The Valden Heat Pump controller is an open source platform to precisely control heat pumps. This controller can be used for the automation of newly built Heat Pumps (HPs), as a repair controller for old systems or as control system for performing experiments on refrigeration equipment.
Further details, appendices, fine-tuning options, illustrations, abbreviations, and so on you can find in the permanent Valden Heat Pump Controller repository: https://github.com/openhp/HeatPumpController/
This process is the same as for other Arduinos:
For arduinos with an old bootloader you need to update it. (Tools-> Burn Bootloader).
For successful compilation, you must have "SoftwareSerial", "OneWire" and "DallasTemperature" libraries installed (see Tools -> Manage Libraries).
For the first time it's enough to upload firmware without any tuning. Think of it as of a commercial closed-source controller, where you cannot fine-tune internal options. And any other manual configuration do not required too, just upload firmware. You will see an error LED indication and hear a beep, since no sensors connected to your controller. Follow the next steps.
QA tests are available to test the assembled board.
Self-test helps you check relays, indicators, speaker and temperature sensors.
To run a self-tests:
//#define SELFTEST_RELAYS_LEDS_SPEAKER //speaker and relays QA test, uncomment to enable
//#define SELFTEST_EEV //EEV QA test, uncomment to enable
//#define SELFTEST_T_SENSORS //temperature sensors QA test, uncomment to enable
To check EEV connection, you can use a stepper motor. If you are testing a real EEV, it will be closed after the first "beep" and partially opened after the second "beep". If it's not, check if stepper or EEV center pin(s) connected to +12V and try to swap coil-end pins (EEV1..EEV4).
To check temperature sensors connectors crimp one array of sensors. Plug it to all sensor connectors one-by-one and check results in a serial console.
After tests completed, comment 3 self-test defines.
Choose your installation scheme and uncomment one of those options:
#define SETPOINT_THI //"warm floor" scheme: "hot in" (Thi) temperature used as setpoint
//#define SETPOINT_TS1 //"swimming pool" or "water tank heater" scheme: "sensor 1" (Ts1) is used as setpoint and located somewhere in a water tank
Re-upload firmware. Your controller is ready for the first start (after wiring). Probably you'll never need to change other options.
Here are no instructions for choosing the right placement for permanent installation of the controller. It depends. You're building your system, and you know much better "where" and "how".
Assuming you have installed your controller to the permanent place, the next step is wiring.
Wiring is very simple, despite a lot of terminals.
Phases (1st wire in electrical cables):
12V Power Supply:
Crimp and plug low-voltage connectors:
You may prefer to solder the wires over using terminals and crimping connectors. But in this case, it will be difficult to disassemble the system if you want to change something. The choice is yours.
And one more: remember! 230V inside! Do not turn on the phase without need.
Have you ever received 230V with your own hands? If yes - you know. If no - do not try.
Also remember about animals and children during the installation at a permanent place.
This is a first interface to Heat Pump controller you'll see after uploading firmware (Tools->Serial Monitor).
The console itself is simple to use, several commands are available. Type in command, press "Send". Help and hotkeys:
Every 30 sec. (HUMAN_AUTOINFO option) you'll see stats. For example, after a startup of your compressor, you'll see something like this:
At this example, "hot in" ~30 °C, compressor ~80 °C and so on. Heat Pump (HP, compressor) ON, Hot water pump ON, Cold water pump ON. Power consumption 980 watts.
Abbreviations: refer to Appendix A below.
Also, you'll see diagnostic messages in your serial console.
Do not connect +5V wire from USB-UART converter, if you are using a serial console.
This is a way for the end user to control Heat Pump.
End user does not want to know much about refrigerants, evaporation, discharge temperatures and so on, so this display designed as simple as it was possible. See Remote Display page for details. And yes, this display is open product too, with available Gerber, PCB and source code.
One day I've realized that a netbook with a serial console is a good diagnostic tool, but I want a compact tool to get maximum available information from a Heat Pumps. So, this "Quickly Assembled Service Display" appeared. It fits everywhere and with a good power bank it can work 2-3 days long, without any additional power source. The diagnostic display is build from scratch, no PCB and housing here (and no plans to create it), because I do not see this service display as a permanently mounted device.
If you want a compact and visual tool - this device is for you, so check the Service Display Page .
This is an easy part, but if you don't have experience it will take time.
You have performed a pressure test and vacuuming. It's time to charge your system.
Let's say you don't know how to calculate the amount of refrigerant in a recently built system, so follow next steps:
This algo is good and safe both the first time and as a starting point. As you gain experience, you will get yours much easier and faster.
Also, use "manual EEV mode" during refilling process.
Keep your eyes protected and do not freeze your fingers.
For more information about Heat Pumps look at Wikipedia HP page.
If you want to know "how the refrigeration systems work", read Patrick Kotzaoglanian books.
If you want more technical details, sophisticated schemes, "how EEV can be driven by temperature" diagrams, etc. refer to vendor manuals (you'll find all you need in the Alfa Laval brochures, Danfoss guides, and so on).
For refrigerants and oils types comparison see wiki.
Note that the SCT013 sensor and the current monitoring scheme cannot be used for accurate measurements and accurate COP calculations. Use a watt meter for accurate power measurements.
Temperature sensor installation at a warm floor surface is a bad idea - it's better to get "hot in" water temperature coming from all over the floor, as implemented in firmware.
The weather-dependent (both outdoor and indoor temperature dependent) system does not work fine for 30-150 m2 buildings. Such a system is too complex and works unpredictable due to random ventilation. And also due to the unpredictability of heat emitted in the house by other sources.
I tried the scheme with a flooded evaporator in 2019 and found it terribly tricky, then refused to use it.
Deep regeneration schemes are useful only for some refrigerants and only in certain temperature ranges. I've tried deep regeneration too. As a result, the theory coincided with practice and I also refused this idea.
In general, it is possible by complicating the refrigeration scheme to win somewhere 1%, somewhere 3%, but all this leads to significant time and money cost getting suddenly a small profit.
Summary: If you want experiments - Experiment. Want reliably - make the system simple.
Are you still reading? It seems you are interested in Heat Pumps, so this appendix is for you.
About sensors: avoid using cheap "waterproof epoxy-covered" sensors. "Waterproof" lasts for a short time.
Buy DS18B20s chips. No matter what sensors are buying: cheap or at a high price. I've never seen "bad" DSes. Solder sensors to the wires and cover with two layers of 2-component epoxy resin as pictured below. It will work for years. White/orange - GND, white/blue - signal, orange - +5V.
For sensors at your compressor and discharge (+100 °C and higher) use heat-resistant sleeves at every wire.
To get precise temperature readings protect sensors against ambient air temperature influence with additional thermal insulation. Temperature readings from most of the sensors are interesting, but +/- few degrees does not matter. So, cover most of the sensors with thermal insulation as you wish.
But two sensors "Before evaporator" and "After evaporator" are critical to EEV and needs an extra attention. The temperature of these sensors must be as close to the temperature of the copper tube as it possible. So, install Tae and Tbe sensors as pictured below. You can use thermal paste, but it is no significant difference with much more available silicone. Tape not shown at photos below, for clarity, but should be used with every insulation layer.
About water(glycol)<->refrigerant heat exchangers. You can use plate heat exchangers. Pros: the best efficiency. Cons: costs money. Potential oil return difficulties.
And oxygen brazing with (20%+)silver+copper solder required here:
You can build your own "tube-in-tube" heat exchangers. It's not hard. Cheaper. The heat exchange efficiency is worse. No oil return problems. Very easy soldering. Heat exchanger math: 0.7..1.5 m2 of a copper tube per every 3kW of heat transfer.
Additionally, you can think "I'll take an old AC parts... Housing... Slightly change... An hour or two, day of work maximum and I'll get a refrigerant<->water heat exchanger in for a penny!". This idea is obvious. It was the first thing I've tried. You can try this, but to achieve "not very bad" performance it'll take more than a one day and much more than a few $$, even if you have unlimited access to older ACs.
Ok, I think that's enough for this appendix, this is a controller page, and not how-to-build-refrigeration-systems page.
Overall, your system with sensor locations will look like at a scheme below. Refrigerators (heat pumps) are simple devices.
Your system works (or sleeps) depending on Thi temperature. For the end user it looks like setting up comfortable temperature of the warm floor via Remote Display.
QA tests, uncomment to enable
//#define SELFTEST_RELAYS_LEDS_SPEAKER //speaker and relays QA test, uncomment to enable
//#define SELFTEST_EEV //EEV QA test, uncomment to enable
//#define SELFTEST_T_SENSORS //temperature sensors QA test, uncomment to enable
Communication protocol with an external world. Choose one
//#define RS485_JSON 1 //JSON, external systems integration
//#define RS485_HUMAN 2 //RS485 is used in the same way as the local console, warning: Use only if 2 devices (server and this controller) connected to the same RS485 line
#define RS485_MODBUS 3 //default, MODBUS via RS485, connection to the display (both sensor or 1602, see https://GitHub.com/OpenHP/Display/) or connection to any other MODBUS application or device
System type, comment both if HP with EEV
//#define EEV_ONLY //Valden controller as EEV controller: NO target T sensor. No relays. Oly EEV. Sensors required: Tae, Tbe, current sensor. Additional T sensors can be used but not required.
//#define NO_EEV //capillary tube or TXV, EEV not used
Sensor used to check setpoint, uncomment one of those options
#define SETPOINT_THI //"warm floor" scheme: "hot in" (Thi) temperature used as setpoint
//#define SETPOINT_TS1 //"swimming pool" or "water tank heater" scheme: "sensor 1" (Ts1) is used as setpoint and located somewhere in a water tank
Some more options
#define HUMAN_AUTOINFO 30000 //print stats to console, every milliseconds
#define WATCHDOG //disable for older bootloaders
Next sections: advanced options
Temperature sensors used in a system, comment to disable
#define T_cold_in; //cold side (heat source) inlet sensor
#define T_cold_out; //cold side outlet sensor
#define T_before_evaporator; //"before" and "after evaporator" sensors required to control EEV, both "EEV_ONLY" and "full" schemes
#define T_after_evaporator; //"before" and "after evaporator" sensors required to control EEV, both "EEV_ONLY" and "full" schemes
#ifdef SETPOINT_TS1
#define T_sensor_1; //T values from the additional sensor S1 used as a "setpoint" in "pool" or "water tank heater" schemes
#endif
//#define T_sensor_2; //additional sensor, any source; for example, outdoor temperature, in-case temperature, and so on
#define T_crc; //if defined, enables the crankcase T sensor and crankcase heater on the relay "Crankcase heater"
//#define T_regenerator; //an additional sensor, the regenerator temperature sensor (inlet or outlet or housing); used only to obtain a temperature data if necessary
#define T_afrer_condenser; //after condenser (and before valve)
#define T_before_condenser; //before condenser (discharge)
#define T_hot_out; //hot side outlet
//In full scheme Hot IN required! Optional in "EEV_ONLY" scheme (see "EEV_ONLY" option),
#define T_hot_in; //hot side inlet
Temperature limits
#define MAGIC 0x66; //change this value if you want to rewrite the T setpoint in EEPROM
#define T_SETPOINT 26.0; //This is a predefined target temperature value (start temperature). EEPROM-saved. Ways to change this value: 1. Console command 2. Change the "setpoint" on a display 3. Change value here AND change "magic number" 4. JSON command
#define T_SETPOINT_MAX 48.0; //maximum "setpoint" temperature that an ordinary user can set
#define T_SETPOINT_MIN 10.0; //min. "setpoint" temperature that an ordinary user can set, lower values not recommended until antifreeze fluids at hot side used.
#define T_CRANKCASE_MIN 8.0; //compressor (crankcase) min. temperature, HP will not start if T lower
#define T_CRANKCASE_MAX 110.0; //compressor (crankcase) max. temperature, overheating protection, HP will stop if T higher
#define T_CRANKCASE_HEAT_THRESHOLD 16.0;//crankcase heater threshold, the compressor heater will be powered on if T lower
#define T_WORKINGOK_CRANKCASE_MIN 25.0;//compressor temperature: additional check. HP will stop if T is lower than this value after 5 minutes of work. Do not set the value too high to ensure normal operation after long pauses.
#define T_BEFORE_CONDENSER_MAX 108.0; //discharge MAX, system stops if discharge higher
#define T_COLDREF_MIN -14.0; //suction min., HP stops if T lower, cold side (glycol) loop freeze protection and compressor protection against liquid
#define T_BEFORE_EVAP_WORK_MIN -25.5; //!!!before evaporator (after valve) min. T; can be very low for a few minutes after a startup, ex: capillary tube in some conditions; and for all systems: after long shut-off, lack of refrigerant, 1st starts, and many others
#define T_COLD_MIN -15.5; //cold side (glycol) loop freeze protection: HP stops if inlet or outlet temperature lower
#define T_HOT_MAX 50.0; //hot loop: HP stops if hot side inlet or outlet temperature higher than this threshold
Watts, cycles times (milliseconds)
#define MAX_WATTS 1000.0 + 70.0 + 80.0 //power limit, watt, HP stops if exceeded, example: compressor: ~1000 + hot CP 70 + cold CP 80
#define POWERON_PAUSE 300000 //after power on: wait 5 minutes before starting HP (power faults protection)
#define MINCYCLE_POWEROFF 600000 //after a normal compressor stop: 10 minutes pause (max 99999 seconds)
#define MINCYCLE_POWERON 3600000 //after compressor start: minimum compressor operation time, i.e. work time is not less than this value (or more, depending on the setpoint temperature) 60 minutes = 3.6 KK 120mins = 5.4 kK.
#define POWERON_HIGHTIME 7000 //after compressor start: defines time when power consumption can be 3 times greater than normal, 7 sec. by default
#define COLDCIRCLE_PREPARE 90000 //before compressor start: power on cold CP and wait 90 sec.; if false start: CP will off twice this time; and (hotcircle_stop_after - this_value) must be > hotcircle_check_prepare or HP will go sleep cycle instead of start
#define DEFFERED_STOP_HOTCIRCLE 1200000 //after compressor stop: wait 20 minutes, if no need to start compressor: stop hot WP; value must be > 0
#define HOTCIRCLE_START_EVERY 2400000 //while pauses: pump on "hot side" starts every 40 minutes (by default) (max 9999 seconds) to circulate water and get exact temperature reading, option used if "warm floor" installation (Thi as setpoint)...
#define HOTCIRCLE_CHECK_PREPARE 150000 //while pauses: ...and wait for temperature stabilization 2.5 minutes (by default), after that do setpoint checks...
#define HOTCIRCLE_STOP_AFTER (HOTCIRCLE_CHECK_PREPARE + COLDCIRCLE_PREPARE + 30000) //...and then stop after few minutes of circulating, if temperature is high and no need to start compressor; value must be check_prepare + coldcircle_prepare + 30 seconds (or more)
EEV options.
If you are using a capillary tube or TXV: simply skip next section.
Depending on how many milliseconds allocated per step, the speed of automatic tuning will change.
Remember that your refrigeration system reaction on every step is not immediate. The system reacts after a few minutes, sometimes after tens of minutes.
#define EEV_MAXPULSES 250 //max steps, 250 is tested for sanhua 1.3
//steps tuning: milliseconds per fast and slow (precise) steps
#define EEV_PULSE_FCLOSE_MILLIS 20 //fast closing, closing on danger (milliseconds per step)
#define EEV_PULSE_CLOSE_MILLIS 60000 //accurate closing while the compressor works (milliseconds per step)
#define EEV_PULSE_WOPEN_MILLIS 20 //standby (waiting) pos. set (milliseconds per step)
#define EEV_PULSE_FOPEN_MILLIS 1400 //fast opening, fast search (milliseconds per step)
#define EEV_PULSE_OPEN_MILLIS 70000 //accurate opening while the compressor works (milliseconds per step)
#define EEV_STOP_HOLD 500 //0.1..1sec for Sanhua hold time (milliseconds per step)
#define EEV_CLOSEEVERY 86400000 //86400000: EEV full close (zero calibration) every 24 hours, executed while HP is NOT working (milliseconds per cycle)
//positions
#define EEV_CLOSE_ADD_PULSES 8 //read below, additional steps after zero position while full closing
#define EEV_OPEN_AFTER_CLOSE 45 //0 - set the zero position, then add EEV_CLOSE_ADD_PULSES (zero insurance, read EEV guides for this value) and stop, EEV will be in zero position.
//N - set the zero position, then add EEV_CLOSE_ADD_PULSES, than open EEV on EEV_OPEN_AFTER_CLOSE pulses
//i.e. it's a "waiting position" while HP isn't working, value must be <= MINWORKPOS
#define EEV_MINWORKPOS 50 //position will be not less during normal work, open EEV to this position after compressor start
//temperatures
#define EEV_PRECISE_START 7.0 //precise tuning threshold: make slower pulses if (real_diff-target_diff) less than this value. Used for fine auto-tuning
#define EEV_EMERG_DIFF 1.7 //liquid at suction threshold: if dangerous condition occurred, real_diff =< (target_diff - EEV_EMERG_DIFF) then EEV will be closed to min. work position //Ex: EEV_EMERG_DIFF = 2.0, target diff 5.0, if real_diff =< (5.0 - 2.0) then EEV will be closed to EEV_MINWORKPOS
#define EEV_HYSTERESIS 0.5 //hysteresis, to stop fine-tuning: must be less than EEV_PRECISE_START, ex: target difference = 4.0, hysteresis = 0.3, no EEV pulses will be done while real difference in range 4.0..4.3
#define EEV_TARGET_TEMP_DIFF 3.6 //target difference between Before Evaporator and After Evaporator, the head of the whole algorithm
//additional options
#define EEV_REOPENLAST 1 //1 = reopen to last position on compressor start, useful for ordinary schemes with everyday working cycles, 0 = not
#define EEV_REOPENMINTIME 40000 //after system start: min. delay between "min. work pos." (must be > 0 in this case and > waiting position) set and reopening start
//#define EEV_MANUAL //comment to disable, manual set of EEV position via a console; warning: this option will stop all EEV auto-activities, including zero position find procedure; so this option not recommended: switch auto/manual mode from a console
//do not use next option if you're not sure what are you doing
//#define EEV_DEBUG //debug, useful during system fine-tuning, works both with local serial and RS485_HUMAN
Communication addresses
const char devID = 0x45; //used only if JSON communication, does not matter for MODBUS and Valden display https://github.com/OpenHP/Display/
const char hostID = 0x30; //used only if JSON communication, not used for MODBUS
Last option
#define MAX_SEQUENTIAL_ERRORS 15 //max cycles to wait auto-clean error, ex: T sensor appears, stop compressor after counter exceeded (millis_cycle * MAX_SEQUENTIAL_ERRORS)
© 2018-2021 D.A.A. All rights reserved; gonzho AT web.de; https://github.com/openhp/HeatPumpController/.
Text, media and other materials licensed under CC-BY-SA License v4.0.
Attribution: You must clearly attribute Valden Heat Pump Controller (https://github.com/openhp/HeatPumpController/) original work in any derivative works.
Share and Share Alike: If you make modifications or additions to the content you re-use, you must license them under the CC-BY-SA License v4.0 or later.
Indicate changes: If you make modifications or additions, you must indicate in a reasonable fashion that the original work has been modified.
You are free: to share and adapt the material for any purpose, even commercially, as long as you follow the license terms.
The firmware source code licensed under GPLv3.
This product is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for more details.
For third-party libraries licenses used in this product please refer to those libraries.
Further details, appendices, fine-tuning options, illustrations, abbreviations, and so on you can find in the permanent Valden Heat Pump Controller repository: https://github.com/openhp/HeatPumpController/