Octopus Cosy Series Installation Manual

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Cosy Series

Installation Manua

Version 4.0

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Neil court

August 4, 2025

What esbe valve do I need what is the product code

Neil

August 2, 2025

Can I use honeywell 3 port valve and use the the green cable instead of the black that is on the esbe valve

Summary of Contents for Octopus Cosy Series

Page 1 Cosy Series Installation Manua Version 4.0...
Page 2 Foreword This manual describes the unpacking, safe handling, installation, fault ﬁnding and servicing of the Cosy series of R290 air source heat pumps. Please make sure that this manual is read, understood, and kept for reference before beginning the installation. As this manual is a work in progress, successive versions may incorporate signiﬁcant changes to prior procedures, ﬁgures, and guidelines.
Page 3: Table Of Contents
R290 emergency procedures 1.6. Safe siting 1.7. Installation restrictions 1.8. Electrical work 2. Introduction ……………………………………………………………………………………………………………………….. 10 2.1. Cosy series heat pumps 2.2. Legal Disclaimer 3. Cosy Heating System information ………………………………………………………………………… .11 3.1. Cosy system design 3.2. Main components 3.3. Heating architectures with Cosy 6 3.4.
Page 4 Pre-commissioning checks 11.2. Filling the system 11.3. Commissioning the controls 11.4. Setting up Cosy Pods 11.5. Octopus Energy app setup 12. Post-Installation Handover ………………………………………………………………………………………… 68 12.1. Final checks 12.2. Document delivery 12.3. System explanation 13. Servicing the product …………………………………………………………………………………………………… 70 13.1.
Page 5: Safety Information
1. Safety Information 1.1 Before beginning any work Carefully read all installation instructions before installation. ● Use proper protective equipment and follow all safety and warning instructions. ● Aside from the requirements set out in this document, installers must follow ●...
Page 6: Special Qualifications For R290
Refrigerant details Cosy series heat pumps contain the natural refrigerant R290, commonly known as propane. Propane is an excellent refrigerant. It is much safer for the environment, with a global warming potential of only 3 (nearly equal to pure CO2). Other common refrigerants such as R32 have GWP values more than 200 times higher.
Page 7: R290 Emergency Procedures
1.5 R290 emergency procedures FIRST AID MEASURES May cause asphyxiation in high concentrations. Victim may not be aware of asphyxiation. Symptoms may include loss of mobility or General Information consciousness. If asphyxiation is suspected, move the victim to a well-ventilated area, lay down, and seek medical attention immediately.
Page 8: Safe Siting
1.6 Safe siting of heat pump unit WARNING: Unit must be secured against tipping during all phases of installation. Failure to secure the unit may result in injury or death. WARNING: Unit must be installed away from any source of ﬂammable gasses. Accumulation of such gasses around the unit may result in ﬁre or explosion.
Page 9: Electrical Work
● Two or more persons are needed to handle the unit, as it weighs over 20 kg. ● Use only original spare parts as outlined by the manufacturer, or explicitly agreed between manufacturer and installer. ● Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer.
Page 10: Introduction
2. Introduction 2.1 Cosy Series Heat Pumps The Cosy Series of heat pumps are designed and built by Octopus Energy in the United Kingdom. They represent the ﬁrst heat pump built from the ground up that keeps the unique design and heating needs of British homes in mind.
Page 11: Cosy Heating System Information
Octopus technical support or your area manager for further guidance. Likewise, if the instructions in this manual cannot be followed, please stop the installation, and contact Octopus technical support or your area manager. 3.2 Main system components...
Page 12: Underfloor Heating
Single-zone space heating is preferred for the Cosy system in most homes. Multiple zones must be speciﬁed and included in the initial system design. If the customer requests a zone architecture that differs from the design, you should contact Octopus technical support or your manager to obtain an updated design.
Page 13: Plumbing System Components
3.4 Plumbing system components 3.4.1 Water Cylinder Cosy heat pumps require installation of a heat pump-compatible cylinder sized for the home per the provided system design. Standard cylinder models for use with the Cosy are listed in Table 3.A Cosy 6 Compatible Water Cylinders Manufacturer Model Capacity...
Page 14 3.4.5.A Pipe Turnback (Preferred) Default termination method should be a turnback. Plumb PRV 15mm copper pipe as depicted, ensuring outlet is one pipe width (15mm) from the wall. Where the pipe passes through the exterior wall, larger (20mm) pipe should be used to create a sleeve. If another pipe size is used for the PRV outlet, adjust sizes and standoff accordingly.
Page 15: Plumbing Schematics
3.5 Plumbing schematics The following system architectures are provided for reference. Each home is unique and a speciﬁc design for each home should always be used. 3.5.1 Single zone space heating (including 4-pipe buffer) Figure 3.4 - Single zone space heating with 4-pipe buffer tank ver.
Page 16 3.5.2 Multi-Zone heating - Radiator Circuits Figure 3.5 - Multi-zone space heating with radiators only ver. 4 - 09 Oct 24 - 16 -...
Page 17 3.5.3 Multi-Zone heating - Radiator and Underﬂoor Circuits Figure 3.6 - Multi-zone space heating with underﬂoor heating ver. 4 - 09 Oct 24 - 17 -...
Page 18: Electrical System Components
3.6 Electrical system components 3.6.1 Distribution Board Each Cosy system requires a distribution board assembly. The board provides power to the Cosy unit and associated components, protection against overcurrent and current abnormalities, and surge protection. Distribution boards may be mounted inside or outside the home. For internal use, any distribution box that meets the requirements per regulations pertaining to the installation is acceptable.
Page 19 3.6.4 Wiring Wiring used to connect the components of the system must meet or exceed the standards for the cables speciﬁed in Table 3.B below. If in doubt, consult with Octopus support as to the suitability of a cable. Cosy 6 Electric Wiring Speciﬁcations...
Page 20: Electrical Schematic
3.7 Electrical schematic The following wiring diagram is provided for reference. Each home is unique and a speciﬁc design for each home should always be used. Figure 3.8 - Wiring Diagram ver. 4 - 09 Oct 24 - 20 -...
Page 21: Key Safety Features
4. Cosy 6 Onboard Safety Features 4.1 Overview The Cosy 6 has a number of technical design elements to help it safely deliver heating to customer homes under a variety of conditions over its lifetime. However, there may be times when unforeseen circumstances or accidents result in a failure of one or more components.
Page 22: Cosy 6 Monobloc Unit Subsystems
5. Cosy 6 monobloc unit subsystems 5.1. Subsystems overview The Cosy 6 unit is a monobloc heat pump assembly intended for outdoor installation. It comprises a gray plastic weather-resistant casing and ﬁve main operational subsystems, along with a variety of additional materials including sound dampening and foam insulation. The ﬁve main operational subsystems of all Cosy monobloc units are: Refrigerant Circuit 2.
Page 23 Figure 5.1 - Main subsystems ver. 4 - 09 Oct 24 - 23 -...
Page 24: Siting And Installation Clearances
6. Siting & Installation Clearances 6.1 General Siting and Clearances Information Siting and clearances for the Cosy 6 are a function of its operation and its R290 propane refrigerant. R290 is a colorless, odorless, highly ﬂammable substance that exists in gas form at room temperature.
Page 25 Note: Figure 6.2 depicts walls on both sides for reference. However, the unit should not be installed as depicted in Figure 6.2. Only one lateral wall is permitted along with a rear wall. If one side of the unit has a wall/fence >300 mm high within 1 meter, the opposite side must have no walls/fences >250mm tall within 1 meter .
Page 26: Overhead Clearances
6.2.3 Overhead Clearances Minimum height of an overhead surface such as a deck, overhang, or other obstacle that could impede ﬂow of exhaust air is 1500 mm. This limit applies for installations where the heat pump is not bounded laterally by a wall within 1 meter. See Figure 6.4 Where there is a wall within 1 meter, minimum headroom from ground to an overhead surface that could impede ﬂow of exhaust air is increased to 2000 mm.
Page 27: Safety Clearances
6.3 Safety Clearances Additional clearances must be met for safety due to R290. These clearances are in addition to the operational clearances listed in the preceding section. Safety clearances consist of four (4) distinct but overlapping zones around the unit. These zones are depicted together below.
Page 28 6.3.2 No Spark Zone The No Spark Zone deﬁnes an area that must be free of ignition sources, as there can be some level of combustion risk in the event of a leak. The zone consists of two trapezoidal areas measuring 500 mm laterally from the heat pump at their bases , 300 mm laterally from the heat pump at their tops , and 950 mm in height .
Page 29 Figure 6.7 - Door & Window Zone 6.3.3.B Non-openable windows & windows above the zone If the window is permanently sealed and non-openable, the exclusion does not apply. This applies to fully sealed windows that do not open and do not have cracks or gaps around the panes/frames such that a leak of R290 could inﬁltrate the home.
Page 30 6.3.4 Flue & Intake Zone Flues and air intakes are prohibited in the zone extending vertically 1275 mm from the base and extending 300 mm laterally from the sides of the unit. This is to ensure that the ﬂue/intake is not affected by the heat pump’s operation, and to ensure fumes or exhaust are not drawn into the heat pump where they may affect performance.
Page 31 Cosy Unit Clearances Quick Reference Lateral Vertical Prohibitions & Area Additional Considerations Clearances Clearances Restrictions Obstacles should be minimized Front of Unit 500 mm around the front clearway for ease of work. Shrubs and similarly dense plant barriers that impede airﬂow No wall/fence >300 mm is should be considered as walls.
Page 32: Product Data Sheet
7. Product Data Sheet Parameter Unit Value Nominal capacity 6.00 Coefﬁcient of performance (A7/W35) @5.63kW - EN14511 4.29 Coefﬁcient of performance (A7/W65) @5.23kW - EN14511 2.71 Length Height 1125 Depth Weight Sound power level (Heating, A7W35) 53.4 Sound power level (Heating, A7W55) 56.5 (°C) Maximum ﬂow temperature...
Page 33 8. Transporting & Unpacking The Cosy 6 will arrive ﬁxed to a pallet, covered with protective materials. In order to unpack the unit safely, follow the steps below. Cut the strap securing packaging to pallet with scissors or another safe implement. WARNING: Packing strap is under tension.
Page 34: Heat Pump Unit Installation
9. Heat Pump Unit Installation 9.1 Restrictions and Precautions for Installation Please pay careful attention to the following points before beginning the installation or any servicing work. Failure to follow these instructions may result in injury to persons or animals, or damage to the unit itself.
Page 35 Heat pump should be located in a free and well ventilated space. If you have concerns ● about location suitability, contact your area manager or Octopus support. Heat pump should be ideally installed where it is at least moderately sheltered from ●...
Page 36 Mounting out-of-level will result in damage to the unit and components 9.2.1 Heat Pump Base Cosy series heat pumps require a ﬂat hard-surface mounting base. Unlike other heat pumps, Cosy models do not come equipped with integrated feet nor with mounting points suitable for third-party feet.
Page 37: Condensate Drainage
9.3 Condensate drainage When a Cosy heat pump is running in heating mode, ice can accumulate on surfaces of the unit. To prevent ice from growing, the heat pump will regularly go into defrost mode to melt the ice. Water formed from the defrost process will fall to the base of the heat pump where it can escape to ground through the drain holes in the base and through the condensate drain.
Page 38 9.3.2 Condensate Piping Requirements Cosy units come equipped with a 3/4” brass condensate outlet port. Condensation water must be piped from this port to an area clear of the unit. This will most likely be the gravel soakaway deﬁned in section 9.3.1. However, the installer may opt to connect the port via pipework to an existing drain.
Page 39: Mounting Holes
9.4 Mounting the heat pump The unit must be positively and securely mounted to the hard base to prevent movement and ensure safety of people and animals. WARNING: Failure to properly mount the heat pump to the base may result in injury or death to persons or animals due to tipping.
Page 40 5. Measure 350 mm along the scribed line from the rear of the slab and mark. Measure 250 mm from the front of the slab and mark (marks should coincide). This is the bolt hole position. 6. Repeat Steps 1-4 for the opposite side. Ensure the two bolt hole positions are 727 mm apart.
Page 41 9.4.2 Securing the heat pump When securing the unit, there are two options for mounting hardware: M10 x 130 mm threaded rod bolts with a chemical ﬁxative (Preferred) ● M10 x 85mm shield anchor bolts with a chemical ﬁxative (Alternative) ●...
Page 42 Check for sufﬁcient space and alignment of hydraulic and electrical connections before securing. 8. Secure the heat pump the base using the supplied M10 nuts and hand tighten. Use of thread locker or lock-washers is recommended due to vibration. 9.4.2.B Steps for mounting with shield anchor bolts (Alternative) Ensure bolt holes are sufﬁcient depth (clear through the slab) and clear of debris and dirt from drilling 2.
Page 43: Before Beginning Work
9.5 Plumbing connections to heat pump unit Once the heat pump has been sited and secured to the base, proceed with plumbing the unit to the home as detailed in the steps below. 9.5.1 Before beginning work Identify the ﬂow (water outlet) and return (water inlet) pipe tails and mark as needed to avoid misidentiﬁcation during plumbing work.
Page 44: Wiring Overview
9.6 Electrical connections to heat pump unit Electrical install must be conducted by an electrician to the latest edition of standard BS 7671, as well as the relevant national standards in the country of install. 9.6.1 Before beginning work Inspect all cabling for damage or unserviceable condition before beginning electrical work. WARNING : Failure to inspect cables and replace damaged cabling before installation may result in injury or death.
Page 45 9.6.3 Isolator installation Place heat pump isolator switch on the nearest wall, or as close as practical and in accordance with local and national wiring regulations. Isolator should be placed above the 950mm line . If impractical to mount above 950mm from base, place outside the later limits of the No Spark Zone .
Page 46 Figure 9.11 - Wiring Plate & Channel 6. Remove terminal cover and connect wires into provided terminal blocks according to Figure 9.12 below. Connections should be hand-tightened, ensuring sufﬁcient purchase on the wire ends to prevent slipping/loosening due vibrations. Figure 9.12 - Wiring diagram Secure wiring tails to the supplied mounting block on the terminal board using cable ties, taking care to ensure all wiring is clear of contact with surfaces and conditions that could result in premature or excessive wear.
Page 47: Controls Overview
10. Cosy Hub installation 10.1 Controls Overview The Octopus Cosy Hub is the indoor controller for Octopus Cosy heat pumps. The system communicates to valves and pumps via the four relays integrated inside it, allowing a conﬁguration of a single hot water and up to three space heating zones (note: any of the heating zones can be used and wired as an underﬂoor zone) The system relies on the...
Page 48 10.2 Controls architecture and requirements Each Cosy heat pump needs one (1) controller ● Each controller can support up to four zones (3 space heating plus DHW as a zone) ● Each spacing zone must have at least one pods ●...
Page 49 10.4 Cosy Hub wiring Once the Cosy Hub is mounted to a wall, proceed with wiring as detailed below. Wiring can be done either through the surface wiring breakout tabs or through the holes in the wall plate as seen in Figure 10.2 above. Figure 10.3 - Cosy Ports 10.4.1 Setting Modbus DIP switch Ensure the Modbus DIP switch is conﬁgured as follows.
Page 50 10.4.2 Wiring Modbus ports Using the supplied Modbus cable, wire the Modbus ports to the Cosy heat pump as follows: SGND: Connect one end of the green wire into port SGND and the other end into the ● correct port on the Cosy Heat pump (SGND is not earth and should not be connected to earth ) A: Connect one end of the red wire into port A and the other end into the correct port ●...
Page 51 10.4.4 Wiring the mains power ports Connect the mains power into the power port: PE: The Cosy Hub is double insulated and does not require earthing (optional) ● L: Connect the brown wire into port L ● N: Connect the blue wire into port N ●...
Page 52 10.5.2 DHW zone / dual heating zones / ESBE valve & two 2-port valve Hot Water Ports: Follow the instructions in Section 10.4.1 above. Zone 1 Heating Ports: Connect the ﬁrst heating zone as follows below. PE: Connect the green/yellow wire from port E of the 2-port valve into port PE of the ●...
Page 53 10.5.3 DHW zone / three heating zones / ESBE & three 2-port valves Hot Water Ports: Follow the instructions in Section 10.4.1 above. Zone 1 Heating Ports: Follow the instructions in Section 10.4.2 above. Zone 2 Heating Ports: Follow the instructions in Section 10.4.2 above. Aux/Zone 3 Heating Ports: Connect the third heating zone Aux/Zone3 ports as follows below.
Page 54 10.5.4 DHW zone / three heating zones using four 2-port valves Hot Water Ports: Connect the hot water zone ports as follows below. HW: Connect brown wire from port L of the two-port valve into port HW of the Cosy ●...
Page 55 10.6 Wiring for Circulating Pump with 4-pipe buffer This section details the methods and diagrams for connecting a circulating pump where installed on either a single-zone or multi-zone system 10.6.1 DHW zone / single heating zone with circulating pump Hot Water Ports: Connect as shown in section 10.5.1 Circulating Pump: Connect as described below.
Page 56 10.6.2 DHW zone / multiple heating zones with circulating pump Hot Water Ports: Connect as shown in section 10.5.1 Circulating Pump: Connect as described below. See Figure 10.9 PE: Connect the green/yellow wire from the pump to the PE connection of the 5A ●...
Page 57: Pre-Commissioning Checks
11. Commissioning The following instructions must be read and understood prior to beginning the process to commission the Cosy 6 heat pump. The full system and installation must meet all requirements speciﬁed in this document before being used. If there are any aspects in which the system or installation does not comply, the heat pump must not be commissioned CAUTION : Attempting to commission a heat pump without verifying that all requirements have been met may result in severe damage to the system.
Page 58: Filling The System
11.2 Filling the system 11.2.1 System Additives If all conditions in section 10.1 are met, the system can be ﬁlled. The system should have the correct corrosion inhibitor added to the correct volume before ﬁlling with water. CAUTION : Failure to add corrosion inhibitor will lead to premature corrosion and clogging of the ﬁlter element, resulting in low ﬂow and other issues.
Page 59 Status Description Flashing Purple Booting up Flashing Blue Bluetooth Enabled (Ready to pair to Octopus Energy app) Solid Blue Wi-Fi AP mode activated (ready to connect to installer site) Flashing Yellow Zigbee Pairing Mode (ready to connect to Cosy Pods)
Page 60 11.3.1 Cosy Hub commissioning - Enabling ‘Installer Mode’ The Cosy heat pump system is conﬁgured and commissioned via the installer website. The Cosy Hub needs to be put into ‘Installer Mode’ to enable access to the installer website. Follow the steps below: When the Cosy Hub is ﬁrst powered up, the status LED should change from ﬂashing purple to solid red. ...
Page 61 11.3.2 Cosy Hub conﬁguration Press the menu button in the top left corner and select System Conﬁguration and scroll down to Manual Pump Control , which will allow conﬁguration of system modes. Figure 11.5 - Manual Pump Control page From the Manual Pump Control page, conﬁgure the heat pump systems as follows: 1.
Page 62: Purging The System
11.3.3 Purging the system While remaining on the Manual Pump Control page, purge the system according to the following procedure, referring to Figure 11.4 as needed: Ensure Heat Pump status is Standby (if not, go to the Home page and turn off all zones –...
Page 63 11.3.5 Setting the ﬂow temperatures To set the ﬂow temperature, ﬁrst press the menu button on the top left and go to the Setpoints page. Figure 11.8 - Setpoints page From the Setpoints page shown above, set the ﬂow temperature as follows: 1.
Page 64 11.4 Setting up Cosy Pods The Cosy Pods are room temperature and humidity sensors. Customers will be given a maximum of four Cosy Pods during install, though smaller homes may have only 2-3 pods. There must be at least one Cosy Pod installed per heating zone (known as the Primary Pod ).
Page 65 Figure 11.10 - Pod and wall plate Install the Cosy pod(s) as follows: Remove the wall plate at the back of the Cosy Pod. 2. Identify a mounting point on the wall that is reasonably central in the room, and also: a.
Page 66 Figure 11.12 - Link Room Sensor page 5. If there is more than one heating zone, the pod must be assigned to a Zone. Note: every zone must have at least one pod. CAUTION : Failing to properly assign at least one pod to each zone will result in a system fault and improper operation 6.
Page 67 Figure 11.14 - System Conﬁguration page 11.5 Octopus Energy app setup with Customer The Octopus Energy app is the primary control method for the customer. To complete the commissioning, the heat pump must be onboarded to the app. Onboarding procedure:...
Page 68: Document Delivery
Before calling the install complete and the system fully commissioned, ensure the following steps are completed. 12.1 Final checks System clear of faults - conﬁrm with Octopus support team 2. Radiators balanced and conﬁrmed warming properly 3. DHW functionality working 4.
Page 69: Defrost Cycles
The Octopus Energy app provides controls of the hot water temperature and schedules. If the customer chooses, they can enact a legionella cycle 12.3.4 Defrost cycles Defrosting: When the outdoor temperature is low, it is possible for ice to form in and around the unit.
Page 70: General Precautions
13. Servicing 13.1 General precautions Before beginning work on systems containing ﬂammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.
Page 71: Electrical Safety Guidelines
13.2 Electrical safety guidelines Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used.
Page 72 13.3.2 Product ingress considerations & servicing Leaves: it is important to keep the Cosy 6 clear from garden debris such as leaves, ● bushes or tree branches. As outlined above, a suitable location should be chosen in order to avoid these materials entering the unit. In the case that garden debris has built up around the unit, especially after ○...
Page 73: Noise Trouble-Shooting
Ask the customer to check that both the indoor and outdoor units are switched on and check that the customer’s Octopus Energy app is connected to the system. If both are on and the issue remains, the customer should check the circuit breaker for a tripped circuit.
Page 74 13.7 Repairs involving refrigerant 13.7.1 Refrigerant leak detection If a refrigerant leak is suspected an engineer should be called immediately and all electronics and sources of ignition should be kept clear of the unit. A refrigerant leak will result in the unit working harder to meet the demand and if it continues the unit could stop working altogether.
Page 75: Refrigerant Charging Procedures
Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to ﬁll until the working pressure is achieved, then venting to atmosphere, and ﬁnally pulling down to a vacuum. This process shall be repeated until no refrigerant is within the system. When the ﬁnal OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place.
Page 76 13.7.5 Repair to intrinsically safe components Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a ﬂammable atmosphere.
Page 77 14. Decommissioning 14.1 Uninstalling the unit Ensure heat and hot water demand have been switched off at the Cosy Hub and that the heat pump has entered standby mode. 2. Isolate power to the outdoor unit. To ensure the unit is safe from electrical risks, allow 10 minutes before interacting with the unit, as some components will require time to discharge.
Page 78 good condition. Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult the manufacturer if in doubt.
Page 79 8. Make sure that cylinder is situated on the scales before recovery takes place. 9. Start the recovery machine and operate in accordance with the manufacturer's instructions. 10. Both gauges on the refrigerant recovery manifold should read and maintain a negative pressure of 0.3mbar to ensure the unit is free of refrigerant.
Page 80: Appendix I: Diagrams Of Cosy
Appendix I: Diagrams of Cosy 6 ver. 4 - 09 Oct 24 - 80 -...
Page 81 ver. 4 - 09 Oct 24 - 81 -...

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Cosy 6