HTP HPW-50-6 User Manual

Heat Pump

This manual must be used by a qualified installer/service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to comply could result in substantial property damage, severe personal injury, or death.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

Water Heater

INSTALLATION

START-UP

MAINTENANCE

PARTS

Hybrid Electric Heat Pump Water Heater Models

HPW-50-6

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

LP-374 REV. 3.25.14

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property

damage.

This manual must only be used by a qualified HVAC installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the Hybrid Electric Heat Pump Water Heater. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Electrical Code, ANSI/NFPA 70, be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the local code authorities and utility companies which pertain to this type of water heating equipment.

FOR THE INSTALLER

This water heater must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the water heater, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Electrical Code, ANSI/NFPA 70.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Electrical Code, ANSI/NFPA No. 70, available from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269. In Canada – Canadian Electrical Code, CSA 22.1, available from Canadian Standards Association, 5060 Spectrum Way, Suite 100,

Mississauga, Ontario, Canada L4W 5N6.

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TABLE OF CONTENTS

PART 1 – GENERAL SAFETY INFORMATION .......................................................................................................................... 4

A. PRECAUTIONS .......................................................................................................................................................................... 4

B. WATER TEMPERATURE ADJUSTMENT .................................................................................................................................. 4

C. COMBUSTIBLE MATERIALS ..................................................................................................................................................... 5

D. INSTALLATIONS IN THE STATE OF CALIFORNIA .................................................................................................................. 5

E. MAINTENANCE CONSIDERATIONS ......................................................................................................................................... 5

F. HYDROGEN GAS ....................................................................................................................................................................... 5

G. SAFETY CONSIDERATIONS .................................................................................................................................................... 6

H. SAFETY CONTROLS ................................................................................................................................................................. 6

PART 2 – INSTALLATION INSTRUCTIONS ............................................................................................................................... 6

A. DETERMINING WATER HEATER LOCATION .......................................................................................................................... 6

B. REQUIRED CLEARANCES ........................................................................................................................................................ 7

C. CONDENSATE DRAIN ............................................................................................................................................................... 8

D. THERMAL EXPANSION ............................................................................................................................................................. 8

E. WATER SUPPLY CONNECTIONS ............................................................................................................................................. 8

F. CONDENSATION DRAIN TUBES ............................................................................................................................................ 10

G. RELIEF VALVE......................................................................................................................................................................... 10

H. TO FILL THE WATER HEATER ............................................................................................................................................... 11

I. ELECTRICAL CONNECTIONS .................................................................................................................................................. 11

PART 3 – CONTROLS............................................................................................................................................................... 12

A. CONTROL OVERVIEW ............................................................................................................................................................ 12

B. DISPLAY OVERVIEW ............................................................................................................................................................... 13

C. SETTING THE WATER TEMPERATURE ................................................................................................................................ 14

D. ADJUSTING THE FUNCTION MODE ...................................................................................................................................... 15

E. ABOUT THE USER INTERFACE FEATURE BUTTONS .......................................................................................................... 15

F. USING THE BUTTONS IN COMBINATION .............................................................................................................................. 15

G. DEMAND RESPONSE ............................................................................................................................................................. 16

PART 4 – MAINTENANCE, VACATION, AND CLEANING ...................................................................................................... 17

A. ROUTINE PREVENTIVE MAINTENANCE ............................................................................................................................... 17

B. DRAINING THE WATER HEATER ........................................................................................................................................... 17

C. VACATION AND EXTENDED SHUTDOWN ............................................................................................................................ 18

D. CLEANING THE FILTER .......................................................................................................................................................... 18

E. CLEARING THE CONDENSATION DRAIN TUBES ................................................................................................................. 18

PART 5 – INSTALLATION CHECKLIST ................................................................................................................................... 18

PART 6 – STARTUP: WHAT TO EXPECT ................................................................................................................................ 19

PART 7 – MAINTENANCE CHECKLIST AND ERROR CODES .............................................................................................. 22

INSTALLATION AND MAINTENANCE NOTES ..................................................................................................................................................... 24

HTP CUSTOMER INSTALLATION RECORD FORM ............................................................................................................................................. 25

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For your safety, the information in this manual must be followed to minimize the risk of fire, explosion, electric shock, and to prevent property damage, personal injury, or death.

INSTALLER – Read all instructions in this manual before installing. Be sure to understand all instructions before installing or operating this water heater, as this may save time and cost. Perform steps in the order given. Should you have problems understanding the instructions in this manual, or any questions, STOP and get help from a qualified service technician or local electric utility.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the water heater is exposed to the following, do not operate until all corrective steps have been made by a qualified

serviceman:

1. FIRE

2. DAMAGE

3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the water heater as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this water heater and related components near high heat sources.

Water temperature over 125oF can instantly cause severe burns or death from scalds. Children, disabled, and the elderly are at the highest risk of being scalded. See instruction manual before setting temperature at the water heater. Feel water before bathing or showering! Temperature limiting valves are available.

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This water heater is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. The water heater must have room for service: 16” top, 12” sides, and 7” front and back are minimum recommended service clearances. If you cannot provide these clearances, it may not be possible to service the water heater without removing it from its installation location.

This water heater needs at least 700 cubic feet of unconditioned indoor ambient air to operate properly. Do not install this water heater in a closet or confined space. Ensure the water heater is installed on a floor that can support its full filled weight (660 lbs).

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician. Replace any part of the control unit that has been under water.

B. WATER TEMPERATURE ADJUSTMENT

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Gasoline, as well as other flammable materials and liquids (adhesives, solvents, etc.), and the vapors these items produce are extremely dangerous. DO NOT handle, use, or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of the water heater. The arc drawn in the water heater controls can ignite these vapors. Failure to follow these instructions can result in property damage, serious personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE! To dissipate such gas and reduce the risk of injury, it is recommended that the kitchen sink hot water faucet be opened for several minutes before using any electrical water heater connected to the hot water system. If hydrogen is present, there will be an unusual sound, such as air escaping through the pipe as water begins to flow. Do not smoke or use an open flame near the faucet while it is open. Failure to follow this warning could result in property damage, severe personal injury, or death.

APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS

120oF

More than 5 minutes

125oF

1 ½ to 2 minutes

130oF

About 30 seconds

135oF

About 10 seconds

140oF

Less than 5 seconds

145oF

Less than 3 seconds

150oF

About 1 ½ seconds

155oF

About 1 second

Table 1 – Table Courtesy of Shriners Burn Institute

Figure 1

Safety and energy conservation are factors to be considered when selecting the water temperature setting via the water heater user interface. Water temperatures above 125oF can cause severe burns or death from scalding. Be sure to read and follow the warnings outlined on the label pictured in Figure 1. This label is also located on the water heater near the top of the tank.

Mixing valves for reducing point-of-use water temperature by mixing hot and cold water in branch water lines are available. Contact a licensed plumber or the local plumbing authority for further information.

NOTE: Households with small children, disabled, or elderly persons may require a 120oF or lower thermostat setting to prevent contact with “HOT” water.

C. COMBUSTIBLE MATERIALS

D. INSTALLATIONS IN THE STATE OF CALIFORNIA

California Law requires that residential water heaters must be braced, anchored, or strapped to resist falling or horizontal displacement due to earthquake motions. For residential water heaters up to 52 gallon capacity, a brochure with generic earthquake bracing instructions can be obtained from: Office of the State Architect, 400 P Street, Sacramento, CA 95814, or you may call 916-324-5315, or ask your water heater dealer for more information.

Applicable local codes shall govern installation. For residential water heaters of a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable bracing procedures.

E. MAINTENANCE CONSIDERATIONS

 To avoid electric shock, disconnect electrical supply before performing maintenance.  To avoid severe burns, allow water heater to cool before performing maintenance.

F. HYDROGEN GAS

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The cause of the high temperature condition must be investigated by a qualified service technician and corrective action must be taken before placing the water heater in service again.

This water heater must be properly grounded before usage. Failure to comply could result in substantial property damage, severe personal injury, or death.

G. SAFETY CONSIDERATIONS

1. Turn off power to the water heater if it has been subjected to overheating, fire, flood, or physical damage.

2. Do Not turn on water heater unless it is filled with water.

3. Do Not turn on water heater if cold water supply shut-off valve is closed.

4. Do Not store or use gasoline or other flammable vapors or liquids, such as adhesives or paint thinner, in the vicinity of this or any other water heater. Open doors and windows for ventilation if such flammables must be stored near the water heater.

NOTE: Flammable vapors may be drawn by air currents from surrounding areas to the water heater.

5. If there is any difficulty in understanding or following the Control Instructions or the Maintenance and Cleaning Sections, it is recommended that a qualified person or serviceman perform the work.

H. SAFETY CONTROLS

The water heater is equipped with two temperature-limiting controls (TCO and TOD) that are located above the heating element in contact with the tank surface. If for any reason the water temperature becomes excessively high, the temperature-limiting control (TCO or TOD) breaks the electrical circuit to the heating element. Once the control opens, it must be reset manually. Resetting the temperature limiting controls should only be done by a qualified service technician.

To reset the temperature-limiting control:

1. Turn off the power to the water heater.

2. Remove the jacket access panel(s) and insulation. DO NOT remove the thermostat protective cover.

3. Press the red RESET button.

4. Replace the insulation and jacket access panel(s) before turning on power to the water heater.

PART 2 – INSTALLATION INSTRUCTIONS

A. DETERMINING WATER HEATER LOCATION

The location chosen for the water heater must take the following into consideration:

LOCAL INSTALLATION REGULATIONS

This water heater must be installed in accordance with these instructions, local codes, utility codes, and utility company requirements or, in the absence of local codes, the latest edition of the National Electrical Code. It is available from some local libraries or can be purchased from the National Fire Prevention Association, Batterymarch Park, Quincy, MA 02169 as booklet ANSI/NFPA 70.

POWER REQUIREMENTS

Check the markings on the rating plate of the water heater to verify the power supply corresponds to the water heater requirements (240V/30A).

LOCATION

Locate the water heater indoors, in a clean, dry area as near as practical to the area of greatest heated water demand. Long uninsulated water lines can waste heat, energy and money.

NOTE: Because this unit draws in air from the room to heat water, the room must be at least 10’ x 10’ x 7’ (700 cubic feet) or larger. If the room is smaller, there must be a louvered door to allow for free air passage into the mechanical room. The louvered panel must be at least 2 ft. by 3 ft. in size.

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The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent to it or to lower floors of the structure. Where such areas cannot be avoided, it is recommended that a suitable, adequately drained catch pan be installed under the water heater.

This water heater SHOULD NOT be installed in a space where liquids which give off flammable vapors are used or stored. Such liquids include gasoline, LP gas (butane and propane), paint or adhesives and thinners, solvents, or removers. Because of natural air movement in a room or other enclosed space, flammable vapors can be carried from where flammable liquids are being used or stored. The operation of the control system within the water heater can ignite these vapors, causing an explosion or fire which may result in property damage, as well as potentially severe burns or death to those in range.

Place the water heater in such a manner that the air filter, cover, and front panels can be removed to permit inspection and servicing, such as removal of elements or cleaning of the filter.

The water heater and water lines should be protected from freezing temperatures and highly corrosive atmospheres. Do not install the water heater in outdoor, unprotected areas.

Figure 2 – Catch Pan Detail

Figure 3 – To facilitate condensate drainage and proper operation, ensure the water heater is installed level.

B. REQUIRED CLEARANCES

In the event service is needed, there must be AT LEAST 16” top, 12” sides, and 7” minimum clearance (air space) between any object and the front and rear covers.

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Figure 4 – Front and Rear Clearances Figure 5 – Top Clearance

A 16” minimum clearance is required to remove the filter for cleaning. The hot and cold water plumbing and electrical connections must not interfere with the removal of the filter.

C. CONDENSATE DRAIN

The water heater has a condensate drain: therefore a drain must be available in close proximity to the unit. The drain must be no higher than 36” above the floor (laundry drain is acceptable). If no drain is available, a common condensate pump with a capacity no less than 1 gallon/day must be purchased from a local plumbing supply store and installed.

D. THERMAL EXPANSION

Determine if a check valve exists in the inlet water line. It may have been installed in the cold water line as a separate backflow preventer, or may be part of a pressure-reducing valve, water meter, or water softener. A check valve located in the cold water inlet line can cause what is referred to as a “closed water system”. A cold water inlet line with no check valve or backflow prevention device is referred to as an “open water system”.

As water is heated, it expands in volume and creates an increase in the pressure within the water system. This action is referred to as “thermal expansion”. In an open water system, expanding water which exceeds the capacity of the water heater flows back into the city main, where pressure is easily dissipated.

A closed water system prevents the expanding water from flowing back into the main supply line, and the resulting thermal expansion can create a rapid and dangerous pressure increase in the water heater and system piping. This pressure increase can quickly reach the safety limit of the relief valve, causing it to operate during each heating cycle. Thermal expansion, and the resulting rapid and repeated expansion and contraction of components in the water heater and piping system, can cause premature failure of the relief valve and possibly the water heater itself. Replacing the relief valve will not correct this problem.

The suggested method of controlling thermal expansion is to install an expansion tank in the cold water line between the water heater and the check valve (refer to the illustration in Figure 6). The expansion tank is designed with an air cushion built in that compresses as the system pressure increases, thereby relieving the thermal expansion and eliminating the repeated operation of the relief valve.

Other methods of controlling thermal expansion are available. Contact your installing contractor, water supplier, or plumbing inspector for additional information regarding this subject.

E. WATER SUPPLY CONNECTIONS

Refer to Figures 6, 7, and 8 for suggested typical installations. The installation of unions or flexible copper connectors is recommended on the hot and cold water connections so that the water heater may be easily disconnected for servicing if necessary. The HOT and COLD water connections are clearly marked and are ¾” NPT on all models.

NOTE: Install a shut-off valve in the cold water line near the water heater. This will enable easier service and maintenance of the water heater.

IMPORTANT: Do not apply heat to the HOT or COLD water connections. If sweat connections are used, sweat tubing to adapter before fitting the adapter to the cold water connections on the water heater. Any heat applied to the hot or cold water connections will permanently damage the dip tubes.

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