Reclaim Energy Air-Source CO2 Heat Pump

Product Update V2 Release

FEB 2023 PRODUCT SUPPLY CHANGES

As of February 2023, Reclaim Energy launched the next generation of heat pump with substantial improvements. Unless specified below, all other parameters/specifications are the same between V1 and V2 models. The key changes are summarised in Table A and Table B.

Table A: Key updates on the Reclaim Energy heat pump.

Figure A: Images of three controllers: V1 (Discontinued) with a green display and buttons; V1.1 with a white display and buttons; V2 with a white display and touch-sensitive buttons.

Table B: Key updates on the Reclaim Energy controllers.

Figure B: Image showing a V2 controller and a smartphone displaying the Reclaim Energy mobile app interface. The app shows Wi-Fi connection status, device information, and settings like automatically setting time.

Connection to Wi-Fi and the mobile app is OPTIONAL for the end user. Full functionality of the controller can be used manually or via the FREE Reclaim Energy app, available for iOS & Android mobile phones.

Key Changes on the System Model Numbers

The V2 system model numbers are different from previously supplied models. The following codes must be used for rebate applications such as STC, ESC, and VEECs. There has been a slight improvement of about 1-3 STCs for different model IDs between V1 and V2 models.

The latest up-to-date values should be checked at:

• STC values: rec-registry.gov.au/rec-registry/app/calculators/swh-stc-calculator
• VEEC values: veu-registry.vic.gov.au/Public/Calculator/VEECCalculator.aspx
• ESC values (estimates only): reclaimenergy.com.au

Table C: Updates on the system model IDs.

First Time Commissioning Procedure

How to Use V1.1 or V2 Controllers with the V2 Heat Pump

The V2 heat pump's default mode is with the V1.1 controller. If a V1.1 controller is received, it can be connected directly to the RJ45 port on the heat pump's PCB display, and the general commissioning process can be followed.

If a V2 controller is received, the following steps on the heat pump are required before the V2 controller can be used:

1. STEP 1: Connection of correct cable to the right terminal
   • V1.1 controller: Use the RJ45 terminal block.
   • V2 controller: Use the Modbus terminal block.
2. STEP 2: Change the mode on the PCB display from 1 to 2
   1. Press and hold the UP (⬆️) and DOWN (⬇️) buttons.
   2. The displayed value will be "r1" & "1".
   3. Change the value of "r1" to "2" by pressing the RIGHT (➡️) or LEFT (⬅️) button.
   4. Press and hold the UP (⬆️) and DOWN (⬇️) buttons to complete the setting when the display returns to its original blank state.
   5. To verify "r1" & "2" is set, repeat step 1 and then proceed to step 4 to exit.

Diagram: Illustrates how to attach/detach the piping cover using screws and tabs. Shows the heat pump power terminal and the PCB display where the RJ45 cable connects.

Heat Pump Commissioning

1. STEP 1: Ensure the system plumbing complies with the provided diagram.
2. STEP 2: Ensure the system wiring complies with the provided diagram. Pay special attention to sensor insertion on the lower level of the tank; the sensor must be fully inserted. IMPORTANT NOTE: Do NOT plug in the heat pump or connect the controller communication cable yet.
3. STEP 3: Ensure the tank is filled and all air is purged by opening a tap inside the house until water runs freely. Then, turn the tap off. The cylinder is now purged.
4. STEP 4: Purge the circulating pump by loosening the brass 8mm nut on the underside of the heat pump until water runs freely, then tighten it again. The circulating pump is now purged.
5. STEP 5: Commission the controller: select the correct time of day, select the desired operational mode (options 1-6), power up the controller, and connect the communication cable to the heat pump.
6. STEP 6: Initiate auto purge and system start-up. Ensure the controller is on and displaying the time. Verify the heat pump isolator is ON and power is supplied to the unit. On the controller, push and hold the "menu" or "OK" button (depending on controller version) until "purge" is displayed and flashing (approx. 5 seconds). Release the button. After about 4 seconds, the on-board circulating pump should activate.

System Start-Up Sequence

1. The system runs a 5-minute purge to push air into the tank. The unit fan will not operate during this phase.
2. After the purge, the pump stops, and the fan turns slowly. The system will not heat until it can maintain a consistent 63°C (this may take up to 4 minutes).
3. The unit fan operates normally, and the circulating pump circulates 63°C water through the tank.

The smart top-down heat return system provides 50L of hot water within 20 minutes and a full tank in about 3 hours. After 15 minutes, touch the heat pump return connection to the tank; it should be hot to the touch, indicating successful installation.

Critical Notes

Diagram: Shows a schematic of the heat pump unit and its connections, including the water heat exchanger, evaporator, and various ports. It also indicates the V1.1 and V2 controller connections (RJ45 and Modbus cables respectively) and the temperature sensor. A note mentions a swing check valve is recommended if the heat pump is installed more than 1m above the tank to prevent backflow.

System Description

This section provides a brief overview of the Air-Source CO2 Hot Water Pump's main components and functionality.

1.1 Main Components

The system components include:

• Heat pump Unit
• Storage Tank with PTRV
• Controller
• Heat pump mounting legs

1.2 System Operation

The CO2 heat pump unit draws cold water from the bottom of the tank. Using ambient air heat, it heats the CO2 refrigerant to produce hot water. The hot water (fixed at 63°C) returns to the top of the tank, ensuring fast recovery and good stratification. As the water exceeds 50°C, a tempering valve is required for delivery to bathrooms. Untempered water is permitted for kitchens and laundries per AU/NZS AS 3500 plumbing code.

The controller manages the heat pump based on a tank sensor (55-69% level). The heat pump activates if the tank temperature drops below 59°C (first cycle) or 37°C (second cycle) and runs until it reaches 59°C. System controls meet legionella requirements per Australian standards. The heat pump runs until the sensor level reaches 59°C. The turn-off logic for subsequent heating cycles is adjustable via built-in timer settings. The default setting is continuous operation, but installers can adjust it based on homeowner needs.

At ambient temperatures below 5.5°C, frosting may occur. The heat pump enters defrost mode to protect the unit, running for no more than 15 minutes. During defrost, the pump and fan stop, and refrigerant heat melts ice on the evaporator (air-CO2 heat exchanger). The evaporator temperature increases as defrost progresses.

Once a set temperature is achieved, defrost stops, and the heat pump resumes normal operation. Details are in Section 6.

The "operational window" refers to the heat pump's hot water production mode. In cold climates, operation may be extended by anti-freeze or defrost modes. The defrost cycle occurs during the operational window to clear ice from the evaporator when ambient temperature is below approximately 5°C. The frost cycle lasts about 5 minutes and can repeat, totaling up to 20 minutes. The anti-freeze cycle operates outside the operational window to protect the water circuit from freezing. If ambient and pipe temperatures drop below 3°C, the anti-freeze cycle begins. During this cycle, the heat pump operates normally (fan and pump running). It stops when water inlet temperature reaches 56°C or ambient temperature reaches 6°C.

Installation Details

This section covers the preparation and installation process for the Reclaim Air-Source CO2 Heat Pump system.

2.1 Site Inspection and Installation Preparation

Installation must be performed by a licensed plumber or electrician according to local standards and regulations. Key standards include:

• AS/NZS 3000: Electrical installations (240v, 50 Hz, single phase, 15 Amp circuit breaker required, with a disconnection device).
• AS/NZS 3500: National Plumbing and Drainage Code (Heat Pump component must be installed outdoors).
• AS/NZS 2712.2007: Solar and Heat Pump Water Heaters: Design and Construction.
• AS/NZS AS 3498-2009: Water heaters and hot-water storage tanks.

Installers must adhere to occupational health and safety guidelines. Thoroughly read and understand this manual before installation. For queries, contact Reclaim Energy staff at 1300 38 38 15.

This system is designed for domestic hot water applications only; other uses will void the warranty.

Recommended installation sequence:

1. Conduct site inspection.
2. Identify heat pump and tank installation location.
3. Plan system integration: Piping and fittings.
4. Testing and commissioning.

Site Preparation Recommendations:

• Install the system close to main hot water points (kitchen/bathrooms) to reduce heat loss from piping.
• Maximum distance between controller/timer, tank, and heat pump should not exceed 10 m.
• Install the heat pump unit on the ground next to the tank.
• The heat pump unit MUST be installed outdoors; the tank can be indoors.
• Ensure 0.15 m of free space behind the heat pump for air circulation, as it draws in ambient air.
• A dedicated 15 Amp circuit is required for the Heat Pump, and a separate GPO for the controller.
• Mounting surfaces for tank and heat pump MUST be horizontal.
• Clearance on front (350 mm) and back (600 mm) of the unit is required (refer to Figure 2).
• The tank MUST be installed on a concrete slab.
• Water supply quality must meet system specifications.

Component Inspection, Transportation, and Unpacking

• Component Inspection: Verify all components (Heat pump unit, Tank + PTRV, Controller module, Mounting frames) are present. Report any concerns immediately. Additional components are the installer's responsibility.
• Component Transportation: Note "THIS WAY UP" arrows. Secure boxes to prevent movement. Transport tanks upright; stacking is not recommended. Handle products with care; transport damage is not covered by warranty.
• Unpacking: Unpack carefully to avoid damaging components. Avoid sharp blades or knives.

2.2 Hot Water Storage Tank

Installation Location

• Install the tank vertically upright on a ground or floor level.
• Ensure the tank does not obstruct windows, doors, or exits. Provide adequate clearance for servicing. The PTRV must be accessible.
• Secure tanks on a concrete or plastic mounting slab (Figure 1).
• Position the tank to allow for anode removal.
• Locate the tank close to draw-off points. A circulation loop may be considered for long distances.
• If installed indoors, the tank must be in a properly drained safe tray to contain potential leaks, complying with AS/NZS 3500.4 and local codes.
• Tanks installed outdoors require a suitable concrete slab.
• The tank label must be clearly visible.

Figure 1: Shows concrete or heavy-duty plastic slabs for under the storage tank.

2.3 Heat Pump

Installation Location and Spacing

• Install the heat pump unit horizontally on a flat surface.
• Adhere to the spacing requirements shown in Figure 2.

Figure 2: Required space for heat pump installation. Shows dimensions A (clearance in front), B (clearance on sides), and C (clearance at back). Note 1: PCB must be accessible. Note 2: Installation next to AC unit is approved if exhausts don't interfere.

Mounting

Reclaim Energy ASHP units MUST be installed on the ground using supplied mounting frames OR on the wall with brackets. A plumber needs access underneath for servicing and purge protocols.

Figure 4: Shows ground mounting frames. Figure 5: Shows wall mounting brackets. Figure 6: Shows a heat pump drain elbow plug supplied with the unit.

2.3.3 Attaching the Drain Elbow Plug

A drain plug is supplied in the heat pump unit's packaging. Safely connect the drain elbow and guide the drain hose to a ditch if required.

Figure 7: Illustrates how to attach the drain elbow to the bottom panel of the heat pump, connecting to the drain hose.

2.3.4 Removing/Attaching the Piping Cover

Removal: 1. Remove the screw. 2. Slide the piping cover downwards.

Attachment: 1. Fit the piping cover by aligning 5 tabs. 2. Slide the cover upward and secure with the screw.

Figure 8: Shows the process of removing and attaching the piping cover, indicating screw and tab locations.

2.3.5 Heat Pump Water Piping Installation

After removing the right-side piping cover, the heat pump's cold (inlet) and hot (outlet) pipes are accessible.

• The hot water outlet from the heat pump connects to the top port of the tank (marked "heat pump return").
• The cold-water inlet to the heat pump draws from the bottom tank port (marked "heat pump flow").
• Minimize piping between the heat pump and tank. Avoid non-return valves or strainers in this plumbing, as they restrict flow and void warranty.
• All hot pipes, including the PTRV, must be fully insulated.
• For domestic installations, use copper pipes (1/2" / 12.7mm). PEX piping systems are not to be used.

Figure 9: Plumbing diagram of the Reclaim Energy ASHP hot water system. Shows connections between the Heat Pump Unit, Storage Tank, PTRV, Thermistor, and LOAD. Includes pressure ratings (PLV, ECV, PTRV) and notes on distance limits, bends, valves, and sensors.

NOTE:

• Maximum total distance between heat pump and tank: 10m horizontal, 5m vertical.
• Heat pump can be above or below tank level up to 5m.
• Maximum number of bends allowed: 4.
• Do not use restrictive valves (check valves, strainers) in flow/return lines; this voids warranty and affects performance.
• A 15 A isolator switch is recommended for the heat pump unit.
• Sensors must be fully pushed into the tank and tightened to the gland.

2.3.6 System Wiring

A licensed electrician must install the system according to the wiring diagram (Figure 10) and local/national codes. The power cord must comply with AS/NZS 3191, with a nominal cross-sectional area of 1.5 mm² or more.

The heat pump requires its own circuit (15 A) and must be hard-wired to a 15 A ISOLATOR SWITCH. The controller has its own plug and requires a separate power point, which can be fed from the heat pump circuit.

Figure 10: Wiring diagram of the Reclaim Energy ASHP hot water system. Shows connections between the Heat Pump Unit, Controller, Storage Tank, and power supply via a 15A AC isolator switch. Includes labels for temperature sensor cable, RJ45 cable (V1.1), and Modbus cable (V2).

Connecting V1.1 or V2 Controller to the Heat Pump

The communication protocol differs between V1.1 and V2 controllers:

• V1.1 controller: Connects via RJ45 cable to the heat pump.
• V2 controller: Connects via Modbus cable to the heat pump.

Images show V1.1 controller connecting to the RJ45 terminal on the PCB display, and V2 controller connecting to the Modbus terminal block. Instructions for wiring Modbus cables are provided.

Controller Key Functions

Regardless of controller version, installers must ensure:

1. The controller power cable is wired to a power point.
2. The controller communication cable is correctly wired to the heat pump (RJ45 for V1.1, Modbus for V2).
3. Controller manual references are followed for: time of day setting, operational mode selection (default is option 1), and for V2 controllers, Wi-Fi function enablement and connection to the Reclaim Energy mobile app.
4. The heat pump is purged by the controller during commissioning (press and hold "menu" or "OK" for 5 seconds to initiate a 5-minute purge cycle).
5. Before leaving site, ensure the heat pump receives a signal from the controller and the "heat up" process has started (fan spinning, hot water outlet pipes hot, reaching +60°C). If the time of day conflicts with option settings, initiate a heat-up cycle using the boost function to establish communication.

2.5 Post Installation Inspection Checklist

A licensed installer should check the following before leaving the installation site:

• System Check: Verify all connections for leaks and ensure all components are installed per the manual.
• Take photos of all system components for warranty purposes (plumbing lines, tank, heat pump, sensor connections).
• Note the Tank Serial Number.
• Note the heat pump Serial Number.
• Note the controller Serial Number.
• Complete the installation record form for system warranty and service issues.
• Submit the Installation Record Form via Email: warranty@reclaimenergy.com.au
• Complete the rebate form prior to leaving the site (requires installer's signature). This form is not supplied with the manual; customers are responsible for having it ready.

Checklist

General:

• Water supply meets quality standards.
• No pipe leakage.
• No flammable hazardous materials around the unit.
• No damage, deformation, or contamination to components.
• Sufficient space for inspection/repair.
• Floor below tank/heat pump is waterproofed and can support the component.
• Hot water available with sufficient pressure at taps.

Heat Pump:

• Unit installed properly per guidelines.
• Drain plug properly closed.
• Heat pump drain in correct position.
• Two-step air purge operation completed successfully.
• Wiring cover correctly closed.

Tank:

• PTRV operation is normal.
• Tank unit fixed with anchor bolts if necessary.

Piping/Wiring:

• Mains breaker is correct size; breaker can be turned off; local disconnect in place.
• Power supply wiring, ground wire, and "On/Off RJ45 cables" are fixed firmly.
• Union joints allow for easy part removal.
• Piping insulation work conducted properly.

Controller:

• All 3 connections are firm and in place: 1 – communication (RJ45/Modbus) cable to heat pump, 2 - Sensor cable to tank, 3 – Power connected.
• Correct time of day set on first powering.
• Controller operational mode (OPTION modes) set per customer requirement.

Operation and Maintenance

3.1 Heat Pump

3.1.1 Check for the Operational Mode

End users should check that the heat pump operation matches the selected options at least monthly. If the heat pump operates outside these settings, escalate to a local service agent or Reclaim Energy representative. Potential causes for deviation include: loose tank sensor, winter freeze/frost protection cycles, or accidental activation of Boost function.

3.1.2 Check for Air Flow/Water Blockage

Check the heat pump's drain tray for blockages at least annually. Ensure the surrounding area is clear of plant growth to allow for natural ventilation.

3.1.3 Check for Error Codes

If the heat pump or controller encounters an issue, an error code will be generated. Each error code on the controller corresponds to a label on the heat pump PCB display. If a controller error appears but not on the PCB, it may indicate a damaged or faulty communication cable.

The following tables summarize error codes and troubleshooting steps:

Error Code Table (Part 1)

Error Code Table (Part 2)

Error Code Table (Part 3)

Hot Water Storage Tank

3.2.1 PTRV (Pressure and Temperature Relief Valve)

The system requires a PTRV for pressure release (max 850kPa). It must have a downward copper pipe to a safe drainage location. The PTRV may discharge small amounts of water (1L per 50L heated). If installed indoors, a safe tray is mandatory. Check the PTRV every 6 months by lifting the lever; water should discharge. Operate the manual relief every 6 months to clear deposits.

3.2.2 Anode

The sacrificial anode in glass-lined tanks protects the vitreous enamel for approximately five years. It should be replaced as part of an annual service thereafter. Water supplies with high Total Dissolved Solids (TDS) (>600mg/L or <40mg/L) may require a different anode. Warranty is void if TDS exceeds 2500 mg/L. Check the tank anode initially after 5 years, then every 3 years.

3.2.3 Hydrogen Build Up

The Magnesium anode can release small quantities of hydrogen gas, usually dissolved and flushed away. If the water heater is unused for two or more weeks, or water appears milky, hydrogen build-up may occur. To resolve this, "purge" the tank for approximately 30 seconds using the PTRV lever. Stand clear of the discharge piping.

3.2.4 Draining the Water Heater

Drainage is only required if the system is left without power or for holidays/maintenance. Follow these steps:

1. Turn off electricity supply to the water heater.
2. Turn off cold-water supply at the isolating valve.
3. Gently operate the easing lever on the PTR Valve to release pressure.
4. Disconnect the cold-water inlet union and attach a drain hose.
5. Gently operate the PTR Valve lever to let air into the heater and allow water to escape through the hose.