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(Created page with "= Open Heat Pump Module v1.0 = This page documents an open-hardware heat pump module built from **off-the-shelf, serviceable, replaceable HVAC parts**. The design is a **reversible 2-ton (≈24,000 BTU/h) R-410A heat pump** that can be integrated into air-to-water or water-loop hydraulic systems. == Goal == Create a modular, serviceable, repairable heat pump core using standardized refrigeration components that any trained technician can maintain without proprietary...")
 
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= Open Heat Pump Module v1.0 =
= Open Heat Pump Module v1.0 =


This page documents an open-hardware heat pump module built from **off-the-shelf, serviceable, replaceable HVAC parts**.
This page documents an open-hardware heat pump module built from off-the-shelf HVAC parts.
The design is a **reversible 2-ton (≈24,000 BTU/h) R-410A heat pump** that can be integrated into air-to-water or water-loop hydraulic systems.
Design target: reversible ~2-ton (≈24,000 BTU/h) R-410A heat pump, suitable for air-to-water integration.


== Goal ==
== Goal ==
Create a modular, serviceable, repairable heat pump core using standardized refrigeration components that any trained technician can maintain without proprietary parts or black-box controllers.
Create a modular, serviceable, repairable heat pump core using standardized refrigeration components easily sourced worldwide.


== System Overview ==
== System Overview ==
Each module consists of:
Each module consists of:
* Refrigeration compressor (≈2-ton, R-410A)
* 2-ton R410A scroll compressor
* Reversing valve (4-way)
* 4-way reversing valve
* Brazed plate heat exchanger (refrigerant to water)
* Brazed plate refrigerant-to-water heat exchanger
* Expansion device (catalog TXV or EEV)
* Expansion device (TXV or EEV)
* Filter/drier, accumulator, service valves
* Filter/drier, accumulator, service valves
* Controls (temperature sensors, relays/PLC)
* Simple, open controls
 
Four modules ≈ 96,000 BTU/h.
Four modules in parallel yield ~96,000 BTU/h total capacity.


== Bill of Materials (per 2-ton module) ==
== Bill of Materials (per 2-ton module) ==


=== Core Refrigeration Components ===
=== Compressor (2-Ton R-410A Scroll) ===
Primary:
https://hdsupplysolutions.com/p/copeland-2-ton-r-410a-scroll-compressor-p252077
Alternative:
https://www.ferguson.com/product/goodman-r-410a-208230v-single-phase-scroll-compressor-g50n6229vzakms/7347425
Budget surplus option:
https://surpluscityliquidators.com/products/212-ton-achp-scroll-compressor-208230601-r410a-3?variant=41932566036525
eBay example (for cost discovery):
https://www.ebay.com/itm/286682581692


* **Compressor (2-ton R-410A scroll)** 
Typical ratings:
  * **:contentReference[oaicite:0]{index=0}** – widely stocked OEM scroll compressor, 208/230 V. 
2 ton capacity, R410A, ~208/230V single-phase, scroll type.
  * **:contentReference[oaicite:1]{index=1}** – lower-cost alternative option. 
  * **:contentReference[oaicite:2]{index=2}** – budget surplus compressor option. 
  * **:contentReference[oaicite:3]{index=3}** – cost-competitive eBay option.


* **Reversing Valve (4-way)** 
=== Reversing Valve (4-Way, Heat Pump) ===
  * **:contentReference[oaicite:4]{index=4}** – standard 4-way valve for heat pump duty. 
Ranco V2-408060-170:
  * **:contentReference[oaicite:5]{index=5}** – budget valve option.
https://www.supplyhouse.com/Ranco-V2-408060-170-1-2-x-3-8-Heat-Pump-Reversing-Valve-style-1
  * **:contentReference[oaicite:6]{index=6}** – alternative 2-ton reversing valve. 
Budget Daikin compatible:
  * **:contentReference[oaicite:7]{index=7}** – low-cost generic reversing valve.
https://www.partswarehouse.com/Daikin-Reversing-Valve-2Ton-R22-R410A-DAI-910198406-p/DAI-910198406.htm
Alternative source:
https://www.gsistore.com/products/ranco-v2-408060-270-reversing-valve
Low-cost generic option:
https://www.wilspecdirect.com/products/reversing-valve-2-ton


=== Heat Exchanger (Refrigerant-to-Water / Plate HX) ===
Typical line sizes:
Suction ~ 3/4"
Liquid ~ 3/8–1/2"


The refrigerant-to-water heat exchanger is a key part that replaces an air-side indoor coil and lets you extract or reject heat to a water loop.
=== Refrigerant-to-Water Brazed Plate Heat Exchanger ===
(acts as condenser in heating mode / evaporator in cooling mode)


* **Bell & Gossett brazed plate heat exchangers:** 
Bell & Gossett brazed plate heat exchangers:
  * https://www.nationalpumpsupply.com/bell-gossett-brazed-plate-heat-exchangers/ – a family of quality brazed plate HXs in a range of sizes suitable for 2-ton service (e.g., BP400-20, BP400-30MT, BP400-40). :contentReference[oaicite:8]{index=8}
https://www.nationalpumpsupply.com/bell-gossett-brazed-plate-heat-exchangers/


* Other brazed plate suppliers (R410A capable): 
General R410A plate HX listings:
  * Alibaba R410A brazed plate HX listings – industrial/contractor supply. :contentReference[oaicite:9]{index=9} 
https://www.alibaba.com/showroom/r410a-brazed-plate-heat-exchanger.html
  * Alfa Laval / SWEP BPHE catalogs – high-performance brazed plates. :contentReference[oaicite:10]{index=10}
Westermeyer / industrial quality:
https://westermeyerind.com/products/heat-exchange/brazed-plate/


*Note:* Plate HXs must be rated for R-410A pressures (≈450-650+ psi) and water side pressures typical of hydronic systems. :contentReference[oaicite:11]{index=11}
Requirements:
Must be rated for R410A refrigerant pressure (typically 450-650 psi working).
Water side stainless (316) preferred.


=== Other Refrigeration Parts (Standard HVAC) ===
=== Other Refrigeration Components (standard HVAC) ===
Obtain from any HVAC wholesaler (Johnstone, Ferguson, SupplyHouse, etc):
* 2–3 ton R410A TXV (or EEV)
* Bi-flow R410A filter-drier
* Suction accumulator
* Service valves
* Schrader access ports
* Sight glass (optional)
* Copper lines and fittings


* Expansion Device (TXV or Electronic Expansion Valve) sized for 2–3 ton R-410A duty (from HVAC wholesaler). 
=== Hydronic Integration ===
* R-410A bi-flow filter/drier. 
(not included in refrigeration stack)
* Suction accumulator. 
* Circulator pump
* Service valves and access ports. 
* Water manifold + PEX / copper
* Sight glass (optional) for service diagnostics.
* Thermal storage tank(s) / IBC tote integration
 
* Fan coils OR radiant loops on load side
These parts are commodity HVAC parts available from local wholesalers.
 
=== Hydronic Components ===
 
* Water circulator pump (≈3–8 GPM range depending on module quantity). 
* PEX/Tubing, manifolds, IBC tote manifold headers. 
* Hydronic buffer tank(s) or thermal battery. 
* Load side heat exchangers e.g., fin-coil units or radiant manifolds.


== Refrigerant Circuit (Simplified) ==
== Refrigerant Circuit (Simplified) ==
Compressor discharge → reversing valve →
Either outdoor air coil OR brazed plate HX →
Liquid line with TXV/EEV →
Evaporator (whichever is opposite role) →
Suction accumulator →
Compressor suction.


1. Compressor discharge → reversing valve. 
Use bi-flow filter/drier and appropriate check valves.
2. Reversing valve switches flow between: 
  * Outdoor air coil (evaporator in heat mode) 
  * Brazed plate water coil (condenser in heat mode). 
3. Liquid line filter/drier and expansion device (TXV/EEV). 
4. Evaporator/plate HX → suction accumulator → compressor suction.


*Ensure correct bi-flow filter/drier and proper check valves for bi-directional flow in heat pump mode.*
== Line Sizes ==
 
Typical for 2 ton R410A:
== Line Sizes and Connections ==
Suction: ~3/4"
 
Liquid: ~1/2"
* Suction: ~3/4″ ODF or flare (common for 2-ton compressors). :contentReference[oaicite:12]{index=12} 
Match compressor + valve ratings.
* Liquid: ~1/2″ ODF or flare. :contentReference[oaicite:13]{index=13} 
* Brazed plate HXs: typical 1/2″ to 3/4″ ports depending on model.
 
Match hose/barb or flare adapters accordingly.


== Controls ==
== Controls ==
Sensors:
* Water in/out temperature
* Optional refrigerant suction/discharge pressure


* Temperature sensors on water inlet/outlet. 
Actuators:
* Refrigerant pressure sensors (optional). 
* Compressor contactor
* Relays/solid-state drivers for:
* Reversing valve solenoid
  * Compressor contactor. 
* Water pump relay
  * Reversing valve solenoid. 
* Outdoor fan relay (if used)
  * Outdoor fan motor. 
  * Water circulator pump. 
* Open controller (PLC/ESP32/industrial controller) with basic logic for: 
  * Heat/cool mode. 
  * Defrost (if outdoor coil used as evaporator). 
  * High/low pressure protection.


== Notes ==
Controller may be:
PLC / ESP32 / relay logic.


* This design uses **standard R-410A refrigerant**, which is common in residential HVAC equipment. :contentReference[oaicite:14]{index=14} 
== Safety ==
* All pressurized refrigeration work must be performed by a certified HVAC technician with proper tools and leak testing.
All refrigerant work must be done by qualified personnel.
* Brazed plate heat exchangers for HVAC duty must be rated for R-410A service and hydronic water pressures. :contentReference[oaicite:15]{index=15} 
Pressure test, evacuate, charge properly.
* This open architecture decouples the **heat pump core** from proprietary OEM boards, enabling replacement of compressors, valves, and heat exchangers with catalog parts.
Use components specifically rated for R-410A.


== Open Hardware Intent ==
== Open Hardware Intent ==
 
This design:
This repository’s purpose is to define a **modular, repairable heat pump building block** that:
* Avoids proprietary sealed systems
 
* Uses catalog components
* Uses widely available components. 
* Enables decades of maintainable operation
* Can be maintained without proprietary spares. 
* Supports local fabrication and repair economy
* Serves as the basis for higher-level systems (thermal batteries, PV-driven heating, open water heater modules). 
* Serves as a building block for open thermal infrastructure
* Allows swarm innovation on controls, hydronics, and integration without vendor lock-in.

Latest revision as of 21:53, 26 December 2025

Open Heat Pump Module v1.0

This page documents an open-hardware heat pump module built from off-the-shelf HVAC parts. Design target: reversible ~2-ton (≈24,000 BTU/h) R-410A heat pump, suitable for air-to-water integration.

Goal

Create a modular, serviceable, repairable heat pump core using standardized refrigeration components easily sourced worldwide.

System Overview

Each module consists of:

  • 2-ton R410A scroll compressor
  • 4-way reversing valve
  • Brazed plate refrigerant-to-water heat exchanger
  • Expansion device (TXV or EEV)
  • Filter/drier, accumulator, service valves
  • Simple, open controls

Four modules ≈ 96,000 BTU/h.

Bill of Materials (per 2-ton module)

Compressor (2-Ton R-410A Scroll)

Primary: https://hdsupplysolutions.com/p/copeland-2-ton-r-410a-scroll-compressor-p252077 Alternative: https://www.ferguson.com/product/goodman-r-410a-208230v-single-phase-scroll-compressor-g50n6229vzakms/7347425 Budget surplus option: https://surpluscityliquidators.com/products/212-ton-achp-scroll-compressor-208230601-r410a-3?variant=41932566036525 eBay example (for cost discovery): https://www.ebay.com/itm/286682581692

Typical ratings: 2 ton capacity, R410A, ~208/230V single-phase, scroll type.

Reversing Valve (4-Way, Heat Pump)

Ranco V2-408060-170: https://www.supplyhouse.com/Ranco-V2-408060-170-1-2-x-3-8-Heat-Pump-Reversing-Valve-style-1 Budget Daikin compatible: https://www.partswarehouse.com/Daikin-Reversing-Valve-2Ton-R22-R410A-DAI-910198406-p/DAI-910198406.htm Alternative source: https://www.gsistore.com/products/ranco-v2-408060-270-reversing-valve Low-cost generic option: https://www.wilspecdirect.com/products/reversing-valve-2-ton

Typical line sizes: Suction ~ 3/4" Liquid ~ 3/8–1/2"

Refrigerant-to-Water Brazed Plate Heat Exchanger

(acts as condenser in heating mode / evaporator in cooling mode)

Bell & Gossett brazed plate heat exchangers: https://www.nationalpumpsupply.com/bell-gossett-brazed-plate-heat-exchangers/

General R410A plate HX listings: https://www.alibaba.com/showroom/r410a-brazed-plate-heat-exchanger.html Westermeyer / industrial quality: https://westermeyerind.com/products/heat-exchange/brazed-plate/

Requirements: Must be rated for R410A refrigerant pressure (typically 450-650 psi working). Water side stainless (316) preferred.

Other Refrigeration Components (standard HVAC)

Obtain from any HVAC wholesaler (Johnstone, Ferguson, SupplyHouse, etc):

  • 2–3 ton R410A TXV (or EEV)
  • Bi-flow R410A filter-drier
  • Suction accumulator
  • Service valves
  • Schrader access ports
  • Sight glass (optional)
  • Copper lines and fittings

Hydronic Integration

(not included in refrigeration stack)

  • Circulator pump
  • Water manifold + PEX / copper
  • Thermal storage tank(s) / IBC tote integration
  • Fan coils OR radiant loops on load side

Refrigerant Circuit (Simplified)

Compressor discharge → reversing valve → Either outdoor air coil OR brazed plate HX → Liquid line with TXV/EEV → Evaporator (whichever is opposite role) → Suction accumulator → Compressor suction.

Use bi-flow filter/drier and appropriate check valves.

Line Sizes

Typical for 2 ton R410A: Suction: ~3/4" Liquid: ~1/2" Match compressor + valve ratings.

Controls

Sensors:

  • Water in/out temperature
  • Optional refrigerant suction/discharge pressure

Actuators:

  • Compressor contactor
  • Reversing valve solenoid
  • Water pump relay
  • Outdoor fan relay (if used)

Controller may be: PLC / ESP32 / relay logic.

Safety

All refrigerant work must be done by qualified personnel. Pressure test, evacuate, charge properly. Use components specifically rated for R-410A.

Open Hardware Intent

This design:

  • Avoids proprietary sealed systems
  • Uses catalog components
  • Enables decades of maintainable operation
  • Supports local fabrication and repair economy
  • Serves as a building block for open thermal infrastructure
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