Heat Pump Technology Offers a High-Efficiency Solution for HVAC and More

By Heilind Electronics

Heat pump technology has emerged as a powerful solution in the push toward energy efficiency for a wide variety of applications. Heat pumps can be utilized in residential and industrial HVAC systems, appliances such as clothes dryers and water heaters, and even electric vehicles. Unlike conventional heating systems that generate heat through combustion or resistance, heat pumps transfer heat from one location to another using a refrigeration cycle, making them significantly more efficient, saving money for consumers and building managers, as well as introducing functional improvements in operations.

A heat pump is a closed-loop system involving a refrigerant, compressor, expansion valve, and two heat exchangers (evaporator and condenser). During heating, the system extracts thermal energy from a low-temperature source — such as ambient air, water, or the ground — and elevates it to a usable temperature via compression. For cooling, the process is reversed. Coefficients of performance (COPs) for modern systems range from 3 to 5, meaning for every unit of electrical energy input, 3–5 units of heat are transferred.

The versatility of heat pump technology opens opportunities for system integration in HVAC, district energy systems, and industrial waste heat recovery. They provide both heat and air conditioning, making them ideal for new builds. In rapidly warming climates such as northern Europe, buildings that pre-date air conditioning are being retrofitted with heat pumps (also called mini splits), enabling people in historic cities to cool down and reducing the need for costly fuel. Air-source heat pumps (ASHPs) are cost-effective and easy to install, though their efficiency drops in cold climates. In very cold climates, a supplemental system is still required, although newer systems function at temperatures as low as -22° F.

Heat pumps are still an emerging trend, and engineers are continuously improving these systems and integrating them into new products. Recent developments include the use of CO₂ and other low-GWP refrigerants, variable-speed compressors for improved load matching, and hybrid systems that pair heat pumps with conventional boilers or thermal storage.

For electronics engineers, the evolution of heat pump technology presents a growing demand for precise control, efficient power management, and robust communication systems. Modern heat pumps rely heavily on embedded systems, power electronics, and sensor networks to achieve optimal performance and adaptability in varying environmental conditions. Interconnects are used extensively throughout heat pump systems, particularly within the electronic control architecture.

Interconnects in heat pump architectures

Interconnects within the heat pump’s electronic control system must be designed for reliability in thermally and electrically harsh environments. High-temperature PCBs, vibration-resistant connectors, and EMI-shielded cables are essential. Data communication between sensors (temperature, pressure, and flow sensors) and the control board often uses protocols like I²C, SPI, or CAN bus, depending on system complexity and required data integrity.

Omron’s connectors are engineered to perform in the most challenging HVAC and appliance environments, withstanding extreme temperatures, moisture, and vibration. Featuring secure locking mechanisms, compact designs, and high conductivity, these connectors ensure stable and efficient electrical connections.

Additionally, heat pumps increasingly integrate with smart home automation and energy management systems, requiring secure and reliable wireless modules. These interfaces support wireless updates and diagnostics in Internet of Things systems. Safety and regulatory compliance are also central concerns. Engineers must ensure compliance with standards like IEC 60335 for household appliances and manage insulation, creepage, and clearance distances on PCBs.

Molex’s Edge Matewire to edge card connector mates directly to the PCB edge card without a mating header, reducing inventory, bill-of-material, and manufacturing costs without having to invest in headers. This is compliant with IEC 60335 safe appliance standards.

Explosion-proof construction

HVAC systems involve refrigerants, which call for an additional level of safety consideration. Systems using A2L refrigerants require explosion-proof relays to prevent the ignition of flammable substances, making them essential components in systems using A2L refrigerants. These relays are engineered to withstand potential hazards associated with flammable environments, ensuring the safety of both the equipment and the surrounding area. By utilizing explosion-proof relays, the risk of ignition due to electrical arcing or sparking is significantly reduced.

OMRON’s explosion-proof relays adhere to IEC/EN 60079-15, which specifically addresses equipment protection in explosive atmospheres. These relays undergo rigorous testing to confirm their non-flammability and compliance with safety regulations.

Connecting these relays requires specialized connectors that can maintain the integrity of explosion-proof enclosures while supporting electrical reliability. To ensure the safety and longevity of heat pump systems that are exposed to near continuous operation, extreme heat and extreme cold, and vibration, it’s important to work with a supplier that can advise on issues of quality, performance, and safety, as well as standards adherence and compatibility across multiple component types and vendors. As heat pumps become smarter and more connected, they will become a more important part of modern energy ecosystems.

Visit Heilind to learn more about solutions for heat pumps and other HVAC systems.