HOT WATER HEAT PUMPS Econergy EC180L User manual
Heat Pump Water Heater
Installation Guide
FOR QUALIFIED PERSONNEL ONLY
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
3
Heat Pump Water Heater Installation Guide
Contents
Location of the Unit .................................................. 4
Installation Design.................................................... 5
Ordering Econergy Accessories............................... 8
Installation ................................................................ 10
Installation Procedure............................................... 13
Piping Diagram ........................................................ 14
Commissioning ........................................................ 19
Troubleshooting ....................................................... 20
Important Information .............................................. 22
Wiring Diagram ........................................................ 23
........................... 24
....................................... 26
NOTE TO INSTALLERS: Installation must be completed
by qualied and licensed tradesmen to National Codes
and in strict accordance with this manual.
A pre-made CAT- 5/6 cable is required
for installation of Econergy heat pumps
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
4
Heat Pump Water Heater Installation Guide
Location of the Water Heater Unit
Econergy®water heater units are designed to be installed outside, in the
ceiling cavity (if one exists), under the house or in a garage, adjacent to
the hot water cylinder (HWC). The Econergy® water heater should not be
located within living areas as the unit produces cold air.
Location of the Econergy®water heater will be determined by a combination
of factors including proximity to the hot water cylinder, proximity to bedrooms
and whether there is usable space where the unit is going to be located.
For installation to existing homes, the unit should be installed with a maximum
insulated pipe run of 9 metres.
For new homes, the layout should be designed so that the unit can be
installed as close to the HWC as practical within the 9 metre maximum pipe
run. The HWC can be installed inside or outside but as close to main points
of use as possible.
Econergy® Water Heaters must be installed in a
well ventilated space outside the living areas
!
The Econergy® Water Heater emits 52 dbA
at 1.5 metres (HP4000LT) and should not be
installed adjacent to bedrooms. Ensure that
the unit is located so that noise will not aect
the residents. If installing in roof cavities, the
cavities must be at least 80m2. The unit must be
seismically restrained and located away from
bedrooms to avoid noise breakthrough.
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
5
Heat Pump Water Heater Installation Guide
Installation Design
Design to avoid cavitation
The installation must be designed so that the unit will operate reliably and
To ensure successful operation of the Econergy®water heater on open
vent application where operating pressure is less than 50kPa (or 5m static
increasing the pressure of supply in the house. The installer should be aware
of and avoid adding a relief valve to an old HWC of questionable structural
integrity since it could cause the HWC to fail.
Distance from Hot Water Cylinder
The Econergy®water heater should be mounted as close as possible to the
cylinder should be located within 9 metres of the Econergy®water heater for
Wetback Systems
Wetback systems involve large bore copper pipes running into the cylinder
and back again. Because the heat source is uncontrolled, temperatures can
rise to 100°C, generating steam. Plumbing codes dictate that an open vent
is used to eliminate the possibility of an explosion occurring due to rapid
pressure rise in the system.
Cavitation of the circulating pump may occur
when there is less than 50kPa pressure at the heat
pump inlet. This can lead to a malfunction of the
Econergy® water heater and MUST BE AVOIDED by
ensuring adequate pressure at the system inlet.
!
The Econergy® system cannot be used with a
wetback system where the piping design allows a
thermosyphon to develop
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
6
Heat Pump Water Heater Installation Guide
Econergy®units can be combined with wetback systems but only with strict
constraints as the temperature limit on the Econergy
®
water heater is 80°C. The
Econergy®water heater unit must be mounted level with the hot water cylinder
or below, and the piping designed to eliminate a thermosyhon loop to stop the
possibility of over temperature hot water circulating from the cylinder to the unit.
Solar Water Heating Systems
Solar water heating systems, like wetback systems, are usually uncontrolled
systems. Temperatures can rise to 100°C, boiling the water. As the Econergy®
by the customer then the piping design (as per wetback) must be designed
to avoid thermosyphoning of high temperature water through the unit while
not running.
Hot Water Cylinders
The Econergy®water heater requires a well insulated hot water cylinder to
function correctly. The tank must be sized to the maximum anticipated draw
As a guide, we recommend 300L for a family of 4. The water heater unit can
Econergy®water heaters cannot be installed into gas HWC’s as they are
Econergy Heat Pump Ready HWC - Recommended Storage Sizes
Household Size
# Adults Recommended Size Ordering Code
2180L EC180L
3 250L EC250L
300L EC300L
6+ / high use 350L + EC [capacity]L Custom
The Econergy® system cannot be used with a solar
water heating system where the piping design
allows a thermosyphon loop to develop
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
7
Heat Pump Water Heater Installation Guide
A) New construction
We recommend Econergy®heat pump ready hot water cylinders. Available
are guaranteed from the factory with a 10 year warranty. Use of Econergy®
heat pump ready cylinders avoids any potential warranty issues resulting
B) Retrot
good condition by teeing into the cold water line just before the tank isolation
as this could cause leaks.
The Econergy cannot be retrotted to gas
hot water cylinders, or any storage tank that
cannot deliver more than 50kPa pressure to
the pump inlet.
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
8
Heat Pump Water Heater Installation Guide
Ordering Econergy Accessories
Part No. Application Picture
Outdoor Mounting Kit
For mounting
outdoors & under
surfaces
HPOMK
Ceiling Mounting Kit
For mounting in
ventilated/accessible
ceiling cavities
HPCMK
Roof Mounting Kit
For mounting on
colour steel roofs
(specify Standard or
HPRMK
Wall Mounting Kit
For mounting on
concrete or concrete
block walls (not
suitable for timber or
brick structures)
HPWMK
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
9
Heat Pump Water Heater Installation Guide
Part No. Application Picture
hot water cylinders
HPGRK
Coopers Solar Ready
Coopers Solar Ready
Hot Water Cylinders
HPCRK
Dux/Rinnai
Cylinders (aka Tank
Sensor
HPTSK
Tank Pocket
Stainless Solar
Ready HWC
HPTP
Condensate Fitting
For outdoor
installations requiring
a condensate drain
(for ceilings use
HPCMK instead)
HPCDF
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
10
Heat Pump Water Heater Installation Guide
Installation
Standard Specications
No Installation Component Approved Specication
Plumbing Installation
1
Piping systems from Heat
Pump Unit to Hot Water
Cylinder
15mm nominal bore piping
(no more, no less).
Dux or Buteline Polybutylene
REHAU PE
Kembla PEX
Fusiotherm
Copper AS/NZS compliant
2 Pipe Line Fittings
Dux Secura, REHAU, Fusiotherm,
Kembla PEX or AS/NZS Standard
3 Flexible Hoses NOT ALLOWED
4 Ball Valves
valves. Bugatti, PWL, Econergy
5 Pipe Insulation
equivalent. All piping to be fully
lagged along its length
6 Max Pipe Distance
Electrical Installation
1 Low Voltage Cable CAT5 UTP, 24AWG and rated to 1
amp max
2 Main Cable 2.5 TPS, 2 x 2.5mm2+ E, compliant
to AS/NZS5000.2
3 MCB To suit electric back element rating.
Max permissible 20A
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
11
Heat Pump Water Heater Installation Guide
Installation shall be made to and compliant with, the attached drawings.
Typical Installation Detail – Indoor HWC / Outdoor Unit
Typical Installation Detail – Outdoor HWC and Unit
550
400
400
490
100
750
1500
min 200
Ø 488 / 580
Ø 488 / 580
C 1596 EC250l
B 1770 EC180L
A 1846 EC300L
610
490
200
100
plinth height: 100plinth height: 100
min. distance
from wall
min. distance
from wall
min. distance
from wall
installed unit
height: 610
min. distance
from wall
hot water
cupboard
488 / 580
650
600
400
400
min. distance
from wall
200
200
AIRFLOW AIRFLOW
min. height required
to remove unit: 910
min. distance
from wall
550
400
400
490
100
750
1500
min 200
Ø 488 / 580
Ø 488 / 580
C 1596 EC250l
B 1770 EC180L
A 1846 EC300L
610
490
200
100
plinth height: 100plinth height: 100
min. distance
from wall
min. distance
from wall
min. distance
from wall
installed unit
height: 610
min. distance
from wall
hot water
cupboard
488 / 580
650
600
400
400
min. distance
from wall
200
200
AIRFLOW AIRFLOW
min. height required
to remove unit: 910
min. distance
from wall
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
12
Heat Pump Water Heater Installation Guide
Typical Installation Detail – Roof Cavity
Support
beams
Seismic
restraint
wires
Drain
Ensure ceiling
is ventilated
At least 600mm
clearance
Support
beams
Seismic
restraint
wires
Drain
Ensure ceiling
is ventilated
At least 600mm
clearance
Support
beams
Seismic
restraint
wires
Drain
Ensure ceiling
is ventilated
At least 600mm
clearance
Support
beams
Seismic
restraint
wires
Drain
Ensure ceiling
is ventilated
At least 600mm
clearance
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
13
Heat Pump Water Heater Installation Guide
Installation Procedure
1. Mounting System
a) Outdoor Mounting. Use accessory HPOMK. Lay the unit on its side using
the cardboard packing as protection. Attach the plastic mounting feet to the
underside of the unit using the cap screws provided.
b) Ceiling Installation. Use only accessory HPCMK. Mount the ceiling tray
in the roof space in a suitable location. The unit should then be placed on the
drip tray and secured in place using the seismic restraints, which should be
attached to the side of the unit and to the support beams.
Please note: Adequate access and room for service must be allowed for the
tradesperson’s safety and to prevent potential property damage.
Any damage
caused to private property due to incorrect installation, including damage
caused whilst rectifying faults, is not covered under warranty.
1.
through it easily.
2. A walkway must be installed from the access point to the heat pump.
3. The heat pump must be located on a platform at least 2m x 2m and a
minimum height requirement at heat pump of 1500mm to allow working
room around the heat pump.
4. A light of at least 12W LED must be installed above the heat pump.
c) Wall Mounting. Use accessory HPWMK. Mount wall brackets using level
brackets. Screw up into unit using 4x capscrews (supplied).
d) Closed Garage Installations. Cold air leaving the unit must be ducted to
1.
2. Ensure no objects can be placed within 500mm of the heat pump as
3. Allow for drainage of water naturally produced by the cooling coil
(evaporator) from within the heat pump.
Adequate access and space for service must
be allowed for all types of installation
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
14
Heat Pump Water Heater Installation Guide
e) Open Ended Garage Installations. The heat pump must be installed on
the heat pump is installed must also allow the covers to be lifted vertically
over the top of the unit for service and electrical installation.
f) Roof Mounting. Use accessory HPRMK. Mount roof brackets onto roof
following instructions supplied with kit. Screw 2x 50x50 AL angles supplied
into side of unit. Place angles across mounting rails of roof mounting kit.
spring nuts in channels.
Please note:
be made to protect the unit from salt spray to avoid premature corrosion.
2. Pre-wiring & Pre-plumbing for Renovations & New Builds
free play at either end. Run 2x 15mm pipes, fully insulated along their length.
Do not invert the outdoor unit to attach the
mounting feet or at any other time during
installation. This may cause damage to internal
components and may void the warranty.
!
Do not wall mount the unit on any timber
framed wall (with or without brick veneer)
!
A pre-made CAT- 5/6 cable is required
for installation of Econergy heat pumps
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
15
Heat Pump Water Heater Installation Guide
Piping Diagram 1: Retrot to Generic Single Inlet Hot
Water Cylinder (eg Rheem NZ)
Notes: Piping Diagram 1: Generic Single Inlet Hot Water Cylinder
Econergy Accessories Required:
No Part Number Description Purpose
1HPGRK
tank sensor kit).
standard hot water
cylinder
1. Cylinder must be post 1988 and in good condition
2. Fitting of Tank Sensor kit (HPTSK) may void HWC’s manufacturer
warranty
3. Ensure minimum pressure of 50kPa met on low pressure installations
Piping Diagram
Generic Mains
Pressure HWC
Rev B 24/09/14
Mixing Valve
20mm
Outlet
Hot Water
Backup
Module
Cold Water
Expansion
Valve
15mm
TPR
20mm
20mm
Pressure
Reducing
Valve 20mm
20mm
Ball
Valve
Ball Valve
Stop
Valve
Check
Valve Mains
Supply
Regulated
House
Supply
Mixed 50-55°C
Hot Water
60°C Hot
Water
15MM PVC
Condensate
(optional)
Lower Tank
Sensor (Ttl)
- Retrofit to
P solar port
Back up Supply
15mm insulated Line
15mm insulated Line
HP supply
CAT-5
Mains In
DRAIN
Econergy
Water
Heater
Inlet
Outlet
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
16
Heat Pump Water Heater Installation Guide
Piping Diagram 2: Retrot to Coopers Ready Mains
Pressure Hot Water Cylinder
Notes: Piping Diagram 2: Coopers Mains Pressure Solar Ready Hot water
cylinder
Econergy Accessories Required:
No Part Number Description Purpose
1HPCRK Coopers (Solar Ready)
Comprises HPTF
Tank Fitting and
HPTP Tank Pocket
1. DO NOT connect return line to heat pump to solar connection!
2. Ensure minimum pressure of 50kPa met on low pressure installations
Piping Diagram
Coopers Heat
Pump Ready HWC
Rev B 24/09/14
Mixing Valve
20mm
Outlet
Hot Water
Backup
Module
Cold Water
Expansion
Valve
15mm
20mm
20mm
Pressure
Reducing
Valve 20mm
20mm
Ball
Valve
Ball Valve
Stop
Valve
Check
Valve Mains
Supply
Regulated
House
Supply
Mixed 50-55°C
Hot Water
60°C Hot
Water
15MM PVC
Condensate
(optional)
Lower Tank
Sensor (Ttl)
- Fit to
Pocket in
solar port
15mm insulated Line
15mm insulated Line
HP supply
CAT-5
DRAIN
20mm
x2
Ball
Valve
Back up Supply
Econergy
Water
Heater
Inlet
Outlet
HPTP
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
17
Heat Pump Water Heater Installation Guide
Piping Diagram 3: Connection to Econergy® Heat
Pump Ready Hot Water Cylinder
Notes: Piping Diagram 3: Connection to Econergy®Heat Pump Ready Hot
Water Cylinder
No Econergy Accessories Required
1. TPR valve is provided in element cover.
Mixing Valve
20mm
Outlet
Hot Water
Backup
Module
Cold Water
Expansion
Valve
15mm
20mm
20mm
Pressure
Reducing
Valve 20mm
20mm
Ball
Valve
Ball Valve
Stop
Valve
Check
Valve Mains
Supply
Regulated
House
Supply
Mixed 50-55°C
Hot Water
60°C Hot
Water
15MM PVC
Condensate
(optional)
Lower Tank
Sensor (Ttl)
- Fit to
Pocket in
solar port
15mm insulated Line
15mm insulated Line
HP supply
CAT-5
DRAIN
20mm
x2
Ball
Valve
Back up Supply
Econergy
Water
Heater
Inlet
Outlet
20mm
Upper Tank
Sensor (Ttu)
pre-fitted
Mains In
Piping Diagram
Econergy Heat
Pump Ready HWC
Rev B 24/08/14
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
18
Heat Pump Water Heater Installation Guide
3. Plumb Water Heater to Hot Water Cylinder
Plumb the water heater unit in accordance with the correct piping diagram
to match the type of cylinder being connected to. Ensure inlet (blue) of heat
pump is connected to bottom of HWC and outlet (red) of water heater is
plumbed to top of the HWC. All plumbing to be carried out in accordance with
AS/NZS 3500 and NZ BC Section G12
4. Mount Hot Water Backup Run Electrical Cables
The hot water backup module (HPHWB) shall be mounted close to the hot
water cylinder in a location that is easily visible to the hot water user. All
wiring to be completed according to AS/NZS3000 and Field Wiring Diagram
in page 23 of this manual. Fit isolators next to HWC and within 1 metre of
the water heater unit in an easily accessible location. Run all cables from
heat pump unit through conduit or trunking to the hot water cylinder location.
5. Tank Sensor Mounting
a) Econergy Hot Water Cylinder. This comes with dual sensors, upper and
lower. Insert the lower tank sensor into the pocket about 1/3 of the way up the
HWC and secure with adhesive or silicone sealant. Take both sensors and
plug them in to their respective locations in the hot water backup (HPHWB)
module TTu/Ttl
b) Coopers or Rheem Solar Ready Hot Water cylinder. The plumbing
installer needs to thread a tank pocket into the solar port of the hot water
cylinder and ensure there are no leaks. Apply thermal paste to the tank
sensor and insert the tank sensor into the pocket. Secure the tank sensor
with building adhesive or silicone sealant. Plug the tank sensor into the
header marked J4 or Ttl on the circuit board of the HWB module.
c) Generic Hot Water Cylinder. Drill a 51mm (1/2”) diameter hole in the
hot water cylinder jacket at a height ¼ (25%) of the way up the cylinder, when
measured from the bottom.
Apply thermal paste to the tank sensor. Push tank sensor through the tank
sensor cover and lodge it in the tank sensor mount.
Do not wall mount the unit on any timber
framed wall (with or without brick veneer)
!
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
19
Heat Pump Water Heater Installation Guide
Apply 9cc of thermal paste (supplied with Tank Sensor) to the back of the tank
sensor mount and place it in the drilled hole against the inside layer of the cylinder.
Adjust the foam core supplied such that when inserted with the pocket into
the hole it sticks out by at least 10mm. Insert the tank sensor foam core, and
then attach the tank sensor cover using the screws provided. Pilot holes of
3.2mm (1/8”) diameter will need to be drilled for these screws. Plug the tank
sensor into the header marked J4 or Ttl on
the circuit board of the HWB module.
6. Electrical Connections
All electrical connections must be made, by a licensed tradesman, according
to the diagram below. The appliance must be installed in accordance with
AS/NZS 3000:2000. A means for disconnection must be incorporated in the
7. Condensate drain
Condensate drains must be run in the following cases:
a) Where the unit is discharging on a concrete path or other location where
wetness/ mould is not desirable or,
b) Where the unit is located in a ceiling cavity
a) Outdoor Mounting. Use HPCDF accessory. Remove the rear grille and
mount the HPCDF into the punched hole at the bottom right rear of the water
heater unit. Run PVC to the nearest drain location.
b) Ceiling Mounting.
a leak test with water prior to leaving site.
Outer
steel
layer
C
C
Insulation
Inner
copper
layer
SECTION C-C
5
1
2
4
35
4
3
1
26
Item No. Descripton Part No. Quantity
1 Hot Water Cylinder Wall 1
2 Tank Sensor Pocket 1
3 6m Sensor 1
4 Sylomer Insulating Core 1
5 Tank Sensor Cover 1
6 Thermal Paste 200ml
Econergy Installation Manual Rev G 240914 © Hot Water Heat Pumps Ltd 2018
12/03/2018 www.econergy.co.nz
20
Heat Pump Water Heater Installation Guide
Green light indicates
that power is on to
Econergy®HPWH
Glows red when heat
pump is running,
encountered
Red light indicates
Solar Mode is active
Glows red if backup
element has
been switched on
automatically
Allows user
to manually
force backup
element on
if required:
Position 1
power is onto
heat pump,
in position
2, to backup
element
(Note: manual
switch doesn’t
turn on
backup light.)
Commissioning
• Fill system with water and leak test all connections at system pressure.
• Check all electrical connections and ensure that water heater is securely
grounded to the building’s earthing point.
• Ensure both isolation valves on supply and return lines are open.
• Connect laptop to RS232 extension cable on machine and open Econergy®
• Switch on Main Isolator and Heat Pump Isolator.
• The green (power) light should be lit on the Hot Water Backup Box located
on the hot water cylinder.
Only Econergy® factory sensor cables
provided with the unit shall be installed.
Use of substitute sensor cables or splicing
cables may void warranty.
!
This manual suits for next models
3
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