.3........................ Installation of the heat pump .................................................................................. 20

5....................... Setting to Work ............................................................................. 28

5.1.3........................ Adding antifreeze / inhibitors ...................................... ........................................... 30

Q80 Series Range Heat Pump Manual Version 1

8.1.4........................ General exceptions ................................................................................................. 34

9....................... Heat pump and system settings sheet .......................................... 36

Q80 Series Range Heat Pump Manual Version 1

1. Introduction—a message from the CEO

‘Golden Rules’ in the installation section.

For further information on

ground source heat pumps and

Q80 Series Range Heat Pump Manual Version 1

2.1 Access and Egress

Q80 Series Range Heat Pump Manual Version 1

3. General Product Information

emissions compared with traditional fossil fuels.

3.1 Equipment delivery and handling.

Fig 1. Q80 Series Heat Pump

Q80 Series Range Heat Pump Manual Version 1

Fig 3. The internals of a heat pump. (door open)

Q80 Series Range Heat Pump Manual Version 1

Q80 Series Range Heat Pump Manual Version 1

83 5.98 359 21.53 46.3 4 240 14.4 27.6 72.3 64

Q80 Series Range Heat Pump Manual Version 1

It is essential that the following installation guidelines are followed carefully.

qualified electrician in accordance with current IEE regulations.

4.1 The golden rules of installing a Q80 Series heat pump

4.2 Q80 Series heating schematics

efficiency and systems should be designed to reflect this.

Q80 Series Range Heat Pump Manual Version 1

4.3 Q80 Series heating and cooling schematics

4.3.1 Active and passive cooling

this will invalidate the warranty.

Q80 Series Range Heat Pump Manual Version 1

4.4 Secondary boiler back up systems (bivalent alternative systems) Fig 8

4.5 Secondary boiler back up systems (bivalent parallel systems) Fig 9

any aspects of the control of the system, i.e. Regarding:-

Q80 Series Range Heat Pump Manual Version 1

A water treatment device should be provided in hard water areas.

Do not use the appliance as a shelf.

Remember to consider any

If multiple units are used then Fault Finding

these should have a clearance

If a concrete pad is used in front

extended by 1450mm forwards

Fig 10 Heat Pump clearances

Q80 Series Range Heat Pump Manual Version 1

4.6.3 Installation of the heat pump

Fig 11 Q80 Series heat pumps

Q80 Series Range Heat Pump Manual Version 1