Residential Heat Pump Water Heaters Model R060 Installation - Operation Manual Important Note Read this entire manual before beginning installation Manufactured By: 6670-A Corners Industrial Court Norcross, GA. 30092 770-734-9696 Fax 770-453-9323 Email: sales@aers.com
2 Table of Contents Introduction..3 Installation Specifications...4 Location... 5 Plumbing... 6 Condensate Drain... 7 Electrical Connections... 7 Start-Up... 8 Selector Switch... 8 Dimensional Data... 9 Diagrams Plumbing Connections...6 Electrical Connections... 8 Electrical Schematic.11 Warranty Statement.. 12
3 Introduction The R060 Heat Pump Water Heater (HPWH) is an energy-saving appliance that heats water by extracting heat from the surrounding air. The integral refrigeration system also captures the heat generated by the compressor motor and the refrigeration compression cycle, and adds that to the sensible and latent heat extracted from the surrounding air. Potable water is circulated through the R060, heated and returned back into the tank of a conventional electric water heater (Max wattage 5500). The electric water heater must have operating thermostats and a maximum 5.5 KW heating element, rated for a 240-1-60 electrical circuit. The electric water heater tank will provide hot water storage while the tank thermostat controls the operation of the heat pump, and the resistive heat elements provide back-up heating. The R060 recovers about 24 gallons per hour and can provide a tank temperature up to 120 F. A Selector switch is located on the front of the unit that will accommodate manually switching the system into By-pass (Electric Resistive Heating) in the event of a heat pump system problem or turning the system off for no water heating. When installed correctly, the system will not operate in Heat Pump and Electric Resistive Heating simultaneously. CAUTION!! A Hazardous condition is created by overloading the electrical circuit if both the Heat Pump and Electric Resistive Heating systems are allowed, or forced, to operate at the same time. The heat pump cycles on when the tank-mounted thermostat demands water heating and will remain on until the tank thermostat is satisfied. Cool dry air is a by-product emitted from the HPWH. If the surrounding air temperature drops below 46 F, the Air Temp Safety switch will divert power from the Heat Pump to the Resistive Heat Element in the tank. This is to insure continuous water heating continuity. If the surrounding air temperature rises above 100 F (38 C) the system may go out on High Head Pressure at which time power is automatically diverted to the resistive heat element. CAUTION!! Before beginning installation, read this entire manual. Check with the local building, electrical, and plumbing code authorities. If there is any discrepancy between the installation instructions and these or other local codes, adhere to the code requirements. Some municipalities require a building permit before installation. The Heat Pump Water Heater must be installed by qualified persons in the electrical and plumbing fields.
4 Specifications VOLTAGE: 208/230 VAC PHASE: Single FREQUENCY: 60 Hz FULL LOAD AMPS: 8 @ 208 VAC; 7 @ 230 VAC LOCKED ROTOR AMPS: 28 @ 208 VAC; 31 @ 230 VAC See electric water heater requirements for required circuit ampacity. AMBIENT TEMPERATURE Minimum Air Temperature: 46-50 F (7.7-10 C) OPERATING RANGE: (Depends upon relative humidity and inlet water temperature). Maximum Air Temperature: 100 F (38 C) May be extended to 110 F (43 C) if maximum water temperature is limited to 120 F (49 C) Maximum Water Temperature: 125 F (52 C) WEIGHT: 95 Pounds ELECTRIC WATER HEATER SELECTION Recommended Tank Capacity: Residential Applications Based Upon Family Size Family Size (Persons) 1 2 3 4 5 6 8 Tank Capacity (Gallons) 40 52* 52 66 66 82 82-120 Important: A 30 gal. Tank may be suitable for use in climates that are warm year round (e.g., Hawaii & South Florida), however, inadequate storage capacity may cause hot water shortages during extended hot water usage.
5 MODEL R060 INSTALLATION INSTRUCTIONS WARNING The R060 Heat Pump Water Heater (HPWH) must be installed in accordance with local and national codes and the instructions in this manual. Before beginning the installation, read the entire manual and check the local and national building, electrical, and plumbing codes or authorities. Some municipalities require a building permit. Failure to install according to these instructions and codes may result in property damage, bodily injury, or death. The R060 heat pump water heater is designed to connect to an electric resistance water heater. The electric water heater must have operational thermostats and elements. The tank provides hot water storage; the tank thermostats control the operation of the R060, and the elements are used only for back-up heating. The R060 must be: Installed in a location where the HPWH is exposed to temperatures between 45ºF and 100ºF. Installed and connected to an electric water heater (WILL NOT WORK WITH A GAS HEATER) Installed on an electric water heater with heating element capacity of 5,500 watts or less. INSTALLATION Note: Attic installations are not recommended because of high temperature extremes and the possibility of water damage if a water leak occurs. Location 1. The R060 can be set on a shelf that will support 120 lbs minimum. Care should be exercised when mounting the R060 that vibration and noise are not transmitted to other areas. 2. Install the base of the R060 at a height no higher than the top of the water heater. Installing the R060 higher may cause the pump to become air locked. 3. Piping between the R060 and the electric water heater should be kept as short as possible and be well insulated to minimize heat loss. WARNING Before beginning work, disconnect the power to the electric water heater by turning the circuit breaker to the off position or by removing the fuse. Failure to do so may result in property damage, bodily injury, or death. Plumbing The R060 may be connected to the electric water heater using the method as shown in Figure 1.
FIGURE 1. R060 PLUMBING CONNECTIONS FOR STANDARD ELECTRIC WATER HEATER TANK 6 The water connections on the unit drawing above are for reference ONLY! See page 10 for actual location of connections
7 Any heat traps or check valves in the cold water inlet opening of the electric water heater must be removed. The R060 will not operate unless all the air has been purged from the unit and water pipes. To purge the air when using the coaxial connection see Figure 1 and follow these steps: 1. Connect a garden hose to the boiler drain valve and put male end of hose where flowing water will not case a problem 2. Turn on the cold water supply valve A to the water heater 3. Open stop valve C 4. Open the drain valve H and allow water to flow from the tank through the R060 and out of the garden hose, and 5. When all the air has been purged, open valve B and close the drain valve H Note: An automatic air vent may be installed on the highest point on the inlet water line that connects the R060 to the water heater to bleed air from the water lines. If the air bleed valve is used, the purging procedures detailed above must still be followed. Condensate Drain The condensate drain is 1/2 OD, use 1/2 ID clear flexible tubing, to create a condensate trap, an external trap is required. The condensate should be drained to a suitable location or disposed of with a condensate pump. Do not pull on the condensate line, and secure 1/2 clear tubing with a hose clamp. Electrical Connections For new electric water heater installations, size the power supply breaker (or fuse) and wires from the power supply to the heat pump and from the heat pump to the tank elements, to handle the amp capacity requirements of the tank elements. Follow the local codes and the job site requirements. Connect the heat pump/water tank combination using the same size wire and over current protection as if only the electric water heater tank was being installed. All wires should be run in approved conduit with strain relief fittings. Provisions for 1/2 conduit connects are in the side panel of the R060. The same wires that connect to the existing water heater are used to power the R060 and water heater combination. 1. Make sure circuit breaker is OFF and connect the 208/230V power line to terminals L1 and L2 and the ground wire to the ground terminal in the R060 as shown in Figure 2. 2. Connect #10 wire and ground between terminals H1 and H2 and the wires in the tank. 3. All wires should be run in approved conduit with strain relief fittings.
8 Figure 2. Electrical Connections
9 Start-Up 1. Air must be purged from the R060 as described in the Plumbing Section. Fully open the valve on the cold water inlet. 2. Set the water heater tank thermostats to 120ºF or lower, by removing the tank thermostat covers and manually adjusting the thermostats. An upper thermostat setting of 120ºF and a lower thermostat setting of 115ºF (near the lowest setting on thermostats that are not marked in ºF) will often be satisfactory. Efficiency and energy savings decrease as set point temperature is raised. 3. After replacing the tank thermostat covers, turn the power on at the circuit breaker or fuse box. The unit should come on immediately. If the unit is operating properly, the air passing through the R060 will be cooled. 4. Record the date of installation, model number, serial number, installers name, address, and telephone number in this installation manual. Retain this installation manual for future reference. 5. If the thermostats are set too high, the entering water temperature will become too high and the compressor will trip out on high discharge pressure. If this condition occurs a manual reset is required to resume heat pump water heating operation. Corrective action would be to lower the tank thermostat settings. IMPORTANT NOTE If the high pressure switch cycles off after a few minutes of operation, the fault is probably lack of water flow caused by an air lock in the pump or a clogged water line. There will be a large temperature (20º +) difference between the inlet and outlet fittings on the HPWH. If the unit goes off on high pressure after the tank is heated to 120ºF, either one or both of the tank thermostats are set too high. Selector Switch The R060 has a three-position selector switch to operate the heat pump or the elements. A. Element B. Not used / off C. Heat Pump Water Heater
10 R060 Dimensional Data
11 FIGURE 3. ELECTRICAL SCHEMATIC DIAGRAM
12 LIMITED WARRANTY All Residential R Series Heat Pumps Your E-Tech Heat Pump Water Heater is backed by this three-part warranty to provide you warranty protection covering manufacturing defects materials and workmanship as follows: PERIOD OF COVERAGE The first 90 days: From 91 days to 365 days: TYPE OF COVERAGE All reasonable charges necessary to correct any manufacturing defect will be paid by AERS. AERS will furnish new or rebuilt parts to replace any parts which are defective in materials and workmanship. The owner must pay the charges for labor, transportation and freight. NOTE: A separate Service or Maintenance Agreement covering those costs excluded from this warranty may be available from the seller at the time of purchase. The warranty begins at the date of installation or 180 days from the date the unit was manufactured whichever is first. The above warranty applies only if the installation and operating instructions applicable to the model purchased are expressly and completely followed and applies only to units installed in the United States of America, but not territories. THIS WARRANTY CONSTITUTES THE EXCLUSIVE REMEDY OF ANY PURCHASER OF AERS HEAT PUMP WATER HEATERS AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR USE, TO THE FULLEST EXTENT PERMITTED BY LAW. IN NO EVENT SHALL ANY IMPLIED WARRANTY OF MERCHANT- ABILITY OR FITNESS FOR USE EXCEED THE TERMS OF THE APPLICABLE WARRANTY STATED ABOVE AND AERS SHALL HAVE NO OTHER OBLIGATION OR LIABILITY. IN NO EVENT SHALL AERS BE LIABLE FOR IN- CIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. Repairs must be performed by AERS or by an authorized Service Center. If there is no authorized Service Center in the area, AERS will assist you to find someone qualified to make the repairs, or may option to have the unit returned to the factory for repair. When contacting the dealer, service center, or AERS, please provide the model number and serial number of the unit as well as the date of purchase as established by a bill of sale. SPECIAL NOTE: The warranty statements printed in this Owner s Manual are the only warranties made by AERS and may not be altered, enlarged, or changed by anyone. The statements clearly specify that the warranty applies only if the applicable installation and application instructions are expressly and completely followed. Applied Energy Recovery Systems, Inc. 6670-A Corners Industrial Norcross, GA 30092 770-734-9696 Fax 770-453-9323 email: residential@aers.com