Heat pump installation box with modular safety and communication architecture

Abstract

Heat pump installation box comprising a housing for wall mounting with connection devices for the electrical connection of at least one indoor unit and one outdoor unit of a heat pump system, wherein the following components are pre-assembled inside the housing: • at least one residual current device (RCD) and at least one miniature circuit breaker (MCB) for the safe, standard-compliant connection of the indoor and outdoor units, and • a control and communication unit for monitoring and / or controlling the heat pump system, characterized in that the installation box has a modular safety and communication architecture in which the safety components and / or communication modules are designed as separate interchangeable modules that can be inserted into the housing via standardized interfaces.

Description

1. Technical objective and innovative content

[0001] This technical protection specification refers to a pre-wired, industrially manufactured installation solution for heat pump systems. The aim is to standardize and simplify the interfaces between electrical installations and heating systems in the field of modern heat pump technology. The central integration of all safety-relevant, control-related, and communication components within a defined housing significantly facilitates error-free and time-saving installation as well as subsequent maintenance.

[0002] The system replaces improvised construction site solutions and allows for a clearly structured and documented execution - regardless of the heat pump model used - while simultaneously minimizing planning and coordination efforts.

[0003] A key objective is also to avoid typical installation errors, particularly regarding neutral conductor routing, communication line wiring, and residual current device (RCD) tripping. The solution thus promotes standards-compliant and EMC-compliant installations. 2. Structure and Functionality

[0004] The heat pump installation box consists of a compact, industrially manufactured housing with a clear separation of the electrical supply circuits for the indoor and outdoor units. It comes factory-equipped with: • Dual power supply (230 V / 400 V) including all-current sensitive residual current circuit breaker for the outdoor unit (e.g. heat pump) and separate residual current device for the indoor unit (e.g. hydraulic station) • Separate fuse units (3P B16A, 1P B16A) for heating element, control unit, outdoor and indoor unit • Communication interfaces for CAN bus, MODBUS or LAN via RJ45 connector with clear terminal assignment • Terminal blocks for control and signal lines (24V, potential-free contacts, sensors, etc.) • PE / neutral conductor terminal blocks for the structured assignment of both units • Display opening or installation slot for manufacturer-specific controls (e.g., Lambda heat pump display) • Door lock to protect against unauthorized access

[0005] The box is typically mounted directly on the wall in the boiler room and serves as the central distribution point for all electrical connections during heat pump commissioning. It contains all the necessary connections for power supply and communication, enabling a ready-to-connect installation by the heating engineer or electrician – without any intervention in the unit's control system itself.

[0006] Even in service situations, specialists benefit from the documented terminal assignment and structured separation, as fault diagnoses and maintenance operations can be carried out safely and efficiently - without the risk of undefined construction site wiring. 3. Expandability and scope of protection

[0007] The system is modular in design and can be expanded upon customer request with additional fuse circuits, relay modules, network disconnects, or terminal blocks, provided the basic factory structure is retained. The scope of protection of this utility model covers all variants of the described modular connection and control unit, regardless of: • Manufacturer or brand of the connected heat pump • specific dimensioning of the circuit breakers • Housing size or wiring topology • Communication interface (CAN / MODBUS / Ethernet)

[0008] A key protectable feature is the standardized terminal logic, which allows different heat pump systems to be integrated into a uniform connection grid - regardless of the manufacturer.

[0009] Deviations in the configuration, number of terminals or type of fuse do not justify circumvention of this protective device, provided that the basic principle of a centralized, prefabricated, electrically isolated connection and control unit with communication logic is maintained.

[0010] The protected object applies regardless of the external housing shape or the choice of mounting location, provided that the internal functional structure is maintained as described.

[0011] This also expressly applies to later additions such as adding another safety circuit or using an alternative type of line protection.

[0012] Even a software-based or digitally controlled replication of the described functions within a different housing does not constitute a circumvention of the protection, provided that the structure, purpose and effect correspond to the described system. 4. Differentiation from the state of the art

[0013] Conventional installations are carried out decentrally at the construction site level, with individual wiring and often inconsistent safety features. The installation box described here is a pre-assembled, factory-tested functional module that: • standardized the connection, • Reduced planning effort, • Installation time reduced, • and significantly minimizes the susceptibility to errors.

[0014] The solution significantly reduces on-site assembly time, as only a single power and control cable entry into the housing is necessary.

[0015] A comparable design, especially with this clear functional separation and expandability, is not known on the market. 5. Application areas and distribution options

[0016] The heat pump installation box can be used in new construction and renovation projects for single-family and multi-family homes, as well as in commercial applications. It can: • sold directly as a single product, • licensed through partner companies or • can be integrated as an OEM module in technical centers or container solutions.

[0017] The combination with wall brackets, pre-piping systems or meter cabinets is also technically possible and does not represent a new circumvention of intellectual property rights. 6. Summary of protectable characteristics

[0018] The following is protected: • a pre-assembled installation solution for heat pump systems, • with integrated security and communication components, • clear separation between indoor and outdoor units, • standardized terminal assignment, • Modular expandability without functional disruption, integration option of an EMS (Energy Management Module) • regardless of the heat pump manufacturer used, • with a focus on ease of assembly, accessibility for maintenance and error prevention. 7. Structure and components (according to image description) 1. Housing door (lockable, weatherproof) 2. Control board of the heat pump (e.g. Lambda) 3. 230V terminals for indoor unit: pumps, diverter valves, circulation 4. Type A residual current circuit breaker for indoor unit (40 A / 30 mA) 5. 3P B16A circuit breaker for 400V heating element 6. 1P B16A LS circuit breaker for controller board 7. 24V terminal block (e.g. for sensors and switching contacts) 8. RJ45 connector (LAN, CAN-BUS, Modbus) 9. Terminal block 400V supply line 10. Neutral conductor terminal block 11. Type B residual current circuit breaker (all-current sensitive, outdoor unit) 12. 3P B16A circuit breaker for 400V outdoor unit 13. 1P B16A circuit breaker for 230V control of outdoor unit 14. Common terminal block PE / N for both circuits 15. Door lock 16. Control display (e.g. Lambda display operation) Description of the invention: Heat pump installation box with modular safety and communication architecture

[0019] Technical field: The invention relates to the field of heating and building technology, in particular electrical connection and control units for heat pumps. More precisely, it is a pre-wired installation box that contains all the necessary safety components (circuit breakers) for connecting a heat pump system and optionally also has integrated communication means to integrate the heat pump into modern building management or remote maintenance systems.

[0020] Background and state of the art: Heat pumps typically consist of an outdoor and an indoor unit, which must be electrically connected on-site and integrated into the building's electrical system. In practice, this means that an electrician must install and wire several components (e.g., residual current circuit breakers, miniature circuit breakers, control terminals) in the distribution board, while the heating engineer handles the hydraulic connections. This process requires coordination between trades and is prone to errors.

[0021] Object of the invention: Against this background, the invention aims to provide a universally applicable installation box for heat pumps that significantly simplifies the electrical installation and commissioning of the heat pump units while ensuring a high level of safety. The box should be modularly expandable to meet different requirements – such as different heat pump performance classes, additional safety requirements (e.g., regional regulations), or optional communication and control functions. In particular, the invention should enable the seamless integration of communication connections (such as remote monitoring via the internet, smart grid interaction, etc.) without the need to install separate external modules. This should reduce commissioning time, minimize potential sources of error, and increase the future-proofing of the installation.

[0022] Solution to the problem (Summary of the invention): This problem is solved by the heat pump installation box with modular safety and communication architecture according to claim 1. The basic idea is to provide all the electrical protection and control components necessary for the operation of the heat pump in a single compact housing that is pre-wired at the factory. The novelty lies in the fact that both the safety elements (residual current circuit breaker, miniature circuit breaker, etc.) and the communication / control unit are designed in a modular manner. "Modular" here means that the box has standardized slots or sockets into which various modules can be inserted.

[0023] At a minimum, the box contains modules for: • Mains connection and main fuse: e.g. terminals and a main switch for the 400V supply line from the building network. • RCBO protection indoor circuit: a residual current circuit breaker (30 mA, type A) and associated miniature circuit breakers (e.g. B16A) for the circuits of the indoor unit (heating element, control electronics, etc.). • RCBO protection outdoor circuit: an all-current sensitive RCBO (30 mA, type B) and MCB (B16A) for the outdoor unit (compressor motor, outdoor electronics). • Control and communication unit: a module that contains the control board for the heat pump control and also provides a communication device (e.g. microcontroller with network / WLAN module).

[0024] In addition, expansion slots may be provided, e.g. for: • Surge protection modules, if required by the network operator. • Smart home gateway or interface modules (e.g. KNX, Modbus, EEBus) to integrate the heat pump into building management systems. • Meter and measuring modules, such as a submeter for the heat pump electricity or sensor interfaces for temperatures and pressures, which can be read via the box.

[0025] This modular structure allows the box to be flexibly adapted to different installations. Unnecessary modules can be omitted (saving costs), while required modules can simply be plugged in or connected. All modules are mounted inside the housing on a central mounting rail (e.g., DIN rail) or connectors, which simplifies replacement and maintenance. Example implementation:

[0026] A specific embodiment of the invention is described below with reference to Fig. described. Fig. shows a preferred implementation of the heat pump installation box in an open view, where the internal components are visible. Fig. Interior view of a prototypical heat pump installation box. The numbered components show: (1) the robust plastic housing with cable glands for mains and system sides, (2) main connection terminals for the mains supply, (3) Type B residual current circuit breaker for the outdoor unit, (4) Type A residual current circuit breaker for the indoor unit, (5) three-pole 16A circuit breaker for the compressor, (6) single-pole 16A circuit breaker for the outdoor unit control, (7) three-pole 16A circuit breaker for the electric heating element of the indoor unit, (8) single-pole 16A circuit breaker for the control board of the indoor unit, (9) busbars and wiring (factory prepared), (10) slot for surge protection module (currently with dummy cover), (11) the control and communication board (concealed mounting, behind the carrier plate in the illustration), (12) a service interface or...a display module on the front of the housing for local operation, (13) terminal block for sensors and valves of the heating system, (14) interface for optional WLAN / GSM module, (15) mounting rails for modular components, (16) attached documentation / circuit diagram on the inside of the cover.

[0027] The prototype shown houses all the essential components. The box functions as follows: The control electronics supplied by the heat pump manufacturer are already installed on the control board unit (11). This unit is connected to the terminals and protective devices via internal wiring. The installer simply needs to connect the outdoor and indoor units of the heat pump to their respective terminals (3-8, 13). The residual current circuit breakers (RCCBs) (3) and (4) provide separate personal protection on the outdoor and indoor units, in accordance with regulations (e.g., Type B is required for the frequency converter in the compressor). The miniature circuit breakers (MCBs) (5-8) protect the individual circuits (e.g., (5) for the compressor motor of the outdoor unit, (7) for the heating element of the indoor unit, etc.).This layout corresponds to the usual design and is already pre-wired here - the electrician no longer needs to install individual circuit breakers in the house distribution board. Advantages of the invention:

[0028] The described installation box offers several advantages over the state of the art: • Significant time savings during installation: All critical connections and protective circuits are pre-assembled. On-site installation effort is reduced to connecting the power supply and the connecting cables to the indoor and outdoor units.

[0029] Experience shows that this can save hours of working time and allows heating engineers and electricians to work more independently of each other - similar to existing solutions, but universal in this case. • Error minimization: Factory wiring virtually eliminates wiring errors. Each circuit breaker is correctly sized and already properly connected. The clear labeling of the terminals and modules (see Fig. The use of numbers prevents confusion. Overall, this increases the electrical safety of the system. • Modularity and future-proofing: Unlike manufacturer-specific boxes, our solution has a modular design. Should a standard change (e.g., the requirement for surge protectors) or a component fail, the affected module can be replaced without replacing the entire box. Similarly, the manufacturer can offer future upgrades—for example, a new communication module with extended functionality—that can be easily added. This ensures the installation remains state-of-the-art for longer. • Universal applicability: The box is not tied to a specific heat pump model. It can be adapted to various makes using appropriate adapter settings. The planned standardization of the connections (e.g., a uniform terminal block for outdoor unit feedback, a uniform connector for indoor unit control) allows manufacturers to easily make their heat pumps compatible with this box. This could result in a uniform installation concept for different brands, simplifying the work for installers and reducing errors caused by changing systems.

[0030] Further embodiments: The invention is not limited to the example shown. Alternative module configurations could be chosen – for example, combined residual current circuit breakers (RCBOs) instead of separate components. It is also conceivable to equip the box with additional sensor modules (e.g., a module that reads the temperature and pressure sensors of the heat pump and communicates with the controller). In another embodiment, the box could integrate an emergency power supply (UPS module) to briefly continue operating the controller during a power outage or to shut down the heat pump in a controlled manner. The modular architecture allows such additional functions to be added as needed.

Claims

[1] Heat pump installation box comprising a housing for wall mounting with connection devices for electrical connection of at least one indoor unit and one outdoor unit of a heat pump system, wherein the following components are pre-assembled inside the housing: • at least one residual current device (RCD) and at least one miniature circuit breaker (MCB) for the safe, standard-compliant connection of the indoor and outdoor units, and • a control and communication unit for monitoring and / or controlling the heat pump system, characterized by that the installation box has a modular security and communication architecture in which the security components and / or communication modules are designed as separate, interchangeable modules that can be used in the housing via standardized interfaces. [2] Heat pump installation box according to claim 1, characterized bythat the control and communication unit includes a wireless communication module which connects the heat pump system to an external network or user app to enable remote monitoring and control (e.g. via WLAN or mobile network). [3] Heat pump installation box according to claim 1 or 2, characterized by , that the safety modules include a residual current device (RCD) for all-current sensitive fault currents (Type B) for the connection of the outdoor unit and a separate RCD (Type A) for the indoor unit, as well as several interchangeable circuit breakers for different circuits (such as heating element, control, pumps). [4] Heat pump installation box according to one of the preceding claims, characterized by, that the housing (1) is provided with pre-assembled connection terminals (terminal blocks) which are clearly labelled and divided into groups for indoor and outdoor units, so that installation can be carried out without opening individual modules. [5] Heat pump installation box according to one of the preceding claims, characterized by that the communication architecture is modularly expandable by integrating optional additional modules (such as a smart home gateway, energy management interfaces or future communication standards) into designated slots, while ensuring the basic functions of the box even without these additional modules.

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