Nyle C25W, Geyser C, C250W, C60W, C90W Maintenance Manual

...

Page 1

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.

2018

MODELS C25W-C250W

Installation-Operation-Service Maintenance-Limited Warranty

FOR INDOOR/OUTDOOR INSTALLATION

User Manual

Geyser C-Series Water Source Heat Pump Water Heaters

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.

Nyle Systems

12 Stevens Rd

Brewer, ME 04412

www.nyle.com

watersales@nyle.com

800-777-6953

Page 2

Page 3

Table of Contents.................................................2

Condensed Unit Report.......................................4

Unit Power Wiring.................................................5

Unit Input Wiring...................................................6

Unit Output Wiring................................................7

Safe Installation, Use & Service...........................8

General Safety Information.....................................9

Precautions.........................................................9

Grounding Instructions............................................9

Introduction........................................................10

Qualications.......................................................10

Preparing for the Installation................................10

Principle of Operation..........................................11

The Refrigeration Cycle.......................................11

Source Water Temperature Range........................11

Water Temperature Range....................................11

Refrigerant Charge................................................11

Equipment Disposal...............................................11

Features & Components...................................12

Product Illustrations.............................................13

Rough in Dimensions.......................................13

Performance Specications................................13

Installation Requirements................................14

Water Temperature.............................................14

Maximum System Temperature..........................14

Inlet & Outlet Water Temperature.......................14

Source Water Temperature....................................14

Locating the Water Heater..................................14

Indoor/Outdoor Installation Requirements..........14

Freezing Temperatures.........................................14

Coastal Regions..................................................14

Heat Source.........................................................14

Clearances..........................................................15

Electrical Requirements......................................15

Voltage & Amperage Ratings..............................15

Minimum Circuit Ampacity & Maximum Fuse Size.16

Minimum Wire Size..............................................16

Water Piping.........................................................17

Minimum Pipe Size..............................................17

Pipe Support.........................................................17

Pipe Installation....................................................17

Cold Water Supply...............................................17

Water Pressure....................................................17

Closed Water Systems........................................17

Thermal Expansion..............................................17

Mixing Valves........................................................17

Contaminated Water............................................18

Temperature - Pressure Relief Valve.....................18

Tank Selection.....................................................18

Storage & Handling.............................................19

Installation.........................................................20

Required Tools & Materials.................................20

Installation & Startup Tools..................................20

Service Tools.........................................................20

Unit Placement......................................................20

Pad Mounting........................................................20

Electrical Connections..........................................21

Correct Voltage & Phase......................................21

Branch Circuit Disconnect Switch........................21

Water Connections................................................21

Installation Instructions........................................21

Single Tank Conguration....................................22

Multiple Tank Conguration..................................22

Standard Tank Thermostat...................................22

Temperature Sensor Installation..........................23

Installation Checklist..........................................24

Location................................................................24

Water Piping..........................................................24

Electrical..............................................................24

Pre-Startup Checklist........................................25

3 Phase Startup Procedures................................26

Initial Startup......................................................27

Startup Checklist................................................28

Startup.....................................................29

Electronic Temperature Controls.......................30

Functions Ranges & Settings................................31

Parameter Settings...............................................31

Screen Navigation.................................................31

Basic Mode...........................................................31

Advanced Mode...................................................32

Restricted Mode...................................................32

Programmable Logic Controls.............................33

PLC Controller......................................................33

Temperature & Setpoints.....................................33

Setpoint Ranges & Safeties.................................33

Master Screens.....................................................34

Home Screen........................................................34

Conguration Screen.............................................35

Alarm Screen........................................................35

Slave Screens.......................................................36

Alarm Screen.........................................................36

Stop Screen...........................................................36

Single Unit IP Address Cong Screen...................37

Terminology.............................................37

Alarm Screen.........................................................37

Stop Screen..........................................................38

Maintenance & Service.......................................39

Troubleshooting.........................................40

Limited Warranty...................................................44

Registration..........................................................45

Page 4

Unit Report

Date:

Basic Information

Company Name: Rep. Firm (If Applicable):

Unit Model #: Serial #:

Power Source: Controls:

Electrical Data

Transformer Size: Fuse/Breaker Size:

Compressor Time Delay:Compressor:

Blower: Fans:

Refrigeration Equipment Data

Size:Manufacturer:Thermal Expansion Valve Part #:

Manufacturer: Size: Part #:Solenoid Valve Coil:

Suction Valve Size: Discharge: Liquid Line:

Condenser Data: Evaporator Data:

Refrigerant Type:

Refrigerant Quantity:

Compressor Data

Model #: Serial #:

Connection Condition:

Crankcase Heater:

Voltage:

Capacitor MFD:

Low Pressure Switch Cut In: Cut Out:

Unit Physical Inspection: Pass / Fail

Tested By: Inspected By:Date: Date:

Page 5

Page 6

AI0

AI1

Page 7

Page 8

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

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

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.

situation which, if not avoided, could result in minor or moderate injury.

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

Page 9

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualied 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 qualied 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

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.

Page 10

THIS WATER HEATING APPLIANCE.

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 Qualied Agency (as dened 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 certication as dened in Section 608 of the Clean Air Act.

ANSI Z223.1 2006 Sec. 3.3.83: “Qualied 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

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 21.

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.

The principal components of the HPWH are identified in the Features And Components section of this manual on page

12. 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 24.

6. Installation and service of this HPWH requires ability equivalent to that of a licensed tradesman or Qualified Agency in the field involved. See Qualifications on page 8.

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 Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95811.

Page 11

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 water-to-water heat pump water heaters (HPWH).

Operation of the HPWH is simple in the fact that we are

transferring heat energy from a water source to a DHW tank by means of a compressed refrigeration cycle. Recovering and

using this waste heat increases the overall energy efficiency of the building.

THE REFRIGERATION CYCLE

Refer to Figure 1 on page 12 for the location of components mentioned in this section.

Refrigerant is circulated through the refrigeration circuit by a

Compressor. The refrigerant is a high temperature high

pressure gas when it leaves the compressor. Refrigerant flows from the compressor through the Hot Gas Line to the

Condenser.

The condenser is a refrigerant-to-water heat exchanger with two circuits, refrigerant flows through one circuit and water through the other. The high temperature refrigerant gas transfers its heat to the water flowing through the condenser. As the refrigerant gas cools inside the condenser it changes state (condenses) from a gas to a liquid. A Water Pump circulates water through the condenser.

Refrigerant leaving the condenser is a medium temperature high pressure liquid. It flows through the Liquid Line to the

Thermostatic Expansion Valve. The thermostatic expansion

valve (TXV) regulates the flow of refrigerant into the

Evaporator. The evaporator is a single wall brazed plate source

water-to-refrigerant heat exchanger. The refrigerant changes

state (boils/evaporates) from a liquid state back into a gas (vapor) in the evaporator.

The refrigerant flows out of the evaporator through the Suction Line and into the Accumulator. 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.

SOURCE WATER TEMPERATURE RANGE

The entering source water temperature operating range for the HPWH is 40°F to 100°F (4°C to 38°C).

When the HPWH is operating properly the source water temperature drop through the evaporator (heat exchanger) will be approximately 8°F to 11°F (-13°C to -12°C).

WATER TEMPERATURE RANGE

The inlet (entering) water temperature operating range for the HPWH is 40°F to 140°F (4°C to 60°C).

The HPWH will heat potable water up to 150°F.

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 34. 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 Qualifications on page 10.

Page 12

RECIEVER

COMPONENT REFRIGERATION CIRCUIT

COMPRESSOR CONDENSER (HEAT EXCHANGER) RECIEVER

THERMOSTATIC EXPANSION VALVE (TXV)

EVAPORATOR (HEAT EXCHANGER) ACCUMULATOR

COMPONENT HEATED WATER CIRCUIT

HEATED WATER INLET CONDENSER (HEAT EXCHANGER) HEATED WATER OUTLET

COMPONENT SOURCE WATER CIRCUIT

SOURCE WATER INLET EVAPORATOR (HEAT EXCHANGER) SOURCE WATER OUTLET

FEATURES AND COMPONENTS

ELECTRICAL PANEL

ACCUMULATOR

EVAPORATOR

(HEAT EXCHANGER)

(WATER TO REFRIGERANT)

SOURCE

WATER OUTLET

HEATE D

WATER OUTLET

SOURCE

WATER INLET

HEATE D

WATER INLET

COMPONENT REFRIGERATION CIRCUIT

REFRIGERANT STATE

CONDENSER

(HEAT EXCHANGER)

(REFRIGERANT TO POTABLE WATER)

THERMOSTATIC

EXPANSION VAVLE

(TXV)

COMPRESSOR

COMPRESSOR CONDENSER (HEAT EXCHANGER) RECIEVER THERMOSTATIC EXPANSION VALVE (TXV) EVAPORATOR (HEAT EXCHANGER) ACCUMULATOR

COMPONENT HEATED WATER CIRCUIT

HEATED WATER INLET CONDENSER (HEAT EXCHANGER) HEATED WATER OUTLET

COMPONENT SOURCE WATER CIRCUIT

SOURCE WATER INLET EVAPORATOR (HEAT EXCHANGER) SOURCE WATER OUTLET

GAS GAS TO LIQUID LIQUID LIQUID LIQUID TO GAS GAS / LIQUID

Page 13

Figure 2

PERFORMANCE SPECIFICATIONS

ROUGH IN DIMENSIONS

Dimensions

1 2

28"

ELECTRICAL

SERVICE DOOR

REFRIGERATION SERVICE DOOR

1 2

3'-0"

5'-11

1 2

C270WM

SERVICE AREA

1 2

1 8

3 8

FRONT

WATER CONNECTIONS

71”

8 7 5 4 2

ZONE

REV.

3 16

DESCRIPTION

REVISIONS

DATE

APPROVED

ELECTRICAL SERVICE DOOR

7 5 4

SERVICE AREA

2'0"

FRONT

1'6"

2'0"

WATER CONNECTIONS

PROPRIETARY AND CONFIDENTIAL:

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF NYLE SYSTEMS LLC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF NYLE SYSTEMS LLC IS PROHIBITED.

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL DECIMAL ANGULAR MACH ANGULAR BEND

DRAWN

CHECKED

EDITED

TITLE:

1/16"

0.02"

NAME

1/2°

1°

DATE

10/5/2017

PART NO:

MATERIAL:

MATERIAL <NOT SPECIFIED>

FINISH:

C60W BASE CABINET

REVISION:

SHEET:

SCALE:

A-

1 OF 1

1:12

DEPT:

SENGINEERING

SHEET SIZE:

WEIGHT (lbs):

51.26

COP

4.4

4.7

4.6

SOURCE WATER

FLOW

(GPM)

9.6

WATER

FLOW (GPM)

5.4

INLET

OUTLET

WATER

(FNPT)

3/4”

1.5"

20 25 1.5”

1.5”

2”

DIMENSIONS

LENGTHA WIDTHB HEIGHT

36.125

38.125

27.25

48.125

TABLE 1

MODEL

NUMBER

C25W

C60W

C90W

C125W

C185W

C250W

HEATING

CAPACITY

kW Btu/hr* Btu/hr Tons

PERFORMANCE

WATER

28,500 22,250 2 4.5 4

57,850 45,400

110,400 84,000 9 4.6

146,900

220,100 169,500 18

278,300 23 4.5 36

COOLING

CAPACITY

116,000

216,450

All unit foot print dimensions are in inches. Weights are approximate shipping weights.

*Performance rating at 75ºF Entering Source Water Temperature and 100ºF Entering Heated Water Temperature. (EWT)

COP = Coefficient Of Performance

All models standard 208/230 VAC, 3Ø, 60 Hz OR

Optional: 460 VAC, 3Ø, 60 Hz or 400/3/50

24.875

27.25

28.875

38.125 28.875

37.375

38.125

51.125

WEIGHT

(LBS)

225

275

350

450

500

1,300

Page 14

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 150°F (66°C). Some commercial water heating applications may require higher temperatures. Install a booster water heater downstream from the storage tank for temperatures above 150°F (66°C). See Figure 8 on page 22.

INLET & OUTLET WATER TEMPERATURE

The inlet (entering) water temperature operating range for the HPWH is 40°F to 140°F (4.4°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 pages 17-18.

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 150°F (66°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 starting on page 35 in this manual for more information.

SOURCE WATER TEMPERATURE

ENTERING SOURCE WATER TEMPERATURE

The entering source water temperature range of operation for the unit is 40° - 100°F (4.4°C to 38°C). The source temperature drop (Delta T - ∆T) through the evaporator (heat exchanger) will be approximately 8°F to 12°F (-13°C to -12°C).

If the source water temperature is outside this operating range the HPWH unit’s Limit Thermostat will discontinue heating operation until the entering source water temperature returns to this operating range.

LOCATING THE WATER HEATER

PROPERTY DAMAGE!

All water heaters may eventually leak.

•

• Do not install without adequate drainage.

INSTALLATION

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 floors of the structure. See Unit Placement on page 20.

FREEZING TEMPERATURES

The HPWH unit must not be installed in space where freezing temperature will occur, without a low ambient air kit. 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 recommended. The corrosive duty package includes a stainless steel cabinet. 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 adequate source water from which to extract waste heat and where the source water cooling benefit can be utilized when possible.

Page 15

ELECTRICAL REQUIREMENTS

CLEARANCES

To ensure optimal performance a minimum of 36" clearance is required from the front of the HPWH unit and any wall obstruction. 24" is acceptable on all other sides.

Abbreviation Denitions For Table 2 Figure 3

RLA-Rated Load Amps

FLA-Full Load Amps

LRA-Locked Rotor Amps

MCA-Minimum Circuit Ampacity

MCC-Maximum Continuous Current

MFS-Maximum Fuse Size

TABLE 2

Figure 3

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 data sticker 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

Model Volts/Phase/HZ

208-230/1/60 16.0 25.0 2.5 1.4 2.5 22 25

C25W

C60W

C90W

C125W

C185W

C250W

208-230/3/60 9.0 14.0 2.5 1.4 2.5 13 15 440-480/3/60 4.5 7.0 2.5 1.4 2.5 7 10

575/3/60 3.8 6.0 3.0 1.4 3.0 7 10 208-230/1/60 28.2 44.0 5.5 1.9 5.5 38 40 208-230/3/60 20.2 31.5 6.0 1.9 6.0 28 30 440-480/3/60 9.1 14.2 6.0 1.9 6.0 14 15

575/3/60 7.1 11.0 6.0 1.9 6.0 11 15 208-230/3/60 35.3 55.0 10.0 1.9 10.0 46 50 440-480/3/60 17.9 28.0 10.0 1.9 10.0 25 30

575/3/60 11.5 18.0 10.0 1.9 10.0 17 20 208-230/3/60 48.1 75.0 13.0 4.9 13.0 65 70 440-480/3/60 21.8 34.0 13.0 4.9 13.0 33 35

575/3/60 18.6 29.0 13.0 4.9 13.0 23 30 208-230/3/60 73.1 114.0 20.0 4.9 20.0 97 100 440-480/3/60 30.1 47.0 20.0 4.9 20.0 43 45

575/3/60 24.4 38.0 20.0 4.9 20.0 36 40 208-230/3/60 90.7 127.0 25.0 2 25.0 116 125 440-480/3/60 45.7 64.0 25.0 2 25.0 59 60

575/3/60 37.9 65.0 25.0 1 25.0 49 50

Compressor PUMP

MCA MFS

RLA MCC HP FLA HP

Page 16

MINIMUM CIRCUIT AMPACITY & MAXIMUM FUSE SIZE

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

Table 2 on page 15 provides the MCA (Minimum Circuit Ampacity) and MFS (Maximum Fuse Size). Use MCA to select the minimum field wires size to power the unit and MFS to select the maximum fuse size for over current protection as follows:

Where: MCA= C x 1.25

MFS = C x 2.25

C - Compressor

+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.

Page 17

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.

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, below, for water line connection sizes and water flow rates.

Water line sizing is a critical installation requirement. Installing undersized water piping between the storage tank and the HPWH unit will cause insufficient water flow and will have an adverse impact on performance and equipment life.

Table 4

WATER CONNECTIONS AND FLOW

UNIT GPM CONNECTION SIZE (INCH)

C25W

C60W

C90W

C125W

C185W

C250W

5.4

40 1.5"

¾"

1.5"

2”

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.

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 11 and Figure 7 and Figure 8 on page 22.

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 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, page 18.

Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inrm 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 satises 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 Qualied Installer or Service Agency. Follow the mixing valve manufacturer’s instructions for installation of the valves.

Page 18

TABLE 5

or greater than the total heating input rating of all water heaters

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

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 congurations must meet these criteria:

The HPWH must not be connected directly to a standard gas or electric water heater. If the HPWH is connected to a used storage tank, the tank

2. should be thoroughly cleaned of scale and sediment before

the HPWH is installed. Connection ports used on the storage tank must permit the

3. recommended ow r ate t hrough H PWH. T he 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 17.

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 signicantly reduce the efciency 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.

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 certied combination temperature - pressure relief valve. The valve must be certied 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

Page 19

Potentially harmful fumes and vapors could be introduced into occupied spaces. See Unit Placement on page 18.

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 significant force from the sides or above.

• 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

The pictures may appear different than your actual unit, all information and reference to lifting applies to all of our models.

Page 20

INSTALLATION

5. Refrigerant reclamation storage tank.

REQUIRED ABILITY

Installation and service of the HPWH unit requires ability equivalent to that of a qualied agency i n t he eld involved. Plumbing, ducting and electrical work are required. See Qualifications on page 10.

GENERAL

The installation must conform with these instructions and the local code authority having jurisdiction. 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.

DO NOT start the HPWH unit or test the electrical system before it is connected to the water system, purged of air and filled with water. See Start Up on page 25.

See Features And Components on page 12 to identify the principal components of the HPWH. (Some units will vary)

REQUIRED TOOLS AND MATERIALS

INSTALLATION & START UP TOOLS

1. All tools common to installation and service of commercial electric water heaters such as hand tools, pipe cutter and torch.

2. Heat transfer compound (paste) such as Honeywell part number 107408 or equivalent.

3. Electrical switch lock out device - used to secure disconnect switches/breaker panels while servicing.

4. Electronic thermometer including:

• Four (4) thermocouple sensors capable of measuring surface temperatures on water or refrigerant piping up to 2 inch diameter.

• Temperature range 32°F - 210°F (0°C - 100°C).

5. Volt-Ohm Multi Meter - capable of measuring:

• AC Voltage up to 600 VAC.

• DC Voltage up to 24 VDC.

• Ohms up to 2,000,000 ohms.

• Continuity.

6. AC amp meter - capable of measuring:

• AC amperage up to 200 amps.

7. Calculator.

SERVICE TOOLS

UNIT PLACEMENT

Whether replacing existing water heating equipment or installing the HPWH in new construction, the following critical points must be observed: The HPWH unit:

1. Should be installed near a floor drain for condensate removal.

2. The HPWH, storage tank and water heater(s) should be

located in an area where leakage will not result in damage to adjacent area or to lower floors in the building structure.

3. The HPWH unit must be level for proper condensate drainage. Shim the channel type skid base, pad or floor as necessary if levelling is required.

4. Should be installed close to the point of major hot water usage and power supply.

5. Should be located so that hot water piping and branch circuit wiring will be as short as possible.

Mounting Frame

The mounting frame must support the length, width, and weight of the HPWH unit. The weight of the HPWH unit must be evenly dispersed across the footing channels on the bottom of the unit. See Table 1 on page 13 for unit dimensions and weights.

1. VIBRATION ISOLATORS ARE REQUIRED to prevent

transmission of mechanical vibration into the building structure. Selection of suitable isolators should be made by a qualified engineer.

2. Installation must meet local seismic restraint requirements.

PAD MOUNTING

The HPWH may be pad mounted. Vibration isolator mounts MUST BE placed between the unit and the equipment pad to prevent mechanical vibration transmitting into the building structure. Selection of appropriate vibration isolators should be made by a qualified engineer.

See Qualifications on page 10 regarding regulations and certifications required under Section 608 of the Clean Air Act before servicing the refrigeration circuit.

1. Refrigeration manifold gauges.

2. Refrigeration charging scale.

3. Refrigeration vacuum pump.

4. Refrigerant recovery machine.

Page 21

ELECTRICAL CONNECTIONS

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.

CORRECT VOLTAGE AND PHASE

The HPWH units covered by this instruction manual can be ordered with multiple power supply voltage and phase congurations. 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.

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.

Energizing the HPWH with the wrong voltage and/or phase may cause permanent damage to HPWH components. Damage resulting from applying the wrong power supply voltage or phase to the HPWH is not covered under the limited warranty.

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.

BRANCH CIRCUIT DISCONNECT SWITCH

The power supply wiring and equipment grounding must be installed in accordance with local codes or, in the absence of local codes, the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1.

Install an adequately fused disconnect switch as close to the unit as possible. See unit rating label for maximum fuse size (MFS).

Run the power supply lines from the disconnect to the control box at the front panel of the unit. Connect the lines to the terminals on

three phases. Connect ground wire to ground lug.

See Minimum Circuit Ampacity & Maximum Fuse Size on page 15 for wire, fuse and breaker sizing information.

input side of power distribution block L1, L2 & L3 for

WATER CONNECTIONS

Water piping must be installed in accordance with the instructions in this manual and all local plumbing codes having jurisdiction. See Figure 7 and Figure 8 on page 22 and the Piping Diagrams starting on page 35 as a reference for these instructions.

INSTALLATION INSTRUCTIONS

1. This HPWH unit is not designed to supply hot water directly to hot water fixtures. The HPWH unit must be installed with a separate storage tank as shown in the water piping diagrams in this instruction manual.

2. Water lines installed between the storage tank and the HPWH unit MUST NOT be less than the water pipe connection sizes on the unit. See Table 4 on page 17.

3. The HPWH should be plumbed directly to the storage tank.

4. The cold water supply must be connected directly to the

storage tank at a low connection port on the storage tank on single tank and two tank preheat piping configurations for optimal efficiency. See Figure 7 and Figure 8 on page 22.

5. The cold water supply MUST NOT be connected the inlet (entering/return) water line to the HPWH unit.

6. The outlet (supply) water from the HPWH unit should connect to a middle or lower port on the storage tank.

The inlet (return) water from the HPWH unit should connect to a port on the storage tank lower than the outlet. A heat trap should be installed between the storage tank and

8. the backup water heater on two tank preheat systems. See

Piping Diagram starting on page 35. A T&P valve must be installed in the designated opening on

9. the storage tank per the tank manufacturer’s requirements.

10. For optimal performance minimize the equivalent length of water piping between the HPWH and storage tank.

11. Building hot water recirculation loop should be connected to the inlet of the backup water heater on two tank preheat configurations or to the storage tank on single tank configurations. The recirculating pump MUST BE controlled by a field supplied thermostat installed in the building recirculation return line near the storage tank or back up heater. The thermostat should stop pump operation the moment the recirculation line is hot.

12. Use swing-type check valves (not spring-loaded types) on the water outlet lines of all HPWH units plumbed in parallel to prevent hot water short-circuiting.

13. Water lines shared by parallel HPWH units must be large enough to handle combined water flows. A manifold as well as balancing valves and solenoids are required. Flow rates through the heat pumps and tank(s) must be balanced. See Table 1 on page 13 for HPWH unit flow rates.

Page 22

15. All components in the hot water supply system must be

TANK THERMOSTAT

adequately sized to meet peak water ow requirement

16. When the HPWH unit is installed above the storage tank install a Tee tting at a high point in the outlet water line leaving the unit. Install a purge valve, or if required by local code, a T&P valve (temperature and pressure relief) in a branch of the Tee tting that can be used to purge air from the HPWH unit during start up. See Figure 7 and Figure 8.

17. DO NOT install a (T&P) relief valve in the outlet line of the HPWH unit unless required by local code.

18. Dielectric unions should be installed at the inlet and outlet water lines to the HPWH unit.

19. All HPWH water piping must be insulated.

SINGLE TANK CONFIGURATION

The HPWH must be plumbed to storage tank. The maximum stored water temperature the HPWH unit can produce in the storage tank is 150°F (66°C). Figure 7 shows a typical storage tank piping conguration. Tank p orts m ust be l arge e nough to handle the peak water flow rates through the water heating system. See Piping Diagrams startingon page 35 for detailed piping diagrams.

Purge Valve or T&P

(purge air from system)

Purge Valve or T&P

(purge air from system)

OUTLET

(SUPPLY)

INLET

(RETURN)

ISOLATION

VALVES

HPWH

STORAGE

TANK

DIGITAL TA NK THERMOSTAT

SUPPLY

T&P VALV E

OPENING

PRE-HEATED

WATER OUT

HOT

OUTLET

BACKUP

WATER

HEATER

(OPTIONAL)

PRE HEATED

WATER INLET

DUCT

OUTLET

(SUPPLY)

INLET

(RETURN)

ISOLATION

VALVES

REMOTE TEMPERATURE SENSOR OR MECHANICAL

HPWH

STORAGE

TANK

DIGITAL TA NK THERMOSTAT

Figure 7

T&P VALV E

OPENING

COLD INLET

SUPPLY

DUCT

HOT

OUTLET

REMOTE TEMPERATURE SENSOR OR MECHANICAL

COLD

INLET

Figure 8

You individual HWP design may vary, Air Source as opposed to

Individual HPWH deigns may vary. (Air source as opposed to water source.) The same heated water piping design will

Water Source. The same heated water piping design will apply.

apply.

HPWH

UNIT

When water temperatures above 150°F (66°C) are required the HPWH and storage tank are piped in series (upstream) with a backup water heater. See Water Temperature on page 14. The backup water heater will raise the temperature of the preheated water to the nal system temperature required. Figure 8 shows a typical preheat piping conguration.

MULTIPLE TANK PRE HEAT CONFIGURATION

Figure 9

STANDARD TANK THERMOSTAT

Standard tank thermostats (Aquastat) already installed in the storage tank may be used instead of the factory supplied Digital Tank Thermostat if desired. Ensure the standard tank thermostat is installed the lower third of the tank. Wire the existing tank thermostat to the HPWH terminal strip.

Page 23

TEMPERATURE SENSOR INSTALLATION

The HPWH unit is shipped from the factory with a Digital Tank Thermostat that includes a Temperature Sensor:

1. Secure the Temperature Sensor inside a Sensor or Thermal

Well .

Install the sensor well in the storage tank’s designated temperature control opening. It is not recommended to

install the temperature probe or sensor in the bottom or the top of the tank. It is typical to install in the mid to lower portion of the tank.

Do not install the temperature sensor near the cold water supply connection to the storage tank to prevent short cycling.

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.

HPWH

STORAGE

TANK

REMOTE TEMPERATURE SENSOR

Figure 10

BACKUP

WATER

HEATER

Page 24

INSTALLATION CHECKLIST

The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. This is not a complete list. Before performing any troubleshooting procedures use the list below to check for installation errors. Costs to correct installation errors are not covered under the limited warranty. Ensure all installation requirements and instructions in this manual have been followed.

LOCATION

1. Ensure the HPWH is located where there is a adequate supply of ambient heat for optimal performance or that the HPWH is ducted to such a location.

2. Ensure required clearances are maintained and there is access for servicing. See Clearances on page 13.

WATER PIPING

7. Ensure the outlet (supply) and inlet (return) water piping

connected to the HPWH are not less than the connection size on the unit. See Table 1 on page 13.

8. When the HPWH is connected to a storage tank ensure the storage tank is equipped with a properly rated and sized Temperature and Pressure (T&P) relief valve. Refer to the storage tank manufacturer’s instructions for T&P valve sizing and installation requirements. NOTE: This is a critical installation requirement that must not be overlooked.

9. DO NOT install a T&P valve in the outlet (supply) water line of the HPWH unless required by local code.

6. Ensure isolation valves are installed on the HPWH supply

and return water line at the storage tank for servicing and purging the air from the HPWH during start-up.

7. Ensure the cold water supply is not connected directly to or

Tee fitted to the inlet water line on the HPWH. See the Service and Installation Notes for Inlet & Outlet Water Temperature on page 12. See Figure 7 and Figure 8 on page 22.

15. Connect building recirculation loop piping to the backup

water heater/storage inlet on multi tank preheat piping configurations.

16. Ensure the building recirculation loop pump is controlled by a

field supplied line thermostat and that it stops the pump when the recirculation line is hot. Your particular system may use

the included PLC to control the pump as well.

10.

17. When the HPWH unit is installed "above" the storage tank install a Tee fitting at a high point in the outlet water line with a purge valve to bleed air during start up.

18. Though not required, the manufacturer recommends

11.

installing a strainer at the inlet water line on the HPWH to help prevent scale build up in the heat exchanger. Service costs to clear blockages from the HPWH unit’s heat exchanger due to debris are not covered under the limited warranty.

ELECTRICAL

12.

21. BEFORE ENERGIZING THE UNIT ensure the power supply voltage and phase matches the requirements on the HPWH rating label. Damage resulting from applying the wrong voltage or phase is not covered under the limited warranty.

13.

22. Ensure the power supply breaker or the fuses disconnect switch are within the requirements for the unit as shown on the HPWH rating label.

14.

23. Ensure the power supply wiring meets the MCA (Minimum Circuit Ampacity) requirements shown in this manual and on the HPWH data label.

15.

24. Ensure the HPWH is properly grounded according to the instructions in this manual and local code requirements.

25. Ensure the power supply connections to the HPWH are

16.

connected properly and securely tightened.

26. Ensure all electrical connections in the HPWH control panel

17.

are securely tightened.

18.

27. When the factory supplied Temperature sensor is used:

• Insure the sensor is installed properly.

• Ensure the Temperature Sensor has been installed in a designated temperature control opening in the mid/lower portion of the storage tank.

• Ensure the supplied Temperature Sensor is coated with a suitable heat transfer compound (paste).

Page 25

Pre-Startup Checklist

1. Before applying power, check all electrical connections. Tighten if necessary.

2. Verify electrical installation. Power requirements and branch circuit disconnecting

means match equipment nameplate specifications.

3. Make sure the hydronic system is flushed and purged of air. Remove and clean any strainers or filters if necessary.

4. Make sure the sensor for the temperature control is mounted to either the water tank or strapped to a water line for proper temperature control.

5. Remove the shipping blocks from under the compressor. Loosen the nuts on the spring mounting studs and pry up one side of the compressor at a time and remove. Leave the nuts loose on the spring mounting studs.

6. Power up circulator pump and verify water flow through the heat pump heat exchanger(s).

7. Apply power to the heat pump. Confirm power with an electrical meter. Check for proper control power, should be between 120 to 125 volts. *Note: The control power

should be on for 4 to 6 hours so the compressor crankcase heater has time to warm up the base of the compressor.

8. Start the heat pump by pressing the Start key on the Touchscreen. Go to the INFO screen and monitor the refrigerant pressures, hot water in and out temperatures and cold water in and out temperatures.

9. There are Fan, (or Blower, if so equipped), Direction stickers, mounted on each unit.

It may be helpful to record the operating data initially every 10 to 15 minutes just to see how the heat pump is performing.

Unit 2

Unit 1

Page 26

3 Phase Startup Procedures

 Make sure the disconnect is off and confirm there is no power on the distribution block on the

electrical panel.

 Pull Compressor fuses.  Trip the blower/fan motor starter.  Turn power on. Check and make sure the power at the distribution block is the same as the

power requirements on the data sticker that is on the electrical panel.

 Put an amp meter on one of the legs for the blower/fan motor. Confirm the amperage is in line

with the data sticker.

 Reset the manual motor starter for the blower/fan.  Make sure the blower/fan is going in the correct direction. (Should be blowing air at you when

you're standing in front of it)

 If it is going the wrong direction, then you need to switch the phases. You will need to switch

the phases that you supplied to the distribution block. The rotation on the blower/fan is rotating the same direction as the compressor, that was set at the factor. So, if the blower/fan is operating in the correct direction then your compressor is as well. Make sure to turn the power off before switching the phase. Confirm there is no power with an electrical meter then make the switch. Turn the blower/fan motor start off and then turn the power back on. Check for power and then turn the blower/fan motor starter back on and record the amperage. Confirm the rotation is correct.

 The factory temp setting is 125°F. If you would like to change the temperature, then now is the

(It can be done later as well).

time.

 Turn power off.  Double check to make sure all the air is out of the water line so the heat pump doesn't get air

bound.

 Pump Test – With the compressor fuses pulled and the blower/fan motor starter in the off,

(tripped), position. Turn the power back on. See figure #1 below. Press the orange by-pass button on the pump relay to operate the water pump. You should be able to hear the water flowing through the system. If not, there is a good chance the system is air bound and the air needs to be removed before starting the compressor. Turn power back off after test.

Figure #1

Commissioning Complete:

Signature: ___________________________

Page 27

Initial Start-Up

CAUTION OIL DILUTION! Bearing malfunction! It is important to ensure that new compressors are not subjected to liquid abuse. Turn the crankcase heater on 6 hours before starting the compressor. CAUTION High discharge pressure operation! Compressor damage! Do not use compressor to test opening set point of high-pressure cutout. Bearings are susceptible to damage before they have had several hours of normal running in. Liquid and high pressure loads could be detrimental to new bearings. It is therefore important to ensure that new compressors are not subjected to liquid abuse and high-pressure run tests. It is not good practice to use the compressor to test the high-pressure switch function on the production line. Switch function can be tested with nitrogen prior to installation and wiring can be checked by disconnecting the high-pressure switch during the run test.

Rotation Direction

Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single-phase compressors since they will always start and run in the proper direction. Three-phase compressors will rotate in either direction depending upon phasing of the power to L1, L2 and L3. Since there is a 50/50 chance of connecting power in such a way as to cause rotation in the reverse direction, it is important to include notices and instructions in appropriate locations on the equipment to ensure proper rotation direction is achieved when the system is installed and operated. Observing that suction pressure drops and discharge pressure rises when the compressor is energized allows verification of proper rotation direction. There is no negative impact on durability caused by operating three-phase Copeland Scroll™ compressors in the reversed direction for a short period of time, (under one hour), but oil may be lost. Oil loss can be prevented during reverse rotation if the tubing is routed at least 15 cm above the compressor. After several minutes of operation in reverse, the compressor protection system will trip due to high motor temperature. The operator will notice a lack of cooling. However, if allowed to repeatedly restart and run in reverse without correcting the situation, the compressor will be permanently damaged. All three-phase Scroll compressors are identically wired internally.

Therefore, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the identified compressor terminals will ensure proper rotation direction. Compressors ZB56K* to ZB220K*, ZS56K* to ZS11M* and ZF24K* to ZF48K* have an electronic protection unit (INT69SCY2) that will not let the compressor operate if the phasing of the wires is incorrect.

Starting Sound

During the very brief start-up, a clicking sound is audible, resulting from initial contacting of the spirals and is normal. No start assist devices are required for single-phase compressors, even if a system uses non-bleed expansion valves. Due to the design of the Copeland Scroll, the internal compression components always start unloaded even if system pressures are not balanced. In addition, since internal compressor pressures are always balanced at start-up, low voltage starting characteristics are excellent for Copeland Scroll™ compressors. Moreover, if low voltage conditions exist at start up, protector trips could result.

Page 28

Start Up Check List

START UP

flow is decreased the temperature rise will increase and as water flow is increased the temperature rise will decrease. Because of this relationship between temperature rise and flow rate this test can be useful to determine if the flow rate through the heat exchanger is adequate. Other factors may also affect water flow rate and temperature rise such as debris or lime scale build up inside heat exchanger or water pump operation.

If the temperature rise through the HPWH is consistently lower than 8°F the outlet (supply) valve can be throttled slightly closed to reduce the water flow rate. This may be necessary on installations with a minimum of water piping between the HPWH and the water system or tank.

Throttling should be done in small increments, no more than 1/8 turn of the valve handle at a time. The HPWH must be allowed to run for approximately 5 minutes between each adjustment before the temperature rise is measured again. If the outlet valve is throttled during start up, mark the valve position and remove the valve handle to ensure it is not accidentally changed.

If the temperature rise through the HPWH is consistently greater than 12°F the water flow may be restricted. Ensure all water valves between the HPWH and the tank or water system are fully open. Ensure the external water pump is running. If the temperature rise continues to be excessive call the toll free technical support phone number: 1-800-777-6953 ext. 208

5. Using thermometers or temperature sensors, measure the temperature of the incoming source water to the HPWH and the outgoing source water leaving the unit. The outgoing temperature should be 12°F to 20°F (7°C to 13°C) cooler than the incoming. The higher the flow rate the lower the temperature differential will be.

6. When all of the above procedures are complete, adjust the tank temperature control set point to desired system temperature, not to exceed 150°F (66°C). Remove all test instruments and replace all cabinet doors.

This start-up refers to several tools and test instruments needed to complete the procedure. See Required Tools and Materials on page 18.

Turn off power to the water heater before performing any service.

Electrical Shock Hazard

•

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.

•

1. Ensure the Installation Checklist has been completed.

2. Ensure the HPWH, storage tank and water system has been

purged of air and all valves are in the position for normal operation.

3. Turn on power at the circuit breaker or disconnect switch serving the HPWH. If the HPWH does not start immediately:

• Wait 5 minutes in case the anti short cycle timer has halted operation. This control system feature protects the HPWH from rapid short cycling that can cause permanent damage to the unit.

• Ensure the operating set point on the tank temperature control is adjusted high enough to initiate a call for heat. The recommended setting is 120°F to 150°F (29°C to 66° C).

• DO NOT set the operating set point on the tank temperature control above 150°F. See Water Temperature Range on page 11.

• Ensure the Differential Set Point is not set too high. Higher differential settings will cause greater temperature swings in system temperature. Lower differential settings can cause unit short cycling. The recommended setting is 10°F.

• If the unit does not start after all of the above procedures have been followed. Refer to the troubleshooting section of this manual.

4. Securely attach surface mount thermometers or temperature sensors to the inlet (entering) and outlet (leaving) water lines near the HPWH cabinet. If there are thermometers installed in the inlet and outlet in close proximity to the HPWH water connections they can be used for the following check. Ensure the water outlet (supply) and inlet (return) valves are fully open. Start the HPWH and allow it to operate for 5 minutes. With the HPWH operating record the inlet and outlet temperatures. During normal operation, the outlet line should be 8°F to 12°F (4°C to 7°C) hotter than the inlet line. This is the temperature rise through the heat exchanger inside the HPWH unit. Note: Temperature rise and water flow rate through the heat exchanger inside the HPWH are uniformly linked. As water

Job#_______________Model#___________________Ser#__________________ Date_______

1. Check all wire connections for tightness: OK? □

2. Verify correct voltage

3. Verify water flow rates

4. Run unit at 100% capacity for a minimum of 15 min. OK? □

5. Supply (condenser) water temp. in (Tcondin)__________°F

6. Supply (condenser) water temp. out (Tcondout)__________°F

7. Heating Capacity__________btuh

8. Source (evaporator) water temp. in (Tevapin)__________°F (Only applicable to Water Source Units)

9. Source (evaporator) water temp. out (Tevapout)__________°F (Only applicable to Water Source Units)

10. Compressor amps per phase

11. Superheat measured prior to accumulator ________°F

12. Sightglass circuit 1: Clear? □ Bubbles? □

13. Evaporator Pressure _____________psig

14. Condenser Pressure _____________psig

15. Compressor Discharge Line Temperature ________°F

16. Refrigerant Liquid Line Temperature ________°F

17. Oil Level Sight Glass compressor Full□ ¾□ ½□ ¼□

18. Approach Temperature (SCT – Tcondout )___________ °F

Signature________________________ Print Name___________________________

Voltage = ________VAC

Evap. Flow________gpm Cond. Flow________gpm

Heating Capacity = (Tcondout – Tcondin) X Cond. Flow X 500

Ph1__________ amps Ph2 __________amps Ph3 __________amps

Saturated Evaporator Temperature (SET)______°F

Saturated Condenser Temperature (SCT)________°F

Page 29

START UP

This start-up refers to several tools and test instruments needed to complete the procedure. See Required Tools and Materials on page 18.

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.

1. Ensure the Installation Checklist has been completed.

2. Ensure the HPWH, storage tank and water system has been

purged of air and all valves are in the position for normal operation.

3. Turn on power at the circuit breaker or disconnect switch serving the HPWH. If the HPWH does not start immediately:

• Wait 5 minutes in case the anti short cycle timer has halted operation. This control system feature protects the HPWH from rapid short cycling that can cause permanent damage to the unit.

• Ensure the operating set point on the tank temperature control is adjusted high enough to initiate a call for heat. The recommended setting is 120°F to 150°F (29°C to 66° C).

• DO NOT set the operating set point on the tank temperature control above 150°F. See Water Temperature Range on page 11.

• If the unit does not start after all of the above procedures have been followed. Refer to the troubleshooting section of this manual.

Page 30

ELECTRONIC TEMPERATURE CONTROLS

CONTROLLER

The Geyser C-series comes standard with a Johnson Controls A421 Model # A421GBF-x controller. This control is used to control the water temperature in the tank by supplying a call signal to the Heat Pump Water Heater. The control comes with some factory settings.

The A421 control should never be set higher than 150°F, failure to comply could void the warranty.

Johnson Controls A421 Controller

Model # A421GBF-x

Notice: Please make sure you are running a Johnson controller (pictured above) before you continue to the next page. If you are running a PLC (Programmable Logic Controller) skip to the directions starting on page 38.

33.

Page 31

FUNCTION RANGES &

the OFF value again.

SCREEN NAVIGATION

The A421 control buttons and display operate the same in both Basic and Advanced mode.

• When in Menu screens the parameters and values will ash on and off.

• Use the Arrow keys to navigate through all of the parameters and values

• To select a parameter press MENU

• To save a selected value, press MENU.

This will automatically bring you to the next settable parameter

• To exit menus and return to the main screen press both arrow keys simultaneously.

SETTINGS

Some of the A421 controllers settings are preprogrammed by Nyle before shipment. These settings along with parameter ranges have been provided for your reference in the Parameter Settings table below.

PARAMETER SETTINGS

FUNCTION RANGE

OFF: Desired

Temp Hi

On: Desired

Temp Low

ASd: Anti-short

Cycle Delay

SF: Sensor

Failure

bLL: Back light

Level

ADVANCED PARAMETER SETTINGS

Un: Temp.

Units

tSb: Temp.

Setback

So: Sensor

Offset

HtS: High

Temp. Stop

LtS: Low Temp.

Stop

-40 to 212 °F

-40 to 100 °C

-40 to 212 °F

-40 to 100 °C

0 - 12 Min 0 min

0= Output De-energized

1= Output Energized

0 = off

1-10 = on, varying

brightness

°F and °C °F

-50 to 50°F

-30 to 30°C

-5 to 5°F

-3 to 3°C

-40°F -212°F

-40°C - 100°C

-40°F -212°F

(-40°C - 100°C)

FACTORY

SETTINGS

120°F

30°F

0°F

120°F

40°F

Notes: If you do not press MENU to save a new value, the control reverts to the last saved value.

After 30 seconds of inactivity, while in any screen, the control reverts to the Main screen.

Saved settings remain in the control’s memory during power interruptions.

BASIC MODE

In this mode you can adjust the OFF, On, SF and ASd Parameters ONLY. Most adjustments that are needed to run your unit will be performed in this mode.

Basic Mode Menu:

From the main screen press MENU once. The screen will display the ashing OFF parameter indicating that you have entered the menu.

OFF: This parameter indicates your desired high temperature. When this temp is reached the unit will enter a cool down mode until the On value is reached. WARNING: Never set above 150°F.

ON: This parameter indicates your desired low temperature. When this temperature is reached the unit will enter heating mode until it reaches

Page 32

ASd: The Anti-Short Cycle Delay indicates the time required for the unit to wait before running again. This parameter is set to 0 min

because Nyle units come equipped with safety timers already in place.

SF: Sensor Failure indicates that the

temperature sensor has failed.

bLL: Black Light Level indicates the brightness of the LCD screen.

RESTRICTED MODE

Switching the Controller to Restricted Mode will prevent users from adjusting most or all of the parameter settings. The main screen will function normally.

Note: The OFF parameter is the only parameter that can be accessed in Restricted Mode. So be sure that your desired parameter values are set before changing over to restricted mode.

ADVANCED MODE

In Advanced mode you can adjust all of the basic parameters as well as; Un, Tsb, So, HtS and LtS. The main function of this mode is to add more control over your unit and to set restrictions for parameters in basic mode.

Advanced Mode Menu:

From the main screen press and hold both arrow keys simultaneously. The screen will display the ashing Un parameter to indicate that you have entered the menu.

Un: Indicates the temperature units. This can be in either Fahrenheit (°F) or Celsius (°C).

LtS: Low Temp. Stop indicates the lowest temperature that the On or OFF parameters can be set to in Basic Mode.

In addition, the differential between the OFF/ON parameters is fixed in restricted mode. If the OFF parameter is adjusted the On parameter will adjust to maintain the differential.

Setting the controller to restricted mode:

• Turn power off from the controller

• Carefully remove the front panel

• Locate the jumper and carefully position it on

one pin as shown in the diagram below.

The controller is now in restricted mode. Securely replace the cover before reconnecting power to the controller.

HtS: High Temp. Stop indicates the highest temperature that the On or OFF parameters can be set to in Basic Mode.

tSb: Temp Setback indicates the value for setting back the On and OFF temperature values. Default to 0°F because it is not

applicable to the application of this unit type.

So: Sensor Offset allows for compensation

of any difference between the displayed temperature and the temperature being read by the sensor.

Lock out

You can format your parameters to completely restrict all user adjustment of the control when in restricted mode. To do this set the HtS value equal to the OFF value and the LtS equal to the On value. This makes the OFF/On range equal to the HtS/LtS range and thereby unadjustable in restricted mode.

Page 33

Evaporator temperature defrost cut-in

Evaporator temperature defrost cut-out

Compressor Anti-Short Cycle Delay 500 sec

Compressor Anti-Short Cycle Delay

34°F

410 PSI

300 PSI

12 PSI

15 PSI

Page 34

MASTER SCREENS

MASTER PANEL HOME SCREEN

MASTER PANEL CONFIGURATION SCREEN

TERMINOLOGY

MASTER PANEL ALARM SCREEN

HOME SCREEN

“LP” – Low Pressure: indicates the suction line pressure on the low side of the system “HP” – High Pressure: indicates the discharge line pressure on the high side of the system “LLSV” – Liquid Line Solenoid Valve: indicates the position of the LLSV (open or closed) “Comp” – Compressor: indicates the status of the compressor (on or o) “EvapFlow” – Evaporator Flow: indicates if the blower is on (Air to Water HPWH) OR if there is water owing through the evaporator (Water to Water HPWH) “CondFlow” – Condenser Flow: indicates if there is water owing through the condenser “Cond” – Condenser Temperature: indicates the leaving water temperature from the condenser “Evap1” – Evaporator 1: indicates the evaporator temperature of the rst evaporator “Evap2” – Evaporator 2: indicates the evaporator temperature of the second evaporator (only the C250A Air to Water HPWH has two evaporators) “CTD” – Compressor Time Delay: indicates remaining time in compressor delay countdown “PTD” – Pump Time Delay: indicates remaining time in pump countdown, when the count down starts the pump turns on

Page 35

Indicator Box – indicates if the unit has been called to run (green means run, red means on standby) Heat Call – indicates if the master is calling units to run to meet building demand (green means run, red means on standby) “TempAvg” – Tank Temperature Average: indicates the average current tank temperature which comes from all of the valid connected temperature probes averaged together “TempSet” – Tank Temperature Setpoint: indicates the desired tank temperature to be maintained

CONFIGURATION SCREEN

“Comp HRS” – Compressor Hours: indicates the compressor run time hours of each unit “Tank Di Set” – Tank Dierential Setpoint: sets the minimum tank temperature rise required to avoid calling another unit “System Timer” – System Timer: sets the maximum time that the tank has to achieve the Tank Di Set value to avoid calling another unit “TempDi” – Temperature Dierence: sets the dierence below the setpoint where the master will give a call for slaves to run “SAVE” button – Saves the “Tank Di Set” and “System Timer” parameters “Master IP Address” – IP Address used to connect panel to BMS system “Master IP Subnet” – subnet mask for address range IP is congured in “Master IP Gateway” – IP Address for internet router on site used to connect to unit via VPN

ALARM SCREEN

“HIGH PRESSURE 1” – indicates if unit 1 has alarmed out on high pressure “LOW PRESSURE 1” – indicates if unit 1 has alarmed out on low pressure “COND FLOW 1” – indicates if unit 1 has alarmed out on condenser water ow “EVAP FLOW 1 / BLOWER 1” – indicates if unit 1 has alarmed out on evaporator ow “M PROTECTION 1” – indicates if unit 1 has alarmed out on motor protection “OIL PRESSURE 1” – indicates if unit 1 has alarmed out on oil pressure “ESTOP” – indicates if the Estop has been pressed

“TANK1 PROBE STATUS” – indicates if tank 1’s probe is connected and reading valid data

MASTER CONTROL PANEL

SETUP TO SLAVE UNITS

1) Hardwire all slave units to individual power sources

rated for the equipment with disconnects

2) Hardwire the “Master Control Panel” to a 120V power supply through the junction box

3) Hardwire each temperature probe into the junction box for the Master Control Panel and then permanently attach them to their respective tanks

4) Connect all of the slave units to the router in the junction box

5) Under the conguration screen press the “SEARCH FOR UNITS” button to nd all of the connected slaves (give the master controls 2 minutes to nd all of the slave units)

6) Check the master screen to make sure that all of the slave units are connected

MASTER CONTROLS UNIT SUPPORT

CALL SEQUENCE OF OPERATIONS

1) Set the “Tank Di Set” value to 1°F and the “System

Timer” value to 300s (5min), then press save to update the program

2) Once the master panel determines that there needs to be a heat call it will determine the unit call order based on; compressor run hours, alarm status, and unit number. Then the master will call the unit in the rst unit in the run order to turn on

3) If the tank temperature does not increase 1°F in 300 seconds than the second unit in the run order will be called to run

Page 36

4) The master controls will keep reevaluating these conditions and calling units as necessary to achieve the desired rise in the desired amount of time

5) If you nd that the units are not turning on fast enough to meet building demand change the “System Timer” to a smaller value in order to have units turn on quicker

6) If you nd that too many units are turning on and meeting the building demand very quickly (almost in a manner of short cycling) you should try increasing the “Tank Di Set” value so that additional units will only turn on as needed

SLAVE SCREENS

SINGLE UNIT HOME SCREEN

DISPLAYING ALARM STATUS

SINGLE UNIT HOME SCREEN

OPERATING WITH MASTER CONTROLS

SINGLE UNIT HOME SCREEN

OPERATING AS A SINGLE UNIT (IN DEFROST)

SINGLE UNIT ALARM SCREEN

SINGLE UNIT CONFIGURATION SCREEN

Page 37

SINGLE UNIT IP ADDRESS CONFIGURATION

SCREEN (FOR USE CONTACT NYLE)

TERMINOLOGY

HOME SCREEN

“LP” – Low Pressure: indicates the suction line pressure on the low side of the system “HP” – High Pressure: indicates the discharge line pressure on the high side of the system “LLSV” – Liquid Line Solenoid Valve: indicates the position of the LLSV (open or closed) “Comp” – Compressor: indicates the status of the compressor (on or o) “Blower” – Blower Overload Status: indicates if the blower motor starter is tripped on an Air to Water HPWH “TempSet” – Tank Temperature Setpoint: indicates the desired tank temperature to be maintained “CondFlow” – Condenser Flow: indicates if there is water owing through the condenser “Cond” – Condenser Temperature: indicates the leaving water temperature from the condenser “SLT ” – Suction Line Temperature: indicates the suction line temperature of the unit right before the compressor “Evap1” – Evaporator 1: indicates the evaporator temperature of the rst evaporator “Evap2” – Evaporator 2: indicates the evaporator temperature of the second evaporator (only the C250A Air to Water HPWH has two evaporators)

“CTD” – Compressor Time Delay: indicates remaining time in compressor delay countdown “PTD” – Pump Time Delay: indicates remaining time in pump countdown, when the count down starts the pump turns on Remote Mode Indicator – indicates if this unit is connected to a master panel via ethernet, if it isn’t then it will display a start button Alarm Indicator – indicates if there is a system alarm, click on the button to see which alarm is currently triggered Defrost Indicator – indicates if the unit is in a defrost cycle (in a defrost cycle the compressor shuts o and lets the fans run to warm up the evaporator)

CONFIGURATION SCREEN

“TempDi” – Temperature Dierence: sets the temperature dierence below setpoint where the unit will turn on (only available if the unit isn’t in remote mode) “CondFlow” – Condenser Flow: indicates the owrate through the condenser (based on frequency read by PLC through integrated paddle wheel ow sensor) “Low Limit” – Sets the lowest ow rate limit that the unit will shut o at (enabled for Single-Pass applications only), press the save button to save the lower limit in a Single-Pass conguration “Comp HRS” – Compressor Hours: indicates the run hours of the compressor “Purge” button – this button will run the pump relay for 2 minutes to allow you to purge the system without turning on the units

ALARM SCREEN

“HIGH PRESSURE” – indicates if the unit has alarmed out on high pressure “LOW PRESSURE” – indicates if the unit has alarmed out on low pressure “SHORT CYCLE” – indicates if the unit has been short cycling “OUTLET FLOW” – indicates if the unit has alarmed out on condenser water ow “BLOWER” – indicates if the blower motor starter as tripped “M PROTECTION” – indicates if the unit has alarmed out on motor protection

Page 38

“ESTOP” – indicates if the unit has alarmed out because an Estop has been pressed “FAILOVER 1” – indicates if the unit’s temperature probe has failed “OIL PRESSURE” – indicates if the unit has alarmed out on oil pressure

STOP SCREEN

Unit IP Address – This IP address is the designation for the unit itself, Nyle recommends running the system on factory settings (ex. 192.168.1.(“Unit Number” AKA

1))

Unit IP Subnet – This number is used to determine the size of the network the unit is connecting to. (ex.

255.255.255.0)

Master IP Address – This is the address of the Nyle Systems Master Panel (ex. 192.168.1.50)

Unit Number – Only used for custom network congurations, this congures your Nyle unit to connect to a Master Panel under a desired number.

The stop screen will pop up as a conrmation whenever the “STOP” button on any screen is pressed.

IP CONFIGURATION

New Nyle units can be congured for a variety of dierent networks on the y and the procedure is quick and easy to accomplish.

1. Connect the Sim/Conguration Jumper to your Nyle Systems C250 Unit you would like to congure.

2. Navigate to the “Diag” button in the bottom right corner of your screen and select “IP Conguration”

Page 39

MAINTENANCE AND SERVICE

CLEANING INTERNAL INSULATION

Inspect the internal insulation on a yearly basis for any microbial growth. The insulation never has to be cleaned unless microbial growth is detected. If microbial growth is detected, follow the removal steps below:

1. Disconnect all power to the unit and follow the prescribed lock-out/tag-out procedure.

2. Wear the prescribed personal protective equipment prescribed from the cleaning product instructions.

3. Remove as much dirt and organic material from the insulation using a vacuum device with a HEPA lter (99.97% efcient at 0.3 micron particles). Be careful not to tear the insulation during the cleaning procedure.

4. Apply the microbial cleaning agent as prescribed by the application and usage instructions.

5. Allow the unit to dry thoroughly.

6. If necessary, apply an anti-microbial agent on the insulation per the instructions provided on the product label.

7. Discard collected microbial contaminants as required by local or state codes.

BRAZE PLATE CLEANING INSTRUCTIONS

In some applications the heat exchanger may be subjected to severe uid conditions, including high temperture hard water conditions, causing accelerated scaling and corrosion rates, and will diminish performance.

It is important to establish regular cleaning schedules, A 5% solution of Phosphoric Acid or Oxalic Acid may be considered. Other types of solutions can be obtained from your local wholesaler. Make sure cleaning solution is applicable for stainless steel and copper and all directions are followed.

Do not heat solution. Be sure to flush heat exchanger with fresh water after cleaning. See Figure 12.

Figure 12

Page 40

TROUBLESHOOTING

CHECKING REFRIGERANT CHARGE

Servicing of the refrigeration circuit must only be performed by agencies or individuals possessing Type II or Universal certification as defined in Section 608 of the Clean Air Act. See Qualifications on page 8.

This HPWH unit is factory charged with 134a refrigerant. See the rating label on the HPWH unit and Table 9 for refrigerant charge by weight. It should not be necessary to add or remove refrigerant during installation or start up. Refrigerant lost during frequent refrigerant pressure testing can cause low refrigerant conditions. Air and water ow should always be checked rst to eliminate

other potential problems before checking the refrigerant charge.

Check Water Temperature Rise

Always check water temperature rise through the HPWH unit’s internal heat exchanger before checking the refrigerant charge. See Start Up on page 29 for information on how to measure the water temperature rise.

If the measured water temperature rise during start up was within 8°F to 12°F (4°C to 7°C) checking the charge is not necessary unless other conditions warrant testing.

If the measured temperature rise through the HPWH unit is less than 8°F (4°C) checking the charge is not necessary unless other conditions warrant testing. Short water piping runs between the HPWH and the storage tank will produce lower temperature rises and are not problematic.

If the measured temperature rise through the HPWH unit is more than 12°F (7°C) check for restrictions in the inlet and outlet water piping connected between the HPWH unit and the storage tank.

SUPERHEAT CALCULATION

Measure and record the suction pressure at the suction line pressure access port inside the unit. Convert the recorded suction pressure to saturated temperature.

3. Measure the suction line temperature near the suction line pressure access port inside the unit.

4. Compare the suction line temperature to the to the saturated

temperature in Table 10.

TABLE 10

R134A SATURATED TEMPERATURE CHART

SATURATED

TEMPERATURE °F

SATURATED

TEMPERATURE °C

REFRIGERANT

PRESSURE (PSI)

0 -18 7

5 -15 9

10 -12 12

15 -9 15

20 -7 18

25 -4 22

30 -1 26

35 2 30

40 4 35

45 7 40

50 10 45

55 13 51

60 16 57

65 18 64

70 21 71

75 24 79

80 27 87

85 29 95

90 32 104

95 35 114

100 38 124

105 41 135

110 43 146

115 46 158

120 49 171

125 52 185

130 54 199

135 57 214

140 60 229

145 63 246

150 66 263

155 68 281

5. The difference between saturated temperature and suction

line temperature is the superheat. Superheat normal range

should be 8°F to 12°F (4.4°C to 6.7°C).

TABLE 9

MODEL FACTORY CHARGE R134A

C25

C60

C90

C125

C185

C250

14#

20#

60#

PROBLEM POSSIBLE CAUSES CORRECTIONS

Heat pump is too noisy.

Water on oor around

the heat pump and/or

water tank.

Heat pump is not running -

electrical issues.

Heat pump is not running -

high pressure fault

Heat pump is not running -

low pressure fault

Water is never hot enough.

* Reset the heat pump by removing then restoring power to the unit at the breaker or from the manual switch. (There will be a three minute delay

before heat pump restarts.) If the heat pump cuts out again on LOW or HIGH PRESSURE, additional troubleshooting is necessary to nd the cause

DO NOT CONTINUE TO RESET THE HEAT PUMP, AS CONTINUED SHORT-CYCLING MAY STRESS OR DAMAGE INTERNAL COMPONENTS.

1. Sheet metal fasteners are loose.

2. Operating vibration is transferring to oor or building structure.

1. Tubing, valves, or fittings are leaking.

4. Condensation forming on the bottom of unit

1. Circuit does not have adequate ampacity.

2. Short circuit or loose connection in field wiring.

3. Short circuit or loose connection in the cabinet

4. Thermostat failure.

5. Defective anti-short cycle timer.

6. Compressor burn-out.

1. Thermostat setting too high

2. Source Water temperature over 100° F

3. Low water flow causes

A. external pump is not operating

B. piping between the heat pump and storage tank

exceeds 50 equivalent feet

C. heat exchanger has scale buildup

D. shut off valves are partially closed

1. Source Water temperature below 40°F

2. Loss of refrigerant

1. Thermostat setting is too low.

2. Heat pump/storage tank undersized for application.

Heat pump is not properly connected to storage tank.

4. Unit cooling coil is overcooling the source water.

Tighten fasteners.

Place vibration dampeners underneath unit.

Repair leaks as necessary.

Shim unit to level. See installation section.

Cover bottom of unit with foam insulation.

Refer to nameplate for unit requirements.

Check eld wiring diagram. Tighten all connections.

Check for loose wiring and tighten.

Replace thermostat

Reset phase monitor

Unknown

Replace compressor (refer to compressor change-out page)

Thermostat setting should not exceed 150°F.

Keep heat pump off until room temperature

is back in operating range

Low water ow corrections

replace unit pump

reduce piping or add booster pump

clean heat exchanger with a mild acid wash

open all shut off valves

Keep heat pump off until room temperature is back in

operating range

Find source of leak, repair and recharge

Set thermostat for storage tank to a higher temperature.

Increase size of storage tank or install gas or electric heater to make up for shortfall.

Refer to field piping diagrams for recommended piping.

Page 41

CHECKING REFRIGERANT CHARGE

other potential problems before checking the refrigerant charge.

Check Water Temperature Rise

If the measured water temperature rise during start up was within 8°F to 12°F (4°C to 7°C) checking the charge is not necessary unless other conditions warrant testing.

If the measured temperature rise through the HPWH unit is more than 12°F (7°C) check for restrictions in the inlet and outlet water piping connected between the HPWH unit and the storage tank.

SUPERHEAT CALCULATION

Measure and record the suction pressure at the

suction line pressure access port inside the unit. Convert the recorded suction pressure to

saturated temperature.

3. Measure the suction line temperature near the suction line pressure access port inside the unit.

4. Compare the suction line temperature to the to the saturated

temperature in Table 10.

5. The difference between saturated temperature and suction

line temperature is the superheat. Superheat normal range

should be 8°F to 12°F (4.4°C to 6.7°C).

TABLE 9

MODEL FACTORY CHARGE R134A

C25

C60

C90

C125

C185

C250

14#

20#

60#

TABLE 10

R134A SATURATED TEMPERATURE CHART

SATURATED

TEMPERATURE °F

0 -18 7

5 -15 9

10 -12 12

15 -9 15

20 -7 18

25 -4 22

30 -1 26

35 2 30

40 4 35

45 7 40

50 10 45

55 13 51

60 16 57

65 18 64

70 21 71

75 24 79

80 27 87

85 29 95

90 32 104

95 35 114

100 38 124

105 41 135

110 43 146

115 46 158

120 49 171

125 52 185

130 54 199

135 57 214

140 60 229

145 63 246

150 66 263

155 68 281

SATURATED

TEMPERATURE °C

REFRIGERANT

PRESSURE (PSI)

Page 42

LEGEND

thermostat.

4. See Closed Systems and Thermal Expansion on page 13

5. See Water Connections on page 17.

6. If a building recirculation loop is present the circulation pump must be controlled by a

BUILDING

RECIRCULATION

LOOP RETURN

HOT WATER

OUT TO

FULL PORT BALL VALVE

CHECK VALVE

TEMPERATURE & PRESSURE

PRESSURE RELIEF VALVE

RELIEF VALVE

DRAIN

TEMPERATURE GAGE

TANK OR LINE TEMPERATURE

CIRCULATING PUMP

WYE STRAINER

CONTROL

LINE THERMOSTAT

WATER OUT

PREHEATED

HEAT TRAP PIPING

MINIMUM 18 INCHES

FIXTURES

PIPE T&P TO

BACKUP

TAN K

THERMOSTAT

OPEN DRAIN

WATER

HEATER

COLD

WATER

SUPPLY

EXPANSION

TANK

TO THE STORAGE TANK ON PREHEAT

IMPORTANT INSTALLATION NOTES:

1. COLD WATER SUPPLY MUST CONNECT

PIPING CONFIGURATION AND OTHER DEVICES;

ONE HEAT PUMP, SINGLE TEMPERATURE, PREHEAT SYSTEM WITH

VERTICAL STORAGE TANK AND BACKUP WATER HEATER

3. See Temperature - Pressure Relief Valve on page 14.

WATER PIPING DIAGRAMS

2. See Water Temperature on page 10.

Before installation of water piping review the following:

1. See Mixing Valves on page 13.

WARNING: THIS DRAWING SHOWS SUGGESTED

WITH FORCED BUILDING RECIRCULATION

SYSTEMS

RETURN LINE MUST CONNECT TO THE

INLET OF THE BACKUP WATER HEATER

ON PREHEAT SYSTEMS.

2. BUILDING RECIRCULATION LOOP

PURGE &

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

PIPE T&P TO

OPEN DRAIN

VALV E

FLUSH

HPWH

STORAGE

WATER

(OUTLET)

SUPPLY

TANK

RETURN

WATER

(INLET)

VALV E

FLUSH

DRAIN &

SUPPLY

FOR HPWH MODELS

FIELD SUPPLIED PUMP

WITHOUT FACTORY PUMP

FINISHED

FLOOR

Page 43

FULL PORT BALL VALVE

CHECK VALVE

DRAIN

TEMPERATURE GAGE

LEGEND

thermostat.

4. See Closed Systems and Thermal Expansion on page 13

5. See Water Connections on page 17.

6. If a building recirculation loop is present the circulation pump must be controlled by a

NOTE:

CONNECT BUILDING

RECIRC RETURN TO

INLET OF BACKUP

WATER HEATER

WHEN PRESENT

COLD WATER

SUPPLY

EXPANSION

TANK

BUILDING

RECIRCULATION

LOOP RETURN

LINE THERMOSTAT

WYE STRAINER

TANK OR LINE TEMPERATURE

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

CONTROL

CIRCULATING PUMP

TANK THERMOSTAT

TANK

STORAGE

PIPING CONFIGURATION AND OTHER DEVICES;

ONE HEAT PUMP, SINGLE TEMPERATURE WITH

VERTICAL STORAGE TANK

3. See Temperature - Pressure Relief Valve on page 14.

WATER PIPING DIAGRAMS

2. See Water Temperature on page 10.

Before installation of water piping review the following:

1. See Mixing Valves on page 13.

WARNING: THIS DRAWING SHOWS SUGGESTED

WITH FORCED BUILDING RECIRCULATION

HOT OUTLET

WATER HEATER

TO FIXTURES OR

INLET OF BACKUP

PIPE T&P TO

OPEN DRAIN

FLUSH

PURGE &

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

VALV E

SUPPLY

HPWH

WATER

(OUTLET)

(INLET)

WATER

RETURN

VALV E

FLUSH

DRAIN &

SUPPLY

FOR HPWH MODELS

FIELD SUPPLIED PUMP

WITHOUT FACTORY PUMP

FINISHED

FLOOR

Page 44

NOTE:

CONNECT BUILDING

BUILDING

RECIRC RETURN TO

RECIRCULATION

LOOP RETURN

WHEN PRESENT

INLET OF BACKUP

WATER HEATER

LEGEND

thermostat.

4. See Closed Systems and Thermal Expansion on page 13

5. See Water Connections on page 17.

6. If a building recirculation loop is present the circulation pump must be controlled by a

FULL PORT BALL VALVE

TEMPERATURE & PRESSURE

RELIEF VALVE

CHECK VALVE

PRESSURE RELIEF VALVE

TEMPERATURE GAGE

CIRCULATING PUMP

DRAIN

WYE STRAINER

TANK OR LINE TEMPERATURE

CONTROL

HOT OUTLET

WATER HEATER

TO FIXTURES OR

INLET OF BACKUP

LINE THERMOSTAT

TANK THERMOSTAT

TANK

STORAGE

COLD WATER

SUPPLY

EXPANSION

TANK

TWO HEAT PUMPS, SINGLE TEMPERATURE WITH

VERTICAL STORAGE TANK

3. See Temperature - Pressure Relief Valve on page 14.

WATER PIPING DIAGRAMS

2. See Water Temperature on page 10.

Before installation of water piping review the following:

1. See Mixing Valves on page 13.

WITH FORCED BUILDING RECIRCULATION

PIPE T&P TO

OPEN DRAIN

VALV E

PURGE

WATER

(OUTLET)

SUPPLY

PIPING CONFIGURATION AND OTHER DEVICES;

WARNING: THIS DRAWING SHOWS SUGGESTED

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

HPWHHPWH

FLUSH

VALV ES

FLUSH

VALV ES

DRAIN &

(INLET)

WATER

RETURN

SUPPLY

FOR HPWH MODELS

FIELD SUPPLIED PUMP

WITHOUT FACTORY PUMP

FINISHED

FLOOR

Page 45

CHECK VALVE

FULL PORT BALL VALVE

LEGEND

TEMPERATURE & PRESSURE

RELIEF VALVE

PRESSURE RELIEF VALVE

DRAIN

TEMPERATURE GAGE

TANK OR LINE TEMPERATURE

CIRCULATING PUMP

WYE STRAINER

CONTROL

BUILDING

RECIRCULATION

LOOP RETURN

LINE THERMOSTAT

NOTE:

CONNECT BUILDING

TANK THERMOSTAT

RECIRC RETURN TO

INLET OF BACKUP

WATER HEATER

WHEN PRESENT

COLD WATER

SUPPLY

EXPANSION

TANK

thermostat.

4. See Closed Systems and Thermal Expansion on page 13

5. See Water Connections on page 17.

6. If a building recirculation loop is present the circulation pump must be controlled by a

VALV E

PURGE

HOT OUTLET

WATER HEATER

TO FIXTURES OR

INLET OF BACKUP

WATER

(OUTLET)

SUPPLY

HPWHHPWH

PIPE T&P TO

OPEN DRAIN

FLUSH

VALVES

TANK

STORAGE

SUPPLY

RETURN

WATER

(INLET)

FINISHED

FLOOR

TWO HEAT PUMPS, SINGLE TEMPERATURE WITH

HORIZONTAL STORAGE TANK

WITH FORCED BUILDING RECIRCULATION

3. See Temperature - Pressure Relief Valve on page 14.

WATER PIPING DIAGRAMS

2. See Water Temperature on page 10.

Before installation of water piping review the following:

1. See Mixing Valves on page 13.

WARNING: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND OTHER DEVICES;

CHECK WITH LOCAL CODES AND ORDINANCES

FOR ADDITIONAL REQUIREMENTS.

FLUSH

VALVES

DRAIN &

Page 46

LIMITED WARRANTY

COMMERCIAL HEAT PUMP WATER HEATERS

Nyle Systems, the warrantor, extends the following LIMITED WARRANTY to the original owner of this commercial heat pump water heater subject to the terms, conditions and disclaimers stated below:

1. COMPRESSOR

If the 5-Year Extended Compressor Warranty is purchased, and if within FIVE (5) years after delivery of this heat pump water heater the compressor shall prove, upon examination by the warrantor, to be defective, the warrantor will provide a replacement compressor.

2. ALL OTHER PARTS

If within ONE (1) year after delivery of this heat pump water heater any other part or portion shall prove, upon examination by the warrantor, to be defective in material or workmanship, the warrantor will repair or replace such part or portion at its option. This warranty also extends to any factory supplied accessories.

3. CONDITIONS AND EXCEPTIONS

Refrigerant, filters, refrigerant driers, and fan belts are not covered under this limited warranty. The warranty on all replacement parts, including the compressor, will be limited to the unexpired term of the original warranty. This warranty shall apply only when the heat pump water heater is installed in accordance with local plumbing and building codes, ordinances and regulations, the warranter's printed instructions provided with it and good industry practices.

a. This warranty shall apply only when the unit is:

(1) used at temperatures not exceeding the maximum system temperatures printed in the instructions provided;

(2) filled with potable water, free to circulate at all times and free of damaging water sediment or scale deposits;

(3) used in a non-corrosive and not contaminated atmosphere;

(4) in its original installation location, and under original ownership;

(5) in the United States, its territories or possessions, Canada, South America, Caribbean and Mexico;

(6) sized in accordance with proper sizing techniques for commercial heat pump water heaters;

(7) bearing the original rating label which has not been altered, defaced or removed, except as required by the warranter;

(8) energized at the proper voltage and phase as stated on the rating label;

(9) maintained in accordance with the instructions printed in the manual included with the heat pump water heater;

b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, will

void this warranty.

4. SERVICE REPAIR AND EXPENSE

Under this limited warranty the warranter will provide only a replacement heat pump water heater or part thereof. The owner is responsible for all other costs. Such costs may include but are not limited to:

a. Labor charges for service, removal, repair, or re installation of the water heater or any component part;

b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest

distributor and returning the claimed defective heater or part to such distributor;

c. All cost necessary or incidental for any materials and/or permits required for installation of the replacement heater or part.

5. LIMITATIONS ON IMPLIED WARRANTIES

Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

6. CLAIM PROCEDURE

Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is not practicable, the owner should contact:

Nyle Systems, LLC 12 Stevens Road Brewer, Maine 04412 Telephone: 1-800-777-6953

a. The warrantor will only honor replacement with identical or similar water heater or parts thereof which are

manufactured or distributed by the warrantor.

Dealer replacements are made subject to in-warranty validation and approval by warrantor.

7. DISCLAIMERS

NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR, OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT. a. Some states do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitation or

exclusion may not apply to you.

b. This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

Page 47

Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating label.

Model No. Serial No. Date Installed

Dealer’s Name

Dealer’s Address Phone No.

City and State Zip

Nyle Systems, LLC 12 Stevens Road Brewer, Maine 04412

1-800-777-6953

Sales: Ext 216 Service : Ext 208