TESY HPWH 2.1 200 U02 User manual

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SERVICE MANUAL
v1 –24/09/2019
HPWH 2.1 200 U02; HPWH 2.1 200 U02 S; HPWH 2.1 260 U02; HPWH 2.1 260 U02 S;

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CONTENT:
A. Operating principle……………………………………………………3
B. Design overview………………………………………………………4
C. Preliminary check and control…………………………………….…6
D. Access to the heat pump…………………………………………….8
E. Electric wiring diagram and heat pump refrigerant scheme……..9
F. Actions to be taken when error code appears on display………11
G. Intervention procedure………………………………………….….13
H. Full list of controller’s parameters…………………………………31
I. Evaporating pressure………………………………………………..33
J. Tools and equipment………………………………………………..34

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A. OPERATING PRINCIPLE
The equipment is capable of producing domestic hot water mainly by using heat pump technology. A heat pump is capable of transferring thermal energy from a low temperature
source to another with a higher temperature and vice versa.
The equipment uses circuit consisting of a compressor, an evaporator, a condenser and a throttle valve; a liquid/gas coolant flows inside this circuit (see paragraph 4.6).
The compressor creates a difference in pressure inside the circuit that allows a thermodynamic cycle to be obtained: this sucks the coolant fluid in through an evaporator, where the
fluid itself evaporates at a low pressure by absorbing heat; it is compressed and driven towards the condenser where the fluid condenses at a high pressure releasing the absorbed heat. After
the condenser, the fluid passes through the so-called “throttle valve” and by losing pressure and the temperature starts to vaporize, it re-enters the evaporator and the cycle starts all over
again.
The operating principle of the equipment is as follows (Fig. 1):
I-II: The coolant fluid sucked in by the compressor, flows inside the evaporator and while it evaporates, it absorbs the “ecological” heat given by the air. At the same time, the ambient air is
sucked in by the equipment by a fan; the air loses it heat by passing over the finned-tube battery of the evaporator;
II-III: The coolant gas passes inside the compressor and it under goes an increase in pressure that causes a rise in temperature; transforming this into superheated steam;
III-IV: Inside the condenser, the coolant gas releases its heat to the water inside the tank (boiler). This exchange process makes it possible for the coolant to pass from superheated steam to
a liquid state by condensing at a constant pressure and undergoing a reduction in temperature;
IV-I: The liquid coolant passes through the throttle valve; it undergoes a sudden drop in both pressure and temperature and it partially vaporizes bringing pressure and temperature back to the
initial conditions. The thermodynamic cycle can begin.

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B. DESIGN OVERVIEW
1
Heat pump.
2
Control panel.
3
External PVC jacket.
4
Enameled storage tank
5
Upper storage tank probe. “T3”
6
Lower storage tank probe. “T2”
7
Refrigerant recharge needles.
8
Ambient air recirculation fan.
9
Electronically regulated expansion valve valve.
10
High-efficiency finned evaporator.
11
Air inlet (∅160 mm).
12
Air outlet (∅160 mm).
13
Hermetically-sealed rotary compressor.
14
Compressor’s accumulator
15
(1.5 kW –230 W) El. heating element
16
Condenser outlet line - liquid
17
Condenser inlet line –hot gas
18
Replaceable magnesium anode.
19
Hot water outlet connection (G 1”).
20
Recirculation fitting (G ¾”).
21
Evaporator’s distributor
22
Condensates drain (G 3/4”).
23
Solar coil (G 1”; 1.2 m2 surface).
24
Cold water inlet connection (G1”).
25
50 mm polyurethane insulation.
26
High pressure switch –automatic reset.
27
Safety thermostat, manual reset.
28
Controller box.
29
Probe for solar coil thermosensor.
30
Low pressure switch –automatic reset.
31
4-way defrosting valve
32
Upper decorative panel
33
Back decorative panel
34
Front decorative panel
35
Lower decorative panel (condense trap)
36
Condenser.
37
Protective fan grid
38
Return gas temperature “T5”
39
Coil temperature “T4”
40
Bolts M6x60
41
Ambient temperature “T1”

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C. PRELIMINARY CHEK AND CONTROL
1. Water flow missing?
Opening the hot water tap, it does
not come out anything
(no flow).
Make sure that:
1. Water supply network is inservice
2. Incoming water pressure isadequate
3. Inlet water valve is open
4. Check if there is any obstruction in the circuit upstream the product (hot water outlet)
2. Hot water missing?
Opening the hot water tap, water
comes out at the same temperature
as the cold water.
Make sure that:
1. Disconnect the product from the mains power supply (at least for one minute) and connect it again properly
2. Verify the presence of power supply voltage
3. Switch on the product
4. Wait for the established time for the water warming up.
5. Verify alarm warnings on the display
3. Water not sufficiently hot?
Opening the hot water tap, water isn’t
hot enough.
Day after day, the performance of
heat pump became worst.
1. Make sure that:
•The established warming up time had passed
•The required temperature has been set up
•There is a correct ventilation.
2. Check if the fan is working
3. Check if the compressor is working.
4. Check alarm notification on the display
5. Check if there is enough refrigerant quantity!

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4. Water loss?
The product is dripping.
Make sure that:
1. Verify if the dripping originates:
•From one of the hydraulic connections (not intact)
•From the overpressure protection device (safety valve).
•Check if it is working properly.
•From inside the product
2. Check if the condensate drain is connected properly and/or if it is obstructed.
3. Check the condition of the filter, which could generate an excessive quantity of condensate.
5. The product is working properly
but there are warnings on the
display?
The product supplies hot water and
the display signals irregular
conditions.
Refer to the section “F”
6. Irregular operation but display
does not indicate any anomaly?
The product supplies hot water
but there are noises, vibrations or
other anomalies (included too hot
water temperature).
1. If the water temperature is higher than the setpoint:
•Anti-Legionella cycle is running/has just finished.
•The system is connected to a solar thermal/PV.
2. Vibrations and irregular noises:
•Check the installation surface (straightness and point of support)
•Open the cover and proceed with a visual inspection checking possible contacts among the
components.

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D. ACCSES TO THE HEAT PUMP –OPENING OF THE EXTERNAL CASE.
1. Unwind the screws No40 (M6x60; DIN564)
2. Pull the upper panel No32 in upper direction
3. Pull the Front 34 and Back 33 panels in upper direction (~3cm) and then in front direction

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E. ELECTRIC WIRING DIAGRAM AND HEAT PUMP REFRIGERANT SCHEME.

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F. ACTIONS TO BE TAKEN WHEN ERROR CODE APPEARS ON DISPLAY
Protection/ Malfunction
Error code
LED indicator
Possible reasons
Corrective actions
Procedure
Standby
Dark
Normal running
Bright
Lower tank water temp. sensor
failure
P1
☆●
(1flash 1 dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check the sensor connection
2) Replace the sensor
3) Change the PCB board
1) Procedure 2
3) Procedure 1
Upper tank water temp. sensor
failure
P2
☆☆●
(2 flashes 1 dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check the sensor connection
2) Replace the sensor
3) change the PCB board
1) Procedure 3
3) Procedure 1
Evaporator coil temp. sensor
failure
P3
☆☆☆●
(3 flashes 1 dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check the sensor connection
2) Replace the sensor
3) change the PCB board
1) Procedure 4
3) Procedure 1
Return gas temp sensor failure
P4
☆☆☆☆●
(4 flashes 1 dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check the sensor connection
2) Replace the sensor
3) change the PCB board
1) Procedure 5
3) Procedure 1
Ambient temp. sensor failure
P5
☆☆☆☆☆●
(5 flashes 1 dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check the sensor connection
2) Replace the sensor
3) change the PCB board
1) Procedure 6
3) Procedure 1
Solar temp. sensor failure
P6
☆☆☆☆☆☆☆☆☆☆●
(10 flash1dark)
1) The sensor open circuit
2) The sensor short circuit
3) PCB board failure
1) Check and change the solar sensor
2) Replace the sensor
3) change the PCB board
1) Procedure 7
3) Procedure 1
T6 Solar temperature too high
temp. protection
P8
Dark
1) T6 too high temp.
2) T6 sensor has problem
1) P8 appears at 125°C and
disappears at 120°C
2) Check and if it’s necessary replace
the sensor
2) Procedure 7
Emergency switch off
EC
only show the protection
code
1) Connecting wire off
2) PCB board failure
1) According to the physical truth
judging whether is normal or not
2) change the PCB board
2) Procedure 1
High pressure protection (HP
Switch)
E1
☆☆☆☆☆☆●
(6 flashes 1 dark)
1) Too high air inlet temp
2) Less water in the tank
1) Check if the air inlet temp is over
the working limited
2) Check if the tank is full of water. If
not, charge water

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3) The electronic expansion valve
assembly blocked
4) Too much refrigerant
5) The switch damaged
6) The uncompressed gas is in
refrigerant system
7) PCB board failure
3) Check and replace the electronic
expansion valve assembly
4) Discharge some refrigerant
5) Replace a high-pressure switch
6) Discharge and then recharge the
refrigerant
7) change the PCB board
3) Procedure 8
4) Procedure 9
5) Procedure 10
6) Procedure 9
7) Procedure 1
Low pressure protection (LP
Switch)
E2
☆☆☆☆☆☆☆●
(7 flashes 1 dark)
1) Too low air inlet temp
2) The electronic expansion valve
assembly blocked
3) Too less refrigerant
4) The switch damaged
5) The fan assembly cannot work
6 PCB board failure
1) Check if the air inlet temp is over
the working limited
2) Replace the electronic expansion
valve assembly
3) Charge some refrigerant
4) Replace a new low-pressure switch
5) Check if the fan working when the
compressor working. If not, some
problems with the fan assembly
6) change the PCB board
3) Procedure 9
4) Procedure 10
5) Procedure 11
6) Procedure 1
Over heat protection (HTP Switch)
E3
☆☆☆☆☆☆☆☆●
(8 flashes 1 dark)
1) Too high tank water temp
2) The switch damaged
3) PCB board failure
1) If the tank water temp is over 85C,
the switch will open and the unit will
stop for protection. After the water
comes to normal temp,
2) Replace a new thermal safety
switch
3) Change the PCB board
2) Procedure 12
3) Procedure 1
Solar thermal collector high
temperature protection
E4
☆☆☆☆☆☆☆☆☆☆☆●
(11flash1 dark)
1) solar water circuit water flow very
little or without water flow
2) Related connecting wires off
3) Water pump failure
4) PCB board failure
1) Solar water circuit fluid infusion
and exhaust
2) Related connecting wires being
reconnected
3) Change the water pump
4) change the PCB board
4) Procedure 1
Water flow failure
E5
☆☆☆☆☆☆☆☆☆●
(9 flash 1dark)
1) solar water circuit water flow very
little or without water flow
2) Related connecting wires off
3) water pump failure
4) water flow switch failure
5) PCB board failure
1) Solar water circuit fluid infusion and
exhaust
2) Related connecting wires being
reconnected
3) Change the water pump
4) Change the water flow switch
5) Change the PCB board
5) Procedure 1
Defrost
☆☆☆☆☆☆☆☆……
(all long flashes)
Communication failure
E8
Bright

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G. INTERVENTION PROCEDURE.
Procedure 1
1. CHANGING THE MAIN PCB
PSB code: G0010018; PSB model: HY473024
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply!!!
1) Switch off the HPWH
2) Disconnect the unit from main electricity supply
3) Unscrew four screws No: 1; 2; 3; 4
4) Open the front cover
5) Disconnect all cables and wirings of the PCB
6) Gently dismantle the main PCB from plastic clips No: 5; 6; 7; 8;
7) Replace the PCB with a new one with the same code
8) Make an assembly in the reverse order
Fig: pr.1.1. Fig: pr.1.2.
Fig: pr.1.3. Fig: pr.1.4 Fig: pr.1.5
2
3
4
1
5
6
7
8

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Procedure 2
2. CHECK AND CHANGE OF LOWER TANK TEMPERATURE SENSOR T2
NTC thermosensor code: G0030153; NTC thermosensor model: 5K/L1200T
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply!!!
1) Switch off the HPWH
2) Open the PCB box as per procedure 1.
3) Tear up the cable bundle containing the cable of T2
4) On terminal CN3 (Fig: pr.2.3), disconnect the cable of lower tank
temperature sensor T2, designated by Number “2” on a yellow ring
5) Pull the cable out
6) Replace with a new one on reverse order.
7) When pushing a new sensor into the thermo-pocket tube (see Fig:
pr.2.1.), assure that the sensor is dived at 420mm measured from the upper
edge of thermo-pocket tube. Be sure that the position is the right one as per
picture Fig: pr.2.1.
8) Assemble everything at the reverse order, do not forget to tighten again the
cables into the bundle. Assure that no cables are in contact with moving parts
or sharp edges.
Fig: pr.2.1:
Fig: pr.2.2:
Fig: pr.2.3: Fig: pr.2.4:
T3
T2
T2
Lower
T3
Upper
Lower T2 &
Ground
Terminal
CN3

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Procedure 3
3. CHECK AND CHANGE OF UPPER TANK TEMPERATURE SENSOR –T3
NTC thermosensor code: G0030153; NTC thermosensor model: 5K/L1200T
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply!!!
1) Switch off the HPWH
2) Open the PCB box as per procedure 1.
3) Tear up the cable bundle containing the cable of T3
4) On terminal CN3 (Fig: pr.3.1), disconnect the cable of upper tank
temperature sensor T3, designated by Number “3” on a yellow ring
5) Pull the cable out
6) Replace with a new one on reverse order.
7) When pushing a new sensor into the thermo-pocket tube (see Fig:
pr.2.1.), assure that the sensor is dived to the end. Be sure that the position is
the right one as per picture Fig: pr.2.1.
8) Assemble everything at the reverse order, do not forget to tighten again the
cables into the bundle. Assure that no cables are in contact with moving parts
or sharp edges.
Fig: pr.3.1:
Procedure 4
4. CHECK AND CHANGE OF EVAPORATOR COIL TEMPERATURE SENSOR
NTC thermosensor code: G0030153; NTC thermosensor model: 5K/L1200T
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply
1) Switch off the HPWH
2) Open the PCB box as per procedure 1.
3) Tear up the cable bundle containing the cable of T4
4) On terminal CN3 (Fig: pr.4.2), disconnect the cable of coil tank
temperature sensor T4, designated by Number “4” on a yellow ring
5) Pull the cable out
6) Replace with a new one on reverse order.
7) When mounting a new sensor into the holder (see Fig: pr.4.1.), assure
that the sensor is well fixed by the spring clamp. Be sure that the position is the
right one as per picture Fig: pr.4.1.
8) Assemble everything at the reverse order, do not forget to tighten again the
cables into the bundle. Assure that no cables are in contact with moving parts
or sharp edges.
Fig: pr.4.1
Fig: pr.4.2
Upper T3 &
Ground
Coil (Evaporator) T4 &
Ground
Spring clamp
Sensor holder

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Procedure 5
5. CHECK AND CHANGE OF RETURN GAS TEMPERATURE SENSOR
NTC thermosensor code: G0030153; NTC thermosensor model: 5K/L1200T
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply
1) Switch off the HPWH
2) Open the PCB box as per procedure 1.
3) Tear up the cable bundle containing the cable of T5
4) On terminal CN3 (Fig: pr.5.2), disconnect the cable of return gas
temperature sensor T5, designated by Number “5” on a yellow ring
5) Pull the cable out
6) Replace with a new one on reverse order.
7) When mounting a new sensor into the holder (see Fig: pr.5.1.), assure
that the sensor is well fixed by the spring clamp. Be sure that the
position is the right one as per picture Fig: pr.5.1.
8) Assemble everything at the reverse order, do not forget to tighten
again the cables into the bundle. Assure that no cables are in contact
with moving parts or sharp edges.
Fig: pr.5.1:
Fig: pr.5.2:
Return gas T5 &
Ground
Spring clamp
Sensor holder

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Procedure 6
6. Check and change of ambient air temperature sensor
NTC thermosensor code: G0030152; NTC thermosensor model: 5K/L1200S
Tools:
Screw driver PH2; Pliers
Risk of electric shock!
Disconnect the HPWH from the main electric supply
1) Switch off the HPWH
2) Open the PCB box as per procedure 1.
3) Tear up the cable bundle containing the cable of T1
4) On terminal CN3 (Fig: pr.6.2), disconnect the cable of return gas
temperature sensor T1, designated by Number “1” on a yellow ring
5) Pull the cable out
6) Replace with a new one on reverse order.
7) When mounting a new sensor into the holder (see Fig: pr.6.1.), assure
that the sensor is well fixed. Be sure that the position is the right one
as per picture Fig: pr.6.1.
8) Assemble everything at the reverse order, do not forget to tighten
again the cables into the bundle. Assure that no cables are in contact
with moving parts or sharp edges.
Fig: pr.6.1:
Fig: pr.6.2:
Procedure 7
7. CHECK AND CHANGE THE SOLAR SENSOR
See procedure 6
Ambient air T1 &
Ground
Ambient air
thermosensor T1

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Procedure 8
8. CHECK AND REPLACE THE ELECTRONIC EXPANSION VALVE ASSEMBLY
Electronically regulated expansion valve ERV; Code: C0050014; Model: DPF(Q)1.3C-01(1-RK
Tools:
Screw driver PH2; Pliers; spanner S10; S12; S13; Cutting tool for copper pipe; burner for brazing; brazing rods; vacuum pump; recovery unit; bottles for refrigerant; scales; leak detectors;
pressure hoses; Instrument for parameters check
Risk of electric shock!
Disconnect the HPWH from the main electric supply!
Risk of injuries due to refrigerant vapors!
Discharge refrigerant!
Use special protective gloves for refrigerant and eyeglasses!
Risk of burning while brazing copper pipes!
Use special protective gloves and eyeglasses!
1) Switch off the HPWH
2) Disconnect the HPWH from the main electric supply!
3) Open the PCB box as per procedure 1.
4) Tear up the cable bundle containing the cable of ERV
5) On terminal CN19 (Fig: pr.8.2), disconnect the cable of ERV
6) Discharge the refrigerant as per procedure 9
7) Dismantle ERV by unbraze its supplying copper pipes
8) Attach a new one
9) Replace both refrigerant filter/dryers too
10) Braze its copper connection
11) Vacuuming as per procedure 9
12) Charge refrigerant 880 –890g as per procedure 9
13) Check for refrigerant leakage as per procedure 9
14) Check working parameters as per procedure 9
15) Assemble everything at the reverse order, do not forget to tighten
again the cables into the bundle. Assure that no cables are in contact
with moving parts or sharp edges.
Fig: pr.8.1:
Fig: pr.8.2:
ERV
Refrigerant
filter

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Procedure 9
9. VACUUMING, CHARGING AND DISCHARGING REFRIGERANT
Tools:
Screw driver PH2; Pliers; spanner S10; S12; S13; Cutting tool for copper pipe; burner for brazing; brazing rods; vacuum pump; recovery unit; bottles with refrigerant; scales; leak detectors;
pressure hoses; Instrument for parameters check
Risk of electric shock!
Disconnect the HPWH from the main electric supply!
Risk of injuries due to refrigerant vapors!
Discharge refrigerant!
Use special protective gloves for refrigerant and eyeglasses!
Working with an equipment under high pressure!
All activities described below must be done by qualified specialist using a
quality and trouble-free equipment according to the all safety regulation!
1) Switch off the HPWH
2) Disconnect the HPWH from the main electric supply!
DISCHARGING REFRIGERANT
3) Unscrew the protective cap of low-pressure probe (Fig pr.9.1)
4) Connect the high-pressure hose, equipped in both ends with taps to
the probe and to the recovery machine. By the same way connect
recovery machine to the empty bottle for R134a (Fig pr.9.6).
5) Open the tap 1&2 and all others. Then start the recovery machine in
“discharging mode” and use it according to its user manual.
6) When the machine stops, the discharging process is done. Close all
taps and switch off the recovery machine.
7) CLOSE THE TAP OF THE BOTTLE WITH R134a!
VACUUMING:
8) Unscrew the protective cap of high-pressure probe (Fig pr.9.1)
9) Connect the high-pressure hose, equipped in both ends with taps to
the probe and to the vacuuming pump (Taps 1&2; Fig pr.9.2 and
pr.9.3)
10) Open the taps and start the pump. Then the pressure gauge will look
like on (Fig pr.9.4)
11) Wait ~30 min
12) If there is no leakage, after 30 min, the pressure gauge will look like
on (Fig pr.9.5)
13) Close the tap of the pump and check if there is leakage (if there is a
leakage the black arrow will move back)
14) If there is no leakage, the vacuuming process is done. Close the tap
1. Stop the vacuuming pump.
Fig: pr.9.1:
Fig: pr.9.2: Fig: pr.9.3:
Fig: pr.9.4: Fig: pr.9.5:
High pressure
probe
5/16” SAE
Low pressure
probe
5/16” SAE
Tap 1
Tap 2

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CHARGING WITH REFRIGERANT R134a
15) Unscrew the protective cap of low-pressure probe (Fig pr.9.1)
16) Connect the high-pressure hose, equipped in both ends with taps to
the probe and to the recovery machine. By the same way connect
recovery machine to the filled bottle for R134a (Fig pr.9.6).
17) Put the bottle on scales with precision ±10g and tare it to “0” (Fig
pr.9.7).
18) Be sure that the recovery machine and all pressure hoses are filled
with refrigerant.
19) Open the tap 1&2 and all others. Then start the recovery machine in
“charging mode” and use it according to its user manual.
20) The quantity of refrigerant that should be charged in heat pump is 880-
890g. The gas located into the hoses and recovery machine does not
count!
21) Stop the recovery machine. Close all taps.
22) When the scales read 880 –890g refrigerant consumed, close the tap1
immediately.
23) CLOSE THE TAP OF THE BOTTLE WITH R134a!
CHECKING THE WORKING PARAMETERS OF THE HEAT PUMP
24) Unscrew the protective cap of low and high-pressure probes (Fig
pr.9.1)
25) Connect the high-pressure hoses, equipped in both ends with taps to
the probes and to the instrument. (Fig pr.9.8).
26) Fill the unit with water if it is not
27) Start the heat pump and the instrument.
28) Read the data and compare with the tables point F at the end of this
document (±5%).
Fig: pr.9.6: Fig: pr.9.7:
Fig pr.9.8: