Reclaim Energy Air-Source CO2 Heat Pump Quick Start/Install Manual

Model Numbers Covered (for STC Claims)

• REHP-C02-160GL-V2
• REHP-C02-250GL-V2
• REHP-C02-315GL-V2
• REHP-C02-400GL-V2
• REHP-C02-160SST-V2
• REHP-C02-250SST-V2
• REHP-C02-315SST-V2
• REHP-C02-315SSQ-V2
• REHP-C02-400SST-V2
• REHP-C02-250SSEW-V2
• REHP-C02-315SSEW-V2

For a digital copy of manuals and brochures, visit: reclaimenergy.com.au/downloads

IMPORTANT This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

WARNING This appliance may deliver water at high temperature. Refer to the Plumbing Code of Australia (PCA), local requirements and installation instructions to determine if additional delivery temperature control is required. For continued safety of this appliance it must be installed, operated and maintained in accordance with the manufacturer's instructions.

Issue 10 | Nov 2024

Contents

1. First Time Commissioning Procedure
2. System Description
3. Installation Details
4. Checklist
5. Operation & Maintenance

First Time Commissioning Procedure

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

The V2 heat pump default mode is with V2 controller. If V1 is received, the following steps on the heat pump are required before V1 controller can be used.

STEP 1: Connection

• Connect the correct cable to the right terminal.
• V1.1 controller: RJ 45 terminal block to be used.
• V2 controller: Modbus terminal block to be used.

STEP 2: Change Mode on PCB Display

• Change the mode on the PCB display from '2' to '1' using the PCB display.
• The 'r1' setting shall be changed from '2' to '1' as follows:
• Press and hold UP (▲) and DOWN (▼) buttons.
• The value displayed is "r1" & "2".
• Change the value of "r1" to "1" by pressing the RIGHT (►) or LEFT (◄) button.
• Press and hold UP (▲) and DOWN (▼) buttons to complete the setting when the display returns to its original display (i.e., blank display).
• To check if "r1" & "1" is established, try step 1 one additional time and then go to step 4 to exit.

Diagram: How to Attach/Detach the Piping Cover

Diagram: Heat pump power terminal, Heat pump PCB display, SW3, SW4, SW2

Heat Pump Commissioning

STEP 1

Ensure the system plumbing complies with the diagram provided.

STEP 2

Ensure the system wiring complies with the diagram. Pay special attention to sensor insertion on the lower level of the tank, and the sensor must be fully in.

IMPORTANT NOTE: DO NOT plug in the heat pump or connect the controller communication cable yet.

STEP 3

• Ensure you have filled the tank and purged all the air by opening a tap inside the house. The tank will be purged when water runs freely from the tap.
• Turn tap off. The cylinder has now been purged.

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 again. The circulating pump has now been purged.

STEP 5

• Commission the controller.
• Select the correct time of day.
• Select the desirable operational mode (i.e., options 1-6).
• Power up the controller and connect the communication cable to the heat pump.

STEP 6

• Initiate auto purge and system start up.
• Ensure the system controller is turned on and the time is displayed.
• Ensure the heat pump isolator is in the 'on' position and power is on to the heat pump unit.
• On the controller, push and hold the "menu" or "OK" button (i.e., "OK" for V2 controller) until the word "purge" is displayed and flashing (approximately 5 seconds).
• Now let go of the button.
• In about 4 seconds, you should hear the on-board circulating pump come on.

System Start-Up Sequence

The system is now starting up and will go through the following sequence:

1. The system will run a 5-minute purge that pushes any air within the heat pump unit into the tank. (Note: the unit fan will not be turning at this point).
2. After this 5-minute period, the pump will stop and the fan will turn slowly. The system will not be heating up until the unit can maintain a consistent 63°C (this may take up to 4 minutes).
3. The unit fan then comes on properly, and the circulating pump starts to circulate the constant 63°C water through the tank.

Due to the smart top-down heat return system, your customer will have 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 and ensure it is hot to touch. If you feel good heat here, you are done and can comfortably leave knowing you have completed the install successfully.

Critical Notes

NOTE 1

Remember to drain and purge the heat pump on commissioning (otherwise system might fail). The "drain plug" is shown below. Also, remember to drain from hot water taps inside the house.

NOTE 2

Sensor probe must be fully inserted and secured (using gland or silicon plug) in the bottom tank sensor. The sensor cable comes with a rubber sleeve. Completely push the sensor in and then push the cable sleeve until only 6 mm is protruding. Then tighten up the gland so the sensor is firmly secure.

Diagram: Sensor probes

NOTE 3

Maximum horizontal distance is 10 m and vertical distance is 5 m between heat pump and tank (max of 3 bends).

NOTE 4

Bottom tank sensor MUST be connected as part of the installation process.

Diagram: System plumbing diagram showing heat pump, tank, sensors, and connections.

System Description

The following system description 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 of the air sourced heat pump that customers will receive include: Heat pump Unit, Storage Tank with PTRV, Controller, Heat pump mounting legs.

1.2 System Operation

The CO2 heat pump unit receives cold water from the bottom of the tank. Using the heat from the ambient air, the heat pump heats the CO2 refrigerant to generate hot water. The hot water returning from the heat pump unit (fixed at 63°C) is injected into the top of the tank to provide fast hot water recovery and excellent hot water stratification. As this system delivers hot water exceeding 50°C, a tempering valve must be installed for delivery of hot water to bathrooms. Untempered water may be delivered to kitchen and laundry according to AU/NZS 3500 plumbing code.

The heat pump operation is controlled by an external controller. The controller operates based on a sensor connected to the tank at 55-69% level depending on tank model ID. The heat pump will be turned on if the temperature at the sensor level on the tank drops below 59°C for the first cycle or 37°C for the second cycle in a day, and it will run until the tank temperature at the sensor level reaches 59°C. The system controls are designed to ensure that it meets the legionella requirements as specified in the Australian standards. The heat pump will run until the sensor level on the tank reaches 59°C. In the subsequent heating cycles of every 24-hour period, the heat pump "turn off" logic is adjustable by built-in timer settings.

The default timer setting is programmed to run on continuous operation, but this can be adjusted by the installer based on homeowner requirements to suit their needs. More details regarding the controller operation and settings are outlined in Section 2.

At ambient temperatures below 5.5°C, frosting may occur. If this happens, the heat pump will go into defrost mode to protect the unit (i.e., the defrost functionality will turn the heat pump on and will normally run for no more than 15 minutes in duration). When the unit is in the defrost function, the pump and fan will stop, and the refrigerant heat will defrost the evaporator. As defrost advances, the evaporator temperature will increase.

When a set temperature (preprogrammed) is achieved, the defrost operation stops, and the heat pump will operate in line with its normal settings. More details regarding the controller operation and settings are outlined in Section 6.

The "operational window" in this context refers to heat pump "hot water production" mode, which can be set by using one of the options on the controller. From time to time, especially during the winter and in very cold climates, the heat pump operation may be disrupted or extended by a built-in anti-freeze or defrost operational mode. The defrost cycle can occur ONLY during the operational window to defrost the ice build-up on the evaporator at the back of the unit, which is an air-CO2 heat exchanger. The defrost cycle occurs when the ambient temperature is less than about 5°C. During the defrost operation, the fan and pump stop, and the high-temperature refrigerant, which is originally used for hot water production, shall be supplied to melt frost on the evaporator (=air-CO2 heat exchanger).

The frost cycle can take about 5 minutes, and this can happen multiple times depending on the ambient temperature, so up to 20 minutes can be expected for the entire defrost cycle. The heat pump also comes with a built-in freeze protection cycle. Anti-freeze operation can ONLY occur outside the operational window of the heat pump, and the purpose of the cycle is to protect the water circuit (i.e., piping between tank and heat pump) from water freezing. If the ambient and water pipe temperatures drop below 3°C, the heat pump will do the anti-freeze operation. During the anti-freeze operation, the heat pump works as a normal heating cycle, so the fan and pump should be running. The anti-freeze operation stops when the water inlet temperature reaches 56°C or the ambient temperature reaches 6°C.

Installation Details

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

The installation of a Reclaim Energy air source heat pump can only be completed by a licensed plumber or electrician in accordance with the local standards and regulations. Please see:

• AS/NZS 3000 - Electrical installations rules: Electrical requirements of the system are 240v, 50 Hz, single phase, with 15 Amp circuit breaker. This appliance is to be wired with a disconnection device, as per AS/NZS 3000 wiring rules.
• AS/NZS 3500 - National plumbing and Drainage Code: The Heat Pump component of the system is to be fitted outside.
• 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

A licensed installer must adhere to occupational health and safety guidelines and other relevant industry associations. Under no circumstances should any installer attempt to install a Reclaim Energy system without reading and understanding this installation manual. For any queries, Reclaim Energy staff may be contacted on 1300 38 38 15.

Note that the Reclaim Energy system has been designed to provide hot water for domestic applications only; other applications such as space heating are not supported by this product. Installing the unit for any other application other than for domestic hot water application will void the warranty. The installation guide for each major component of the system as well as the whole system is covered in this section.

The following sequence is recommended for installation:

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

2.1 Site Inspection and Installation Preparation

The very first step of installation is to find an appropriate location for the installation of the heat pump unit that includes: heat pump, tank, timer, and the controller. It is recommended that:

• To reduce heat loss from piping, the whole system should be installed as close as possible to the main hot water points in the house (kitchen and/or bathrooms).
• The maximum distance between controller/timer, tank, and heat pump should not exceed 10 m.
• It is recommended that the heat pump is installed on the ground next to the tank.
• The heat pump unit MUST be installed outdoors; the tank can be installed indoors.
• The back of the heat pump unit draws in ambient air; therefore, it MUST NOT be covered. To have sufficient air circulation behind the heat pump, the minimum free space should be 0.15 m.
• The system requires one 15 Amp designated circuit for the Heat Pump and a separate GPO power outlet for the controller.
• The mounting surface of tank and heat pump MUST be horizontal.
• The clearance on the front and back of the unit are 350 mm and 600 mm; please refer to Figure 2.
• The tank MUST be installed on a concrete slab on the ground.
• Water supply quality must be in line with the specifications of the heat pump unit and the storage tank being installed.

Installation Details Cont.

Water quality is an important aspect that can influence the system's operations and functionality. For the system to be warranted, the water used in the system must meet the requirements outlined in Table 1 below.

If you have doubts regarding water quality, please contact your local water authority or have a water test completed. In areas of poor water quality, all major components will have a reduced life due to the hardness of the water. In areas with "hard water" (>200 mg/L or ppm), a water softening device must be installed to ensure the long-term efficient operation of the system. Note that the Reclaim Energy glass-lined tank has a sacrificial anode to protect the vessel from corrosion. The glass-lined tank warranty is linked to an anode inspection that must be completed initially after five (5) years and then every three (3) years, thereafter.

2.1.1 Component Inspection

Prior to installation, please check that the following components have been provided. Any concerns must be brought to the attention of Reclaim Energy immediately:

• Heat pump unit
• Tank + PTRV
• Controller module
• Heat pump mounting frames (checked with a reseller)

NOTE: All other components required for the installation not listed here should be provided by the installer.

2.1.2 Component Transportation

• When transporting boxes, note the orientation of the "THIS WAY UP" arrows.
• Ensure all boxes are strapped and secured to prevent movement during transit.
• All tanks must be transported upright. Stacking is not recommended for any tanks.
• Products should always be handled with care. Damage incurred during transportation is not covered under product warranty.

2.1.3 Unpacking of the Components

• When unpacking, take care to ensure that the components are not damaged in the process.
• Avoid using sharp blades or knives, as this can scratch the surfaces of the products.

2.2 Hot Water Storage Tank

2.2.1 Installation Location

• The storage tank must be installed at ground or floor level and must stand vertically upright as per the manufacturer guidelines.
• Tanks must be secured on a concrete or plastic mounting slab as shown in Figure 1.
• The storage tank should be located as close as possible to the most frequent draw-off points in the building, such as the bathroom or kitchen. If the storage tank is located a long way from hot water draw points, a hot water circulation loop on a timer may be considered to reduce the time-lag for water to reach the tap. Please note this is not supplied by Reclaim Energy, but the installing plumber can consider installing a ring main system for hot water circulation.
• The tank should not obstruct any windows, doors, or exits. Clearances must be provided to make servicing and maintenance convenient without the need for a ladder or scaffold. For servicing, the PTRV must also be easily accessible.
• The tank should be positioned to allow room for anode removal.
• The storage tank must be installed in a properly drained safe tray if installed indoors where leakage may cause damage. The installation of the storage tank and safe tray must comply with AS/NZS 3500.4 and all local codes and regulatory authority requirements with regards to its construction, installation, and draining.
• Tanks installed outside must be installed on a suitable concrete slab.
• The tank label must be clearly visible.

2.3 Heat Pump

Before plumbing and/or wiring of the heat pump unit and integration with the rest of the system, the following sequential steps must be conducted.

2.3.1 Installation Location and Spacing

• Be sure to install the heat pump unit horizontally on a flat surface.
• Be sure to install the heat pump unit in accordance with the spacing provided in Figure 2.

Diagram: Required space for installation of heat pump.

Diagram: Heat Pump Key Parts.

For coastal areas, install in the following places (Otherwise, it may cause a malfunction):

• Places where sea water and/or sea breeze do not directly hit as much.
• Places with good drainage.
• Places where the salt etc. adhered to the main body of the heat pump hot water system can be thoroughly washed away by rainwater.
• A place that is 500m or more away from the sea.

2.3.2 Mounting

Note: Reclaim Energy ASHP MUST be installed on the ground with mounting frames that is a default supplied component OR on the wall with brackets. Note, a plumber needs to have access to the underneath of the unit to service the unit and to complete the purge protocols.

Diagram: Ground mounting frames.

Diagram: Wall mounting brackets.

Diagram: A heat pump drain elbow plug supplied with heat pump unit.

2.3.3 Attaching the Drain Elbow Plug

A drain plug is supplied in the bottom side of the heat pump unit box packaging as shown in Figure 7. Per schematic shown below, safely connect the drain elbow and guide the drain hose to the ditch if required.

Diagram: How to attach drain elbow.

2.3.4 Removing/Attaching the Piping Cover

REMOVAL

1. Remove the screw.
2. Remove the piping cover sliding downward.

ATTACHMENT

1. Fit the piping cover to the unit adjusting 5 tabs.
2. Attach the piping cover sliding upward and fix it with the screw.

Diagram: How to attach/detach the piping cover.

2.3.5 Heat Pump Water Piping Installation

After removing the right-side piping cover of the heat pump unit, the heat pump cold (inlet) and hot (outlet) pipes (connection ports) will be accessible as shown in Figure 9. The hot water outlet from the heat pump should be plumbed up to the top port on the tank (i.e., marked "heat pump return" on the tank). The cold-water inlet to the heat pump should be drawn from the bottom of the tank port (i.e., marked "heat pump flow"). The piping between the heat pump and tank should be as minimal as possible. There should be no valve such as a non-return valve or strainer installed between the heat pump and tank plumbing. The piping should have no restrictions. All hot pipes, including the PTRV, must be fully insulated.

For domestic installations, the recommended pipe is copper, with the following dimensions: 1/2" / 12.7mm. PEX piping systems are not to be used.

Diagram: Plumbing diagram of Reclaim Energy ASHP hot water system.

NOTE

1. The maximum total distance between the heat pump and tank should not exceed 10m horizontal and 5m vertical.
2. The heat pump can be under or above the level of the tank for a distance up to 5m.
3. The maximum number of bends allowed is 4.
4. Do not put any restrictive valves such as check valves or strainers in the heat pump flow/return lines. This will void warranty and affect the unit's performance.
5. A 15 A isolator switch is recommended to isolate the heat pump unit.
6. Sensors should be entirely pushed into the tank and tight up to the gland.

2.3.6 System Wiring

A licensed electrician should install the system with regards to the wiring diagram provided in Figure 10 and in accordance with local/national wiring codes. The power cord chosen must be compliant with AS/NZS 3191 and the nominal cross-sectional area should be 1.5 mm² or more.

It is notable that the heat pump must be installed on its own circuit (i.e., 15 A circuit) AND hard wired to a 15 A ISOLATOR SWITCH. The controller has its own plug and must be connected to a separate power point. The power point supplying the controller can be fed from the heat pump circuit.

Diagram: Wiring diagram of Reclaim Energy ASHP hot water system.

IMPORTANT: Do not supply power to the controller or heat pump unit before completing the process explained in section 6.5.3 and 6.5.4.

Connecting V2 Controller to the Heat Pump

The communication protocol used in V2 controller is:

• If V2 controller is received, the Modbus cable should be wired up to the heat pump.

Diagram: V2 controller connects to the Modbus terminal block.

To wire up the Modbus, the screws must be opened, and after the insertion of the Modbus crimp wire, the screws must be completely tightened up.

The process of connecting the power cable to the heat pump terminal is shown in the figures below:

Diagram: How to attach the power cable.

Diagram: Power Supply Terminal Block.

Controller Key Functions

Regardless of the version of controller received, the installer must ensure the following:

1. The controller power cable is wired up to the power point.
2. The controller communication cable is correctly wired up to the heat pump:
   • a. Modbus cable for V2 controller
3. With reference to the controller manual:
   • a. The time of day is correctly selected on the controller.
   • b. The operational mode is set per customer requirement (i.e., default is option 1).
   • c. Applicable to V2 controller only: The Wi-Fi function on the controller is enabled, and the end user successfully connects the controller to the house Wi-Fi and Reclaim Energy mobile app.
4. The heat pump is purged by the controller during the commissioning process:
   • a. Press and hold the "menu" or "OK" button on the controller will initiate the 5-minute purge cycle.
5. Before the installer leaves the site, he/she must ensure that the heat pump receives signal from the controller and the "heat up" process has been started (i.e., fan is spinning, and hot water outlet pipes are hot and reached +60°C). If the time of day contradicts the option settings (e.g., for example, if the installer installs the system at 10 am and the option selected is option 3), to ensure the communications between the heat pump and controller are established, it is recommended to initiate the heat up cycle by using the boost function.

Post Installation Inspection Checklist

A licensed installer should check for the following before leaving the installation site.

System Check: Check all connections for leaks and that all components are installed as per this manual.

Take photos of all system components for warranty purposes. This should include photos of the plumbing lines to and from the tank, heat pump, and sensor port connection.

Note down the Tank Serial Number.

Note down the heat pump Serial Number.

Note down the controller Serial Number.

Fill out the installation record form supplied for system warranty and service issues. Submit your Installation Record Form via Email: warranty@reclaimenergy.com.au

Complete the rebate form for the system prior to leaving the site; this will require the installer's signature. Note this form is not supplied with us or in this document. This is the responsibility of customers to have the rebate form ready for the installer to fill out.

Checklist

Operation and Maintenance

3.1 Heat Pump

3.1.1 Check for the Operational Mode

It is recommended that the end user check the operation of heat pumps matches with the options setting at least once per month. If the heat pump runs outside the settings of the active option, this needs to be escalated to the local service agent and/or Reclaim Energy representative for troubleshooting. There are some possibilities for running outside of the setting of the controller, such as: 1) the tank sensor is loose and the controller does not read the correct temperature of the tank; 2) in wintertime, the system can undergo freeze or frost protection cycles, which are additional cycles compared to normal settings; 3) Boost function accidentally has been activated.

3.1.2 Check for Air Flow/Water Blockage

It is recommended that the drain tray of the heat pump is checked at least once per year for a possible blockage. The same applies to the surrounding of the heat pump, and if plant is growing around the heat pump, that needs to be trimmed frequently to allow for the natural ventilation of the system.

3.1.3 Check for Error Codes

Apart from running outside the cycle of operational modes, should the heat pump or controller run into an issue, the controller or heat pump should generate an error code, or simply the end user will run out of hot water. Each error code on the controller has its corresponding error code label on the heat pump PCB display. If there is an error code on the controller but the PCB display does not show an error, this can imply that the communication cable is damaged or not working (i.e., possible controller fault or communication cable fault). The table below summarizes the full list of error codes and possible solutions.

Table 11: Details of error codes on external controller and heat pump PCB display and troubleshooting process.

3.2 Hot Water Storage Tank

3.2.1 PTRV

Any system design must allow a means of pressure release at no more than 850kPa, using a PTRV. The PTRV must have a downward direction copper pipe connected that is open to the atmosphere, running the expelled hot water or air to a safe, frost-free, and appropriate drainage location. From time to time, the PTRV may discharge small amounts of water under normal operations (1L for every 50 Liters heated). If the tank is installed indoors, a safe-tray must be installed beneath the hot water tank to safely collect any water expelled from the PTRV. PTRV check every 6 months: Test the manual relief by lifting the lever. Water should come out of the relief valve. It is recommended that the manual relief be operated every 6 months to flush out any deposits that may accumulate under the seal.

3.2.2 Anode

The anode on your Glass lined (vitreous enamel) tanks is sacrificial; however, it is designed to protect the vitreous enamel lined cylinder in most public reticulated water supplies for five years, after which time it should be replaced as part of an annual service. It must be noted, however, that many water supplies can exhibit chemical qualities that are not suitable for the standard anode supplied with glass-lined water heaters. Where the Total Dissolved Solids (TDS) is greater than 600mg/L or less than 40mg/L, the installed anode may be unsuitable for use to protect your water heater. In these circumstances, a plumber or authorized service person should be contacted to fit the correct (hard water) anode. Please note that warranty becomes void if the TDS value exceeds 2500 mg/L. Check the tank anode (for glass-lined tanks only) initially after 5 years, then every 3 years, thereafter.

3.2.3 Hydrogen Build Up

Glass lined (vitreous enamel) tanks are fitted with a Magnesium anode to provide corrosion protection for the tank from the storage water. Small quantities of hydrogen gas can be released by the anode, which generally remains dissolved in the water and flushed away as hot water is used from the tank. Depending on the water quality, there may be a degree of hydrogen build-up in the tank if the water heater hasn't been used for two or more weeks, or if water appears milky in color. To resolve the build-up of hydrogen within the tank, “purge" the tank for approximately 30 seconds from the lever on the PTRV. Stand clear of PTRV discharge piping outlet.

3.2.4 Draining the Water Heater

Reclaim system does not require drainage unless the system is left without power or unused for holidays or maintenance reasons. The steps below must be followed:

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

WARNING: Ensure there are no open flames or ignition sources close to the tank.