American Water Heater RESIDENTIAL HYBRID ELECTRIC HEAT PUMP WATER HEATER manual

RESIDENTIAL HYBRID ELECTRIC HEA T PUMP W A TER HEA TER Service Handbook PRINTED IN THE U . S .A. 051 1 321549-000 SERVICE SHOULD ONL Y BE PERFORMED BY A QUALIFIED SER VICE TECHNICIAN FOR MODEL S: HPE10260H045DV (60 GAL.) HPE10280H045DV (80 GAL.) INST ALLA TION CONSIDERA TIONS - PREVENTIVE MAINTENANCE - OPERA TION & SERVICE - TROUBLESHOOTING[...]

2 Introduction .................................................................................................................. .......................................... 3 Certi fi cation and Approvals ......................................................................................................... ........................... 3 T ools R[...]

3 Introduction: Y our safety , and the safety of others, is extremely important in the servicing of this water heater . Many safety-related messages and instructions have been provided in this handbook and on your water heater to warn you and others of potential hazards. Read, understand and obey all safety messages and instructions that appear thr[...]

4 T erms, De fi nitions and Formulas First Hour Rating (FHR) is a volume of hot water delivered by a water heater during a 1-hour , Department Of Energy mandate test procedure. The FHR is given in gallons or liters. Energy Factor (EF) is an indicator of the combined thermal ef fi ciency and standby ef fi ciency of a water heater . The higher the[...]

5 Safety Precautions Explosion Hazard  7 HPSHUDWXUHSUHVVXUHUHOLHI YDOYHPXVWFRPSOZLWK $16, =&6$ DQG $60( FRGH  3URSHUOVL]HGWHPSHUDWXUH SUHVVXUHUHOLHIYDOYHPXVWEH LQVWDOOHGLQRSHQLQJSURYLGHG  &DQUHVXOWLQRYHUKHDWLQJ?[...]

6 W ater Heater Location • Centrally located with the water piping system. • The fl ooring beneath the water heater must be able to support the weight of the water heater when fi lled with water (see T able 1). T ABLE 1: Weight of water heater , full of water Capacity Weight (lbs) 60 Gallon 760 80 Gallon 967 • Located indoors (such as a bas[...]

7 Potential Installation Issues Symptom Cause Solution T emperature set to 60 ºF and not adjustable V acation mode is on T urn off V acation mode by pressing the V acation button Electric mode selected but the heat pump is running Upon initial start up, the heat pump will run until the tank temperature reaches the set point; this is done so that t[...]

8 Dry Fire is a term used to describe a heating element that is on and not fully submerged in water . This will result in permanent damage to the element. The dry fi re element protection algorithm is installed on this heat pump water heater and prevents damage to the heating elements in the event that power is applied to the water heater without [...]

9 W ater Piping System Cold W ater Inlet V alve Cold W ater Inlet Pressure Reducing V alve (PRV) should be installed where the water supply enters the residence. In a closed system, use a thermal expansion tank. See “Closed System/ Thermal Expansion” section. Cold W ater Outlet Shut-off V alve (Cold) T empered Water to Fixtures Untempered W ate[...]

10 tubing so that any discharge from the valve exits only within 6 in. (152mm) above drain, or at any distance below , the structural fl oor , and does not contact any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstance. IMPORT ANT : Only a new temperature and pressure relief valve should be us[...]

11 General Service information • V olts times Amps = W atts • W atts divided by V olts = Amps • Replacement Elements: Use replacement elements that are rated at the same wattage, voltage and shape indicated on the heater model and rating plate. Installing an element with a higher voltage rating or wattage output may create a safety hazard. (I[...]

12 Operational Overview Heat Pump W ater Heater Operation: Heat pump water heaters remove heat from surrounding air and use that heat to heat water . By doing so, heat pump water heaters can operate much more ef fi ciently and at signi fi cantly lower costs compared to standard electric water heaters. This heat pump water heater has four (4) oper[...]

13 Operating Y our Heat Pump W ater Heater °F/°C LOCK HEAT PUMP ELEMENT EFFICIENCY F VACA TION ELECTRIC HYBRID EFFICIENCY Power Button: On - Green Standby - Red T emperature Down (Decrease) Button T emperature Up (Increase) Button Operational Mode Buttons Wa te r T emperature Set Point W ater Heater Mode/Status Indicator W ater Heater Efficiency [...]

14 A B C D Figure 5 Control Board Overview Heat Pump W ater Heater Control Board Overview: The Control Board on the Heat Pump W ater Heater monitors the complete heating system and reports any errors through the User Interface Module (UIM). Based on the inputs from the sensors and/or the manual inputs from the UIM, the Control Board determines whic[...]

15 FUS202 FUS201 CN207 CN201 Figure 6 CN202 CN206 Section “A” CN 201 Line Power: • Pin 1 - Control board power wire L1 (240V AC) • Pin 2 - Control board power wire L2 (240V AC) • Pin 3 - Not used • Pin 4 - Control board power wire ground CN 202 ECO Bottom: • Pin 1 - Connect to lower heating element • Pin 2 - Connect to L1 behind ECO[...]

16 R Y 203 Upper Element Relay: • T erminal 1 - COM Connects to L1 behind the ECO Switch. • T erminal 2 - NO Connects to the upper heating element. CN 203 Powered Anode: • Pin 1 - Powered anode signal • Pin 2 - Ground Figure 7 T erminal 1 T erminal 2 Pin 2 Pin 1 Section “B” Section “B” of Control Board[...]

17 Section “C” of Control Board CN 204 Upper and Lower tank water temperature sensors: • Pin 1 - Upper water temperature sensor on tank. • Pin 2 - Upper water temperature sensor on tank. • Pin 3 - Lower water temperature sensor on tank. • Pin 4 - Lower water temperature sensor on tank. CN 212 T emperature Sensors: • Pin 1 - Ambient te[...]

18 CN 21 1/215 UIM Communication Cable: • Pin 1 - +5 V • Pin 2 - +12 V • Pin 3 - Signal A+ • Pin 4 - Signal B+ • Pin 5 - Ground Note: Both CN21 1 and CN215 are identical and either can be used for the UIM communication. CN 208 Overload Detection: • Pin 1 - High pressure switch. • Pin 2 - High pressure switch. • Pin 3 - Low pressure [...]

19 Wiring Diagram for Models W ith Relay L1 L2 Red Black Approved Connectors Junction Box Overload Protectio T o 240v 1 Phase Power supply Electrical Service ground Circui Breaker Ground Wire Green n t C R S G COMPRESSOR 1 10 1 5 1 5 1 6 1 4 1 2 1 4 1 2 1 3 1 4 N.O. COM. CN201 CN207 CN202 CN206 RY 203 CN208 CN215 CN211 CN212 CN204 CN203 HEA T PUMP [...]

20 Wiring Diagram for Non-Relay Models L1 L2 Red Black Approved Connectors Junction Box Overload Protectio T o 240v 1 Phase Power supply Electrical Service ground Circui Breaker Ground Wire Green n t FIigure 1 1[...]

21 Accessing the Maintenance Display The User Interface Module on the front of the heat pump water heater has a multi-function display that gives information about the status and condition of the operation of the water heater . In power saving mode, the display will be off; momentarily touching any of the buttons above or below the display area wil[...]

22 E l ement T est (Continuity T ester) I. Preparing for the T est 1. Press the power button on the User Interface Module (UIM). 2. T urn off power to the water heater at the breaker or disconnect switch serving the water heater . 3. V erify there is no power at the incoming power connections to the water heater with an AC V olt meter . 4. Remove t[...]

23 E l ement T est (OhmMeter) IIA. T esting for a Burned Out Element 1. Complete Preparing for the T est before you proceed. 2. Measure the element’s resistance by placing a probe on each terminal. (See graphic at right.) 3. Compare your result with the following: A. If the resistance is between 10 and 25 Ohms, the element is good. Proceed to Com[...]

24 Heating Element Replacement Replacement heating elements must be of the same style and V oltage/wattage rating as the ones originally in the water heater . This information can be found on the fl ange or terminal block of the element or on the water heater data plate. IMPORT ANT : Before replacing any element, con fi rm that you have the corre[...]

25 Energy Cutout (ECO) Switch T roubleshooting ECO Function and T roubleshooting: An energy cutout (ECO) switch is installed on this water heater to shut down the water heating means in the event of a malfunction. If the upper tank temperature reaches 190°F . the ECO contacts will open breaking the L1 and L2 legs that feed the upper heating elemen[...]

26 THERMAL PROTECTOR AUX. MAIN COMPR. MOTOR RUN CAP ACITOR C SR Figure 17 If the compressor is not operating or is not operating correctly , the run capacitor may be the cause and should be checked. A bad capacitor will typically be either shorted or open. Visually inspect the body of the capacitor; look for any sign of the housing bulging, splitti[...]

27 Powered Anode T roubleshooting and Replacement Checking the Powered Anode for Proper Operation: When dissimilar metals are in contact with water , a galvanic cell will likely result and corrosion of the metal components will occur . If left unchecked, corrosion will weaken the wall of a water heater tank which will eventually leak. Passive anode[...]

28 Compressor Check Flow Chart Compressor Fault Check maintenance display Put unit in stand by W ait eight (8) minutes for compressor time out T urn power off at breaker / fuse panel V erify connections and insure they are seated fully Check Compressor shell temperature Allow compressor to cool; thermal switch to reset Restore power at breaker / fu[...]

29 Powered Anode Check Flow Chart Powered anode Fault Check connection at anode Check voltage ≈ 2.5 Vdc Check connection at ground Check connection on control board @ CN203 Disconnect CN203 and measure resistance between pin1 and tab at end of wire ≈ 100 Ω Bad Good Bad Good Bad Good Reconnect terminal to powered anode Reconnect terminal to con[...]

30 Fan Check Flow Chart Fan doesn’t operate when compressor is on; no fault on UIM Check voltage at control board connector CN207 between pins 1 and 3 (240V) No Replace control board * Disconnect CN207 Measure motor resistance of fan wire harness connector at pins 1 and 3 Replace control board * Ye s Hot? Ye s No Replace fan Check fi lter and ev[...]

31 Fan Check Flow Chart Fan connect fault on UIM Check connection at CN207 Good Reconnect on CN207 Replace fan motor assembly Bad Fault cleared? Done Ye s No Check resistance on fan cable connector pin 1 to 3 Good 49-61 Ω Bad ˃ 100 Ω Is case of motor hot? No Ye s Thermal switch may be open; allow to cool Check resistance of cold motor Bad ˃ 100[...]

32 T emperature Sensors Overview: The temperature sensors used in this water heater are negative temperature co-ef fi cient (NTC) thermisitors. With this type sensor , as temperature increases, the resistance across the thermisitor decreases or as temperature decreases, resistance will increase. The control board monitors the resistance of each se[...]

33 Resistance vs. temperature for ambient and coil thermistors 0 5 10 15 20 25 30 35 0 20 40 60 80 100 120 140 160 180 200 220 Temperature (F) Resistance (k Ohms) Char t #1 Resistance vs. Temperature for Tank and Discharge thermistors 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 0 20 40 60 80 100 120 140 160 180 200 220 Temperature [...]

34 Chart #3 PSIG 5 4 3 2 1 0 1 234567 °F -22 -21 -19 -18 -16 -15 -12 -10 -8 -5 -3 -1 1 PSIG 8 9 10 11 12 13 14 15 16 17 18 19 20 °F 3 5 7 8 10 12 13 15 16 18 19 21 22 PSIG 21 22 23 24 25 26 27 28 29 30 31 32 33 °F 24 25 26 27 29 30 31 32 33 35 36 37 38 PSIG 34 35 36 37 38 39 40 42 44 46 48 50 52 °F 39 40 41 42 43 44 45 47 49 51 52 54 56 PSIG 54[...]

35 Cleaning the Evaporator Proper maintenance and cleaning of the supplied, washable air fi lter should prevent the evaporator from getting dirty . However , should the evaporator become dirty , it must be cleaned to maintain performance of the heat pump. Care should be taken during cleaning not to damage the evaporator fi ns. If the fi ns becom[...]

36 T roubleshooting Common Service Problems As a first step in diagnosis and troubleshooting, the unit should be disconnected from power at the breaker/fuse panel for ten seconds, then reconnect power to the unit and determine if the noted error code still appears. The process of waiting for the error code to reappear may take about 8 minutes for t[...]

37 T roubleshooting Common Service Problems PROBLEM POSSIBLE CAUSE TEST/CORRECTIVE ACTION HIGHER THAN EXPECTED OPERA TING COSTS: Electric mode selected Change to ef fi ciency or hybrid for reducing energy costs Ambient air temperature preventing compressor operation Ambient air temperature must be ≥ 45°F and ≤ 109°F to enable compressor oper[...]

38 T roubleshooting Common Service Problems PROBLEM POSSIBLE CAUSE TEST/CORRECTIVE ACTION LEAKS AROUND T ANK FITTINGS (e.g., drain valve, relief valve, etc.): The threads are leaking and need to be resealed Insert a cotton swab between the jacket opening and the fi tting. If the cotton absorbs water , follow these steps: Disconnect power , then dr[...]

39 Upper Element Connect Fault (Upper heating element circuit is open): Loose connection or damaged wire- • T urn off power at the circuit breaker / fuse box and check for a loose connection at the element. For access directions see “Heating Element Replacement” (p.24). Upper element faulty- • Check resistance of the element itself to see i[...]

40 Ambient T emperature Sensor Short or Open or Ad Error (Ambient temperature sensor circuit is not functioning): Loose connection or damaged wire- • T urn off power at the circuit breaker / fuse box. • Check that connector CN212 on control board is seated. • Check wires for damage. Ambient temperature sensor is shorted or open- • Unplug ri[...]

41 Fault Code T roubleshooting Guide connector . Refer to chart #2 (p.33) for expected resistance value. If the measured resistance is >200 Ω or =0 Ω , the thermisitor is faulty . • Replace thermisitor assembly . Control board faulty- • Replace control board. • If replacing the control board doesn’t resolve the issue, contact technical[...]

42 ohms indicates good; high resistance indicates the switch is defective and should be replaced. Heat Pump High T emperature Fault (Compressor discharge temperature is too high): The refrigerant system may be blocked- • Check the heat pump piping and evaporator; if the tubing or evaporator is covered with frost in one spot, this indicates there [...]

43 Low Supply V oltage Fault (V ery low input voltage): Power supply voltage is extremely low- • V erify the unit is connected to 240 V AC, unit is intended for 240 V AC connection only . The unit will not operate below 184 V AC. High T emperature Lock Out (ECO tripped due to excessivly high tank temperature): Eco has detected a tank temperature [...]

44 Power Anode Drive V oltage L T T ank V oltage (Powered anode circuit not working): Anode shorted to tank or upper element- • Check for short circuit- 1. Disconnect the red wire from the tab on the anode; use an Ohm meter to check between the wire tab on the anode and the tank. A low reading (should be ≥ 1 mega-ohm) indicates a short. 2. If s[...]

45 Draining and Filling the W ater Heater D raining and F illing the W ater Heater The water heater should be drained if being shut down during freezing temperatures. Also, periodic draining and cleaning of sediment from the tank may be necessary . 1. Place the water heater in Standby Mode by pressing the power button on the user interface module. [...]

46 Condensate Pump T roubleshooting A condensate pump may be necessary if the drain point is above the level of the condensate drain on the heat pump water heater . A condensate pump failure detect is provided with the heat pump water heater control. Follow the instructions in the installation and operation manual for connection of the condensate p[...]

47 Service Parts List for 60 and 80 Gallon Heat Pump W ater Heaters Item Part Number 1. Ambient / Discharge / Coil T emperature Sensor Assembly ................................................. 9007473015 2. Upper / Lower T emperature Sensor Assembly .................................................................... 9007474015 3. Run Capacitor ..[...]

48 P .O. Box 1597, 500 Princeton Road, Johnson City , TN 37605 T echnical Support: 800-456-9805 • Parts: 800-433-2545 • Fax: 800-644-9306 www .americanwaterheater .com Copyright © 201 1, All Rights Reserved.[...]