A.O. Smith AWH-35, AWH-170 Technical Documents
Instruction Manual
COMMERCIAL ELECTRIC AIR-TO-WATER HEAT PUMP WATER HEATER
MODELS AWH-35 to AWH-170
SERIES 100
820 SW 41st Street
Renton, WA 98057
INSTALLATION - OPERATION - SERVICE
MAINTENANCE - LIMITED WARRANTY
FOR INDOOR INSTALLATION ONLY
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
PLACE THESE INSTRUCTIONS ADJACENT TO HEAT PUMP AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0114 318653-000
TABLE OF CONTENTS
TABLE OF CONTENTS .......................................................................... 3
SAFE INSTALLATION, USE AND SERVICE..........................................4
GENERAL SAFETY INFORMATION ...................................................... 5
Precautions ........................................................................................ 5
Grounding Instructions ...................................................................... 5
INTRODUCTION .................................................................................... 6
Qualications ..................................................................................... 6
Preparing For The Installation ...........................................................6
Principle Of Operation .......................................................................7
The Refrigeration Cycle .............................................................. 7
Air Temperature Range...................................................................... 7
Water Temperature Range ................................................................ 7
Refrigerant Charge ............................................................................ 7
Equipment Disposal ........................................................................... 7
FEATURES AND COMPONENTS ......................................................... 8
Product Illustrations ........................................................................... 8
Rough In Dimensions ........................................................................9
Performance Specications ............................................................... 9
INSTALLATION REQUIREMENTS ...................................................... 10
Water Temperature .......................................................................... 10
Maximum System Temperature ................................................ 10
Inlet & Outlet Water Temperature .............................................. 10
Air Temperature ............................................................................... 10
Entering Air Temperature .......................................................... 10
Locating The Water Heater .............................................................. 10
Indoor Installation Only ............................................................. 10
Freezing Temperatures ............................................................. 10
Coastal Regions ........................................................................ 10
Heat Source .............................................................................. 10
Conditioned Space .................................................................... 10
Unconditioned Space .................................................................11
Clearances .......................................................................................11
Electrical Requirements ....................................................................11
Voltage & Amperage Ratings .....................................................11
Minimum Circuit Ampacity & Maximum Fuse Size .................... 12
Minimum Wire Size ................................................................... 12
Water Piping .................................................................................... 13
Maximum Pipe Length .............................................................. 13
Minimum Pipe Size ................................................................... 13
Pipe Support ............................................................................. 13
Pipe Insulation ........................................................................... 13
Cold Water Supply .................................................................... 13
Water Pressure ................................................................................ 13
Closed Water Systems .................................................................... 13
Thermal Expansion .......................................................................... 13
Mixing Valves ................................................................................... 13
Condensate Removal ...................................................................... 14
Contaminated Water ........................................................................ 14
Temperature - Pressure Relief Valve ............................................... 14
Tank Selection ................................................................................. 14
Contaminated Air ............................................................................. 14
Storage & Handling ......................................................................... 15
INSTALLATION .................................................................................... 16
Required Tools and Materials .......................................................... 16
Installation & Start Up Tools ...................................................... 16
Service Tools ............................................................................. 16
Unit Placement ................................................................................16
Ceiling Suspension ................................................................... 16
Pad Mounting ............................................................................ 16
Electrical Connections ..................................................................... 17
Correct Voltage And Phase ....................................................... 17
Branch Circuit Disconnect Switch ............................................. 17
Transformer Conguration 208 VAC Models ............................. 17
Water Connections .......................................................................... 17
Installation Instructions ............................................................. 17
Single Tank Conguration ................................................................ 18
Two Tank Pre Heat Conguration .................................................... 18
Condensate Drain Line .................................................................... 18
Standard Tank Thermostat .............................................................. 18
Digital Tank Thermostat Installation ................................................. 19
Temperature Sensor Installation ...................................................... 19
Air Flow and Ducting ....................................................................... 19
Duct Sizing ................................................................................ 19
Duct Insulation .......................................................................... 19
Make Duct Connections ............................................................ 19
Building Air Pressure ................................................................. 19
When To Install Ducting ............................................................ 20
Supply Air Ducting ..................................................................... 20
Return Air Ducting ..................................................................... 20
Blower Assembly Adjustments ......................................................... 20
INSTALLATION CHECKLIST ...............................................................22
START UP ............................................................................................23
Digital Tank Thermostat ................................................................... 24
MAINTENANCE AND SERVICE .......................................................... 25
Routine Maintenance ....................................................................... 25
TROUBLESHOOTING ......................................................................... 27
Checking Refrigerant Charge .......................................................... 28
Subcooling Calculation .............................................................. 28
Superheat Calculation ............................................................... 28
CONTROL SYSTEM ............................................................................ 29
Control Board ............................................................................ 29
Pressure Switches .................................................................... 29
Phase Monitor ........................................................................... 30
Compressor Overload Module .................................................. 30
Delay Timers ............................................................................. 30
How To Reset The Control System ........................................... 30
WIRING DIAGRAMS ............................................................................ 31
Thermostat And Accessory Wiring Diagrams .................................. 37
Digital Tank Thermostat Wiring ................................................. 37
Standard Tank Thermostat Wiring ............................................. 38
High Ambient Air Kit Wiring ....................................................... 39
Building Recirculation Pump Wiring Diagram ........................... 40
PIPING DIAGRAMS ............................................................................. 41
LIMITED WARRANTY .......................................................................... 47
3
SAFE INSTALLATION, USE AND SERVICE
The proper installation, use and servicing of this commercial heat pump water heater is extremely important to your safety and the
safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own heat pump water heater to warn
you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use, or service this heat pump water
heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently
DANGER
WARNING
CAUTION
hazardous situation which, if not avoided,
will result in injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
CAUTION
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
appliance can cause low level exposure to some of the substances listed in the Act.
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
4
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualied service agency to
inspect the appliance and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
agency.
1. External re.
2. Damage.
3. Running without water.
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
CONTAINS REFRIGERANT!
System contains oil and refrigerant under high pressure. Recover
refrigerant to relieve pressure before opening the system. See unit
rating label for refrigerant type. Do not use non-approved refrigerants,
refrigerant substitutes, or refrigerant additives.
Failure to follow proper procedures or the use of non-approved
refrigerants, refrigerant substitutes, or refrigerant additives could
result in death or serious injury or equipment damage.
GROUNDING INSTRUCTIONS
This heat pump water heater must be grounded in accordance
with the National Electrical Code and/or local codes. These must
be followed in all cases. Failure to ground this water heater
properly may also cause erratic control system operation.
This heat pump water heater must be connected to a grounded
metal, permanent wiring system; or an equipment grounding
conductor must be run with the circuit conductors and connected
to the equipment grounding terminal or lead on the water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Explosion Hazard
Do not use oxygen to purge or
pressurize system for leak test.
Oxygen reacts violently with oil,
which can cause an explosion
resulting in severe personal
injury or death.
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided
on connected storage tanks.
5
INTRODUCTION
Thank You for purchasing this heat pump water heater. Properly
installed and maintained, it should give you years of trouble free
service.
Abbreviations found In this Instruction Manual include:
• HPWH - Heat Pump Water Heater
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• AHRI - Air-conditioning, Heating and Refrigeration Institute
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY:
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI
below) in the eld involved. Installation skills such as plumbing,
electrical supply are required in addition to electrical testing skills
when performing service.
This heat pump water heater contains R-134a refrigerant and is
regulated as a stationary refrigeration appliance under Section
608 of the Clean Air Act. Servicing of the refrigeration circuit must
only be performed by agencies or individuals possessing Type II
or Universal certication as dened in Section 608 of the Clean
Air Act.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
PREPARING FOR THE INSTALLATION
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
1. Read the “General Safety Information” section of this manual
rst and then the entire manual carefully. If you don’t follow
the safety rules, the heat pump water heater may not operate
safely. It could cause DEATH, SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation,
operation, and maintenance of the heat pump water heater
(HPWH). It also contains warnings throughout the manual
that you must read and be aware of. All warnings and all
instructions are essential to the proper operation of the
HPWH and your safety. READ THE ENTIRE MANUAL
BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS
WATER HEATING APPLIANCE.
Detailed installation diagrams are in this manual. These
diagrams will serve to provide the installer with a reference
for the materials and suggested methods of piping. IT
IS NECESSARY THAT ALL WATER PIPING AND THE
ELECTRICAL WIRING BE INSTALLED AND CONNECTED
AS SHOWN IN THE DIAGRAMS.
Particular attention should be given to the installation of the
system (tank) temperature control. See page 19.
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
Be sure to turn off power when working on or near the
electrical system of the heat pump. Never touch electrical
components with wet hands or when standing in water.
When replacing fuses always use the correct size for the
circuit. See Unit Wiring Diagrams-Fuse Sizes, pages 32-36.
The principal components of the HPWH are identied in the
Features And Components section of this manual on page
8. The rating label on the HPWH also provides useful
information. These references should be used to identify the
heat pump, its components and optional equipment.
2. The installation must conform with these instructions and the
local code authority having jurisdiction and the requirements
of the power company. In the absence of local codes, the
installation must comply with the latest editions of the
National Electrical Code, ANSI/NFPA 70 or the Canadian
Electrical Code CSA C22.1. The National Electrical Code
may be ordered from: National Fire Protection Association,
1 Batterymarch Park, Quincy, MA 02269. The Canadian
Electrical Code is available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland,
OH 44131.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions DO NOT proceed
with the installation. Call the toll free number listed on the
back cover of this manual for technical assistance.
4. In order to expedite your request, please have full model and
serial number available for the technician.
5. Carefully consider your intended placement and location for
the HPWH. See Locating The Water Heater on page 10
6. Installation and service of this HPWH requires ability
equivalent to that of a licensed tradesman or Qualied Agency
in the eld involved. See Qualications on page 6.
7. For installation in California the HPWH appliance must be
braced or anchored to avoid falling or moving during an
earthquake. Instructions may be obtained from California
Ofce of the State Architect, 1102 Q Street, Suite 5100,
Sacramento, CA 95811.
6
8. Ensure the power supply voltage and phase at the job site
matches the power requirements on the HPWH rating label
before installation begins. Energizing the HPWH with the
wrong voltage or phase will cause permanent damage to the
unit.
PRINCIPLE OF OPERATION
The appliances covered by this Instruction Manual are
commercial air-to-water heat pump water heaters (HPWH).
Operation of the HPWH is similar to that of a package air
conditioning system though the HPWH is designed for indoor
installation only. The primary difference in operation is that
the HPWH unit utilizes the heat removed from the conditioned
space to heat water where package air conditioning systems
discard this heat outdoors. Recovering and using this waste heat
increases the overall energy efciency of the building.
THE REFRIGERATION CYCLE
Refer to Figure 1 on page 8 for the location of components
mentioned in this section.
Refrigerant is circulated through the refrigeration circuit by a
Compressor (1). The refrigerant is a high temperature high
pressure gas when it leaves the compressor. Refrigerant
ows from the compressor through the Hot Gas Line (2) to the
Condenser (3).
The condenser is a refrigerant-to-water heat exchanger with two
circuits, refrigerant ows through one circuit and water through
the other. The high temperature refrigerant gas transfers its heat
to the water owing through the condenser. As the refrigerant
gas cools inside the condenser it changes state (condenses)
from a gas to a liquid. A Water Pump (B) circulates water through
the condenser.
Refrigerant leaving the condenser is a medium temperature
high pressure liquid. It ows through the Liquid Line (4) to the
Thermostatic Expansion Valve (5). The thermostatic expansion
valve (TXV) regulates the ow of refrigerant into the Evaporator
(6). The evaporator is a tube-and-n constructed coil. It is an airto-refrigerant heat exchanger with refrigerant owing through the
tubes and air owing across the ns.
The Blower moves ambient air from the installed space or air
ducted to the HPWH from another location across the ns of
evaporator coil. The refrigerant absorbs heat from the air in the
evaporator. The refrigerant changes state (boils/evaporates)
from a liquid state back into a gas (vapor) in the evaporator.
The refrigerant ows out of the evaporator through the Suction
Line (7) and into the Accumulator (8). The accumulator traps any
liquid refrigerant the evaporator is unable to vaporize during low
temperature operating conditions. The accumulator prevents
liquid refrigerant from entering the compressor where it could
damage internal components.
Low temperature low pressure refrigerant gas (vapor) is drawn
out of the accumulator by the compressor. The compressor
increases the pressure and temperature of the refrigerant gas
circulating it to the condenser again where the refrigeration cycle
starts over or continues.
AIR TEMPERATURE RANGE
The entering air temperature operating range for the HPWH is
50°F to 95°F (10°C to 35°C).
When the HPWH is operating properly the air temperature drop
through the evaporator (heat exchanger) will be approximately
12°F to 20°F (7°C to 11°C).
WATER TEMPERATURE RANGE
The inlet (entering) water temperature operating range for the
HPWH is 50°F to 140°F (10°C to 60°C).
When the HPWH is operating properly the water temperature rise
through the condenser (heat exchanger) will be approximately
8°F to 12°F (4°C to 7°C).
REFRIGERANT CHARGE
The HPWH is factory-charged with R-134a refrigerant. The
refrigerant charge is weighed in at the factory. See Table 9
on page 28. It should not be necessary to add or remove
refrigerant during installation or start up.
EQUIPMENT DISPOSAL
This heat pump water heater contains R-134a refrigerant and is
regulated as a stationary refrigeration appliance under Section
608 of the Clean Air Act. Disposal of this unit must be performed
in accordance with the provisions in Section 608 of the Clean Air
Act and any state or local regulations that may also apply. See
Qualications on page 6.
7
PRODUCT ILLUSTRATIONS
COMPRESSOR
CONTROL
PANEL
WATER
PUMP
FEATURES AND COMPONENTS
ACCUMULATOR
THERMOSTATIC
EXPANSION VALVE (TXV)
EVAPORATOR COIL
(HEAT EXCHANGER)
(AIR TO REFRIGERANT)
BLOWER
MOTOR
RETURN AIR
INLET
(AIR FILTERS)
CONDENSER
(HEAT EXCHANGER)
(REFRIGERANT TO WATER)
SUPPLY AIR
OUTLET
WARM RETURN
AIR IN
COOL SUPPLY
AIR OUT
CONDENSATE
BLOWER
COMPONENT REFRIGERATION CIRCUIT
1) COMPRESSOR
2) HOT GAS LINE
3) CONDENSER / HEAT EXCHANGER
4) LIQUID LINE
5) THERMOSTATIC EXPANSION VALVE (TXV)
6) EVAPORATOR
7) SUCTION LINE
8) ACCUMULATOR
COMPONENT WATER CIRCUIT
A) WATER INLET
B) WATER PUMP
C) HEAT EXCHANGER / CONDENSER
D) WATER OUTLET
DRAIN
REFRIGERANT STATE
GAS
GAS
GAS TO LIQUID
LIQUID
LIQUID
LIQUID TO GAS
GAS
GAS / LIQUID
Figure 1
8
ROUGH IN DIMENSIONS
Figure 2
PERFORMANCE SPECIFICATIONS
TABLE 1
PERFORMANCE
MODEL
NUMBER
AWH-35 10.4 35,500 27,500 2.3 3.9 1040 7 1.0” 40” 26” 24.75” 7" 315
AWH-55 17.0 58,000 45,500 3.8 4.1 1650 11 1.0” 47” 32” 28.5” 7" 405
AWH-75 22.3 76,000 59,000 4.9 3.9 2150 15 1.5” 57” 32” 28.5” 7" 485
AWH-100 28.7 98,000 78,000 6.5 4.2 3200 20 1.5” 63” 38” 42.5” 8" 660
AWH-115 33.1 113,000 89,000 7.4 4.2 3200 23 1.5” 63” 38” 42.5” 8" 665
AWH-140 41.6 142,000 110,000 9.2 3.9 3800 28 2.0” 63” 38” 42.5” 8" 725
AWH-170 50.1 171,000 133,000 11.1 3.9 4900 34 2.0” 75” 46” 42.5” 8" 880
All dimensions are in inches. Weights are approximate shipping weights.
*Performance rating at 75ºF Entering Air Temperature and 55% Relative Humidity, 100ºF Entering Water Temperature.
** Blower design at 0.35” external static pressure.
C. O. P. = Coefcient Of Performance
All models standard 208/230 VAC, 3Ø, 60 Hz
Optional 460 VAC, 3Ø, 60 Hz
Optional 208/230 VAC, 1Ø, 60 Hz available on AWH-35 and AWH-55 only
WATER
HEATING
CAPACITY
kW Btu/hr* Btu/hr Tons
COOLING
CAPACITY
COP
AIR
VOLUME
(CFM)
WATER
FLOW
(GPM)
INLET
OUTLET
WATER
(FPT)
DIMENSIONS
WIDTHADEPTHBHEIGHT
C
D
WEIGHT
(LBS)
9
INSTALLATION REQUIREMENTS
CAUTION
Read all installation requirements in this manual before installation
begins. The installation must conform to these instructions and
all local and national code authority having jurisdiction.
Costs to diagnose, perform service and repair damage caused
by installation errors are not covered under the limited warranty.
Costs to correct installation errors are not covered under the
limited warranty.
WATER TEMPERATURE
MAXIMUM SYSTEM TEMPERATURE
The HPWH units covered in this manual are capable of
maintaining a maximum system/storage tank temperature of
140°F (60°C). Some commercial water heating applications
may require higher temperatures. Install a booster water heater
downstream from the storage tank for temperatures above
140°F (60°C). See Figure 8 on page 18.
INLET & OUTLET WATER TEMPERATURE
The inlet (entering) water temperature operating range for the
HPWH is 50°F to 140°F (10°C to 60°C). The water temperature
rise (Delta T - ∆T) through the condenser (heat exchanger) will
be approximately 8°F to 12°F (4°C to 7°C).
Outlet water temperatures up to 152°F (67°C) are possible
during normal operation. Exposure to water temperatures this
high can cause serious bodily injury or death. See Mixing Valves
and Table 5 on page 14.
Service & Installation Notes:
If the inlet (entering) water temperature is outside the operating
temperature range for extended periods the control system may
lock out on high or low refrigerant pressure switch events/trips.
When the control system locks out on a refrigerant pressure
switch event the compressor will stop running, the blower and
circulation pump (on models equipped with factory installed
pump) will continue to operate. This is a hard lock out condition.
The control system is manually reset by cycling power to the
HPWH off and then on again.
The tank thermostat must not be set any higher than 140°F
(60°C) to prevent control system lock outs.
Ground water temperatures can fall below 50°F (10°C) for
extended periods during winter months in many regions. For this
reason the cold water supply lines and should not be connected
directly to the HPWH inlet or T tted into the inlet (return) water
piping. The cold water supply lines should be connected directly
to the storage tank only. See the Piping Diagrams on page 41
in this manual for more information.
AIR TEMPERATURE
ENTERING AIR TEMPERATURE
The return (entering) air temperature range of operation for
the unit is 50° - 95°F (10°C to 35°C). The air temperature drop
(Delta T - ∆T) through the evaporator (heat exchanger) will be
approximately 12°F to 20°F (7°C to 11°C).
If the entering air temperature is outside this operating range
the HPWH unit’s Ambient Air Limit Thermostat will discontinue
heating operation until the entering air temperature returns to this
operating range. See Figure 15 on page 37.
High Ambient Air Kits are available that will allow the unit to
operate with entering air temperatures up to 120°F (49°C). These
accessory kits must be installed if entering air temperatures
exceed 95°F (35°C) for extended periods.
Contact your local distributor or call the technical support
phone number listed on the back cover of this manual for more
information on ordering one of these accessory kits.
Service & Installation Notes:
When the High Ambient Air kit is installed the heating stage set
point on the Ambient Air Limit thermostat must be raised to 120°F
(49°C) to allow heating operation up to this temperature.
LOCATING THE WATER HEATER
PROPERTY DAMAGE!
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
INDOOR INSTALLATION ONLY
The HPWH unit is designed for indoor installation only.
Carefully choose a location for the HPWH unit. Placement is a
very important consideration for optimal performance and safety.
Locate the HPWH near a oor drain. The unit should be located
in an area where leakage from the HPWH unit or the storage tank
it is connected to will not result in damage to the area adjacent
to the water heater or to lower oors of the structure. See Unit
Placement on page 16.
FREEZING TEMPERATURES
The HPWH unit must not be installed in space where freezing
temperatures will occur. Exposure to freezing ambient
temperatures below 32°F (0°C) may result in severe damage to
internal components. Damage caused by exposure to freezing
temperatures is not covered under the limited warranty.
COASTAL REGIONS
When the HPWH will be installed within 5 miles of a seacoast the
optional Corrosive Duty Package is required. The corrosive duty
package includes a 316 stainless steel cabinet and a phenolic
coating applied to the evaporator and blower. Damage caused to
units not equipped with the corrosive duty package in coastal
regions is not covered under the limited warranty.
HEAT SOURCE
The HPWH unit should be located where there is an adequate
source of ambient heat and where the cooling benet can be
utilized when possible.
If installation in a space with an adequate heat source is not
possible the HPWH unit can be ducted to/from another space
such as a boiler room or to the outdoors where sufcient heat is
available. See Air Flow and Ducting on page 19.
CONDITIONED SPACE
When installed in a conditioned space ducting supply (outlet) air
to an alternate location may be necessary to avoid over-cooling
of the space where the HPWH is installed or provide spot cooling
in areas for comfort and/or to offset cooling load. See Building Air
Pressure, Air Flow and Ducting on page 19.
10
UNCONDITIONED SPACE
When installed in an unconditioned space ducting return (inlet)
air from an alternate location may be necessary to access an
adequate or greater source of heat for optimal efciency. See
Building Air Pressure, Air Flow and Ducting on page 19.
CLEARANCES
To ensure optimal performance a minimum of 30 inches clearance
is required from the back, left and right sides of the HPWH unit
and any wall obstruction. A minimum of 36 inches clearance on
the front of the unit for access to the control box. See Figure 3
When installed on an equipment pad the HPWH must be level
and elevated at least 6” above oor to avoid dust and debris and
permit connection of the condensate line and trap.
ELECTRICAL REQUIREMENTS
CAUTION
CORRECT POWER SUPPLY!
Ensure the power supply at the job site matches the
•
voltage and phase listed on the HPWH rating label
before connecting power to the HPWH unit.
Energizing the HPWH with the wrong voltage or phase
•
will cause permanent damage to the HPWH unit.
Damage caused to the HPWH as the result of applying
•
the wrong voltage or phase is not covered under the
limited warranty.
Ensure the power supply voltage and phase at the job site
matches the power supply ratings listed on the HPWH rating
label BEFORE INSTALLATION BEGINS.
The installation must conform with these instructions and the
local code authority having jurisdiction and the requirements
of the power company. In the absence of local codes, the
installation must comply with the current editions of the National
Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code
CSA C22.1.
Voltage applied to the HPWH should not vary more than +5% to
-10% of the voltage requirement listed on the HPWH rating label
for satisfactory operation.
VOLTAGE & AMPERAGE RATINGS
Figure 3
TABLE 2
MODEL VOLTS/PHASE/HZ
AWH-35 208-230/1/60 18.60 100.00 29.00 3.60 1/2 0.88 1/8 28 45
AWH-35 208-230/3/60 10.90 77.00 17.00 2.40 1/2 0.88 1/8 17 25
AWH-35 460/3/60 5.40 39.00 8.50 1.20 1/2 0.88 1/8 9 12
AWH-55 208-230/1/60 27.90 175.00 43.50 5.30 3/4 0.88 1/8 42 60
AWH-55 208-230/3/60 19.90 115.00 31.00 3.00 3/4 0.88 1/8 29 45
AWH-55 460/3/60 8.70 63.00 13.50 1.50 3/4 0.88 1/8 13 20
AWH-75 208-230/3/60 24.00 196.00 37.50 3.60 1 0.88 1/8 35 50
AWH-75 460/3/60 11.50 100.00 18.00 1.80 1 0.88 1/8 17 25
AWH-100 208-230/3/60 28.20 225.00 44.00 3.60 1 0.88 1/8 40 60
AWH-100 460/3/60 14.10 114.00 22.00 1.80 1 0.88 1/8 20 30
AWH-115 208-230/3/60 35.30 239.00 55.00 3.60 1 1.00 1/6 49 80
AWH-115 460/3/60 17.90 125.00 28.00 1.80 1 1.00 1/6 25 40
AWH-140 208-230/3/60 48.10 300.00 75.00 4.80 1 1/2 2.50 1/2 68 110
AWH-140 460/3/60 21.80 150.00 34.00 2.40 1 1/2 2.50 1/2 31 50
AWH-170 208-230/3/60 52.60 340.00 82.00 6.20 2 2.50 1/2 75 125
AWH-170 460/3/60 25.60 173.00 40.00 3.10 2 2.50 1/2 37 60
*460 VAC models factory-equipped with step down transformer for 230 VAC pump
Abbreviations:
RLA = Running Load Amps; LRA = Locked Rotor Amps; MCC = Maximum Continuous Current;
FLA = Full Load Amps; MCA = Minimum Circuit Ampacity; MFS = Maximum Fuse Size
COMPRESSOR BLOWER MOTOR PUMP (230 VAC 1Ø)*
RLA LRA MCC FLA HP FLA HP
MCA MFS
11
MINIMUM CIRCUIT AMPACITY & MAXIMUM FUSE SIZE
Table 2 on page 11 provides the MCA (Minimum Circuit
Ampacity) and MFS (Maximum Fuse Size). Use MCA to select
the minimum eld wires size to power the unit and MFS to select
the maximum fuse size for over current protection as follows:
Electrical Shock Hazard
Before removing any access panels or
•
servicing the water heater, make sure
the electrical supply to the water heater
is turned “OFF.”
Failure to do this could result in death,
•
serious bodily injury, or property
damage.
MINIMUM WIRE SIZE
Allowable Ampacities of Insulated Conductors
Single-phase heat pump water heaters are two wire circuits. Three-phase heaters are three wire circuits. In addition to the foregoing,
a grounded conductor is required. Not more than three conductors in raceway, cable, or earth (directly buried), based on ambient
temperature of 30°C (86°F)
TABLE 3
MCA = C x 1.25 + M + P
MFS = C x 2.25 + M + P
Where:
C - Compressor RLA
M - Blower Motor FLA
P - Pump FLA
+The load current rating and the overcurrent protection for these conductors shall not exceed 15 amperes for 14 AWG. 20 amperes for 12 AWG and 30 amperes for
10 AWG copper; or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum and copper-clad aluminum.
*For dry locations only. See 75°C column for wet locations.
12
WATER PIPING
CLOSED WATER SYSTEMS
Read all installation requirements in this manual before
installation begins.
The water piping installation must conform to these instructions
and to all local and national code authority having jurisdiction.
Costs to diagnose, perform service and repair damage caused
by installation errors are not covered under the limited warranty.
Costs to correct installation errors are not covered under the
limited warranty.
MAXIMUM PIPE LENGTH
Factory installed pumps will provide the specied water ow for
up to a total of 50 equivalent feet of water piping between the
HPWH and the storage tank. Example: 25 equivalent feet of inlet
(return) piping and 25 equivalent feet of outlet (supply) piping.
Exceeding these maximum lengths will cause the unit to
malfunction and control system lock outs.
MINIMUM PIPE SIZE
The inlet (return) and outlet (supply) water piping installed
between the HPWH unit and the storage tank must not be smaller
than the water connection sizes on the HPWH. See Table 4 for
water line connection sizes and water ow rates.
Water line sizing is a critical installation requirement. Installing
undersized water piping between the storage tank and the
HPWH unit will cause insufcient water ow and will have an
adverse impact on performance and equipment life.
TABLE 4
WATER CONNECTIONS AND FLOW
UNIT GPM LPM CONNECTION SIZE (INCH)
AWH-35 7 27 1
AWH-55 11 42 1
AWH-75 15 57 1.5
AWH-100 20 76 1.5
AWH-115 23 87 1.5
AWH-140 28 106 2
AWH-170 34 129 2
PIPE SUPPORT
All water piping must be properly supported per local code
requirements.
PIPE INSULATION
All piping installed between the HPWH unit and the storage tank
must be insulated.
COLD WATER SUPPLY
Cold water supply lines should not be connected directly to the
HPWH inlet or T tted into the inlet (return) water piping. The cold
water supply lines should be connected directly to the storage
tank only. See Inlet & Outlet Water Temperature on page 10
and Figure 7 and Figure 8 on page 18.
WATER PRESSURE
System water pressure should be maintained between 40 and 60
PSI. Local code may require, and the manufacturer recommends,
installing a pressure reducing valve (PRV) in the cold water
supply to the building to maintain consistent water pressure.
Water supply systems may, because of code requirements
or such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back ow preventers. Devices such as these cause
the water system to be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase
in water pressure due to thermal expansion. Thermal expansion
can cause premature failure (leakage) of storage tanks, water
heaters and HPWH components such as the condenser.
Leakage caused by thermal expansion is not covered under the
HPWH limited warranty.
Thermal expansion can also cause intermittent TemperaturePressure Relief Valve operation: water discharged due to
excessive pressure build up. The Temperature-Pressure Relief
Valve is not intended for the constant relief of thermal expansion.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed on all closed water systems.
MIXING VALVES
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing,
dish washing, and other sanitizing needs can scald and cause
permanent injury upon contact. See Table 5.
Some people are more likely to be permanently injured by hot
water than others. These include the elderly, children, the inrm
and the physically/mentally disabled. The Table below shows
the approximate time-to-burn relationship for normal adult skin.
If anyone using hot water provided by the water heater being
installed ts into one of these groups or if there is a local code
or state law requiring a certain water temperature at the point of
use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satises the demand of the application a Mixing Valve should be
installed upstream from the building xtures or at the hot water
taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualied Installer or Service Agency. Follow the mixing valve
manufacturer’s instructions for installation of the valves.
13
TABLE 5
Water Temperature
180°F (82°C) Nearly instantaneous
170°F (77°C) Nearly instantaneous
160°F (71°C) About 1/2 second
150°F (66°C) About 1-1/2 seconds
140°F (60°C) Less than 5 seconds
130°F (54°C) About 30 seconds
120°F (49°C) More than 5 minutes
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
CONDENSATE REMOVAL
The HPWH unit produces condensate which must be discharged.
If there is no drain easily accessible, a condensate lift pump must
be installed to discharge the condensate to a remote location. See
Condensate Drain Line on page 18 for installation instructions.
CONTAMINATED WATER
Corrosive Chemical Hazard
Connecting the heat pump to any system other than a water
•
system may lead to premature corrosion of the unit's heat
exchanger and void the unit warranty.
This HPWH unit must not be used to heat any uid other than
water. Corrosive chemicals must not be introduced into the
waterways in this HPWH unit.
TEMPERATURE - PRESSURE RELIEF VALVE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in the designated
opening in the storage tank.
connected to the storage tank. If more than one water heating
appliance is connected to the storage tank the aggregate total
of all heating input ratings of all connected appliances must be
factored when choosing a T&P valve for the storage tank.
The pressure rating of the T&P valve should always be rated
equal to or below the working pressure rating of the storage tank
or water heater, whichever rating is lower.
Contact the manufacturer of the storage tank for assistance in
sizing of a temperature and pressure relief valve. Follow the
storage tank manufacturer’s instructions regarding the proper
installation of these products.
TANK SELECTION
The HPWH unit is not an instantaneous water heater and must
be connected to a storage tank. Storage tank congurations must
meet these criteria:
1. The HPWH must not be connected directly to a standard gas
or electric water heater.
2. If the HPWH is connected to a used storage tank, the tank
should be thoroughly cleaned of scale and sediment before
the HPWH is installed.
3. Connection ports used on the storage tank must permit the
recommended ow rate through HPWH. The connection
ports used on the storage tank must not be smaller than the
inlet outlet connection sizes on the HPWH unit. See Table 4
on page 13.
4. Water heated by the HPWH should be returned to the tank at
a location that is above the level of the tank’s cold water inlet
and/or the heat pump’s inlet source.
5. The HPWH unit’s inlet and outlet lines to the storage tank
should be dedicated. Example: no other line (such as a
building re-circulating loop or cold water supply) should be
connected to the HPWH unit’s inlet or outlet water lines.
SOLAR TANKS
Solar tanks should be used with caution. Some solar tanks with
top connections have dip tubes which may signicantly reduce
the efciency performance of the HPWH unit.
Before using any solar tank in this application, contact your
representative or call the toll free technical support number on
the back cover of this manual for further assistance.
CONTAMINATED AIR
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This heat pump water heater should only be connected to a
storage tank with a properly rated/sized and certied combination
temperature - pressure relief valve. The valve must be certied by
a nationally recognized testing laboratory that maintains periodic
inspection of production of listed equipment of materials as
meeting the requirements for Relief Valves for Hot Water Supply
Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of
ASME.
When the HPWH unit is connected to a storage tank a temperature
and pressure relief valve must be installed in the designated
opening for the T&P valve per the storage tank manufacturer’s
requirements. The T&P valve’s Btu/hr rating must be equal to
or greater than the total heating input rating of all water heaters
Breathing Hazard - Carbon Monoxide Gas
Do not duct air from a garage or other
space where potentially harmful fumes
from solvents, chemicals or exhaust
from automobiles are present into any
other space in the building structure.
Gas and carbon monoxide detectors
are available.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
The supply (outlet) air from a HPWH installed in a garage or a
unit drawing return (inlet) air from a garage or any area where
solvents or other chemicals that emit potentially harmful fumes
are stored or automobiles are located must never be ducted to
any other space inside the building structure. This would include
all occupied and unoccupied spaces such as attics or basements.
14
Potentially harmful fumes and vapors could be introduced into
occupied spaces. See Unit Placement on page 16.
STORAGE & HANDLING
HEAVY OBJECT!
All Heat Pump Water Heaters (HPWHs) covered by this manual
are beyond the safe lifting weight for one person. Use
proper conveyance equipment to move the unit for storage
or during installation. Use OSHA approved safety equipment
when moving the unit
The heat pump water heaters covered in this manual are
stationary refrigeration appliances. Careful handling is necessary
to prevent internal damage.
• IMPORTANT: Do not remove, cover or deface any
permanent instructions, wiring diagrams, labels, or the
rating label from the outside cabinet or the inside panels on
the HPWH unit.
• Do not tilt the unit beyond 45° at any time. All internal
components are braced from the base of unit. Tilting may
compromise the refrigeration piping inside unit and cause
refrigerant leaks.
• Do not hoist the unit with chains or straps unless
spreader bars are furnished and used as depicted in
Figure 4 and Figure 5. The side panels and roof of the
unit are not constructed to handle signicant force from
the sides or above.
• The HPWH unit is heaviest on the compressor side (left
side when facing the front of the unit). See Figure 4 and
Figure 6.
• When using a forklift to raise the HPWH unit ensure the
forks are positioned correctly between the runners on the
bottom of the HPWH unit. See Figure 6.
• The HPWH unit must be lifted from the front side only
when using a forklift to raise the unit. See Figure 6.
COMPRESSOR
SIDE
.
SPREADER
BAR
RIGGING
SPREADER
BAR
SIDE
Figure 5
Figure 6
STORAGE RECOMMENDATIONS
The HPWH units should be stored indoors. Do not stack units or
stack other construction materials on the units while in storage.
The HPWH units contain electrical/electronic components
and should only be stored in conditions between 0ºF to 110°F
(-17°C to 43°C) and 5 to 95 percent relative humidity. Electrical
components are not moisture-tolerant.
NOTE: The limited warranty does not cover damage to the unit or
controls due to negligence during storage.
FRONT
SUPPORT BARS
Figure 4
15
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