Reclaim Energy Heat Pump Controller V1.1 Manual

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.

Issue 01b | Jan 2023

Overview

This controller is designed to work only with the Reclaim CO2 domestic hot water heat pump. The key difference between V1 and V1.1 controller is the introduction of Option 6 which is a remote option control in V1.1. All functionalities between controllers are the same so for more information on how the controller works, please refer to the heat pump installation manual.

v1 Controller

Times at which temperature mode is enabled:

• Option 1: 24/7
• Option 2: 10 pm - 7 am
• Option 3: Midnight - 6 am
• Option 4: 10 am - 4 pm
• Option 5: Two cycles – first must set for a minimum of 6 hours and second can be set as little as 0 hours!
• One shot boost: This activates the heat pump if temperature is less than 59°C and heats up until 59°C at sensor level is achieved.

v1.1 Controller

All options are the same as V1 with the addition of Option 6 as below:

• Option 6: One shot boost is activated by a dry contact signal from home management or PV inverters or dry contact smart switches. This is called "Remote" option.

The controller measures the tank temperature and compares it to set points stored in memory. These set points can be dependent on the time of day. Once the lower temperature is reached, the controller signals the heat pump to start heating via the RJ45 cable. Once an upper temperature is attained, the controller signals the heat pump to stop heating. The controller automatically manages Legionella safety, heating once a day if the Legionella safe temperature has not been attained during the day.

The 7-segment display defaults to the time of day but can also show the measured temperature. 3 status LEDs show additional information.

The onboard Real Time Clock is maintained by a Super Capacitor on the main circuit board. This will keep the time running for 3 weeks with no power applied but itself should last for the lifetime of the controller.

The controller is prewired to be 'plug n play' and there is usually no need to remove the cover on installation. The enclosure is water resistant (to rain) and is UV resistant. The case is made of non-burning tough polycarbonate.

Before You Begin Installation

Case Tools Required

• Philips #1 screwdriver for lid screws (if required to remove cover)
• Pozi #2 screwdriver for mounting screws

READ THESE SAFETY PRECAUTIONS and LIMIT OF LIABILITY BEFORE YOU BEGIN

The following pages contain instructions for qualified personnel only. They involve potentially hazardous adjustments and high voltage mains wiring information.

General Safety Precautions

The installation is to be checked at least annually for damage or malfunction. All servicing is to be carried out by qualified personnel only. All aspects of the installation must comply with local electrical and plumbing regulations.

WARNING

These products are not designed for use in, and should not be used for, applications which are in conjunction with items that are critical to any person's health (e.g. life support systems). In any critical installation, independent fail-safe back-up systems must always be implemented.

Installation Precautions

• Make sure the controller is installed out of direct sunlight, flammable liquids, or radiant heat sources. Power leads must face directly down.
• Ensure controller is in a safe environment for users to inspect the display panel.
• Sensor leads should be kept 300mm (12 inches) away from mains and comms cables if run parallel to those cables.
• A readily accessible power disconnect device is required.

CAUTION

• Dangerous Voltages may be present.
• No user serviceable parts.
• Protective enclosure must only be opened by qualified personnel.
• Remove ALL power sources before removing the protective cover. The Reclaim Controller must be installed by a qualified person.
• Ensure suitable over-current protection and RCD protection for the Reclaim Controller is in place.

Installing the Reclaim Controller

Mounting

1. Allow for the enclosure dropping 5mm (1/5 inch) from screw centres once mounted (keyhole mounting).
2. Place the printed drill guide template (that ships with the controller) against the wall, checking for level alignment. All four mounting holes should be used with at least two firmly secured into wood or masonry.
3. Mark and drill/screw as appropriate, leaving the heads of the screws above the surface by approximately 3mm (1/8 inch).
4. Place the unit over the four screw heads. The unit should slide down 5mm into the 'key' slots and become secured to the wall. You might need to adjust the screw height to obtain a secure fit.

Sensor Mounting

WARNING: It is CRITICAL the sensor is mounted correctly for accurate readings, safe and efficient operation of the system, and durability of the sensors.

The sensor should be fitted into a dry metal immersion 'pocket' in the hot water cylinder. Apply plenty of heat transfer compound (available from your distributor) between the sensor and the lining of the 'pocket', then seal against water ingress where the cable exits the cylinder with neutral cure silicon.

Connect to Heat Pump

Plug RJ45 cable into the heat pump.

Connect PV Remote wires (only if applicable)

A 'clean set of contacts' (passive only) is expected for this input. If not, then the controller could be damaged. The remote input is accessible by removing the cover. Ensure mains power is isolated during this work. Loosen the cable gland and thread the cable next to the sensor cable. Wire in as indicated on the diagram.

Plug in the controller to the power source

Before power up, read all safety instructions, warnings, and liability statements.

The controller will run through start-up checks, including lighting all LEDs. The first display will be the time of day the controller thinks it is. Page 7 has details on how to adjust the time.

Reclaim Controller with the Cover Removed

This section describes the internal components of the controller. The image shows the main circuit board, display, buttons, and terminal blocks. A label points to the "Dry contact terminals for option 6 (page 9)".

First Time Commissioning Procedure

The following steps are required during the commissioning of the controller:

1. The controller is connected to the power point and has power on it.
2. The correct version of the controller is chosen on the heat pump. For V1.1 controller, "r1" needs to be set at "2". This can be checked and changed on the heat pump's main PCB by following specific button press sequences (UP/DOWN, RIGHT/LEFT).
3. The controller shows the correct time of day. To set the time: press the Menu button, then the Temperature button to select "TIME", then press Menu again. Use the Boost button to increment time (⬆️) or the Temperature button to decrement time (⬇️). Press Menu to accept.
4. Connect the RJ45 cable and initiate the purge cycle. The controller communication cable is connected to the heat pump. For V1.1 controller, the RJ45 terminal block is used.

Note: The clock is always in 24hr mode, and all adjustments for daylight saving must be done manually.

Initiate the Purge Cycle

On occasion, the heat pump needs to be purged of air in the system.

To activate Purge Mode, perform the following steps:

1. Ensure the module is in the Normal Display mode, displaying either Time of day or Temperature.
2. Press and hold down the Menu button for approximately 5 seconds.
3. The Display will commence flashing "Purg".
4. The heat pump output will be disabled.
5. The Purge output will be enabled.
6. Purge mode will remain active for 5 minutes.
7. All menu and display modes are disabled during Purge Mode.
8. After 5 minutes has elapsed, the purge output will turn off.
9. All control functionality will resume.
10. When the test operation display above disappears and the purge mode is complete, open the PTRV on the tank for 5 seconds.
11. When water comes out from the PTRV on the tank, close the PTRV.

Note: Purge mode can be turned off at any time by pressing and holding the Menu button for 5 seconds. Purge mode is automatically turned off if the module is currently displaying a heat pump error code.

CAUTION: Make sure to complete the air purge before heating operation. It can cause unit failure.

Select Operational Modes

Select among the 6 operational modes. To verify the option is selected correctly, after setting up the option, go back to the main menu and press the "Temp" button. The current tank option and active option will be shown within seconds.

Front Panel Operation

The front panel features a display and several buttons: BOOST, TEMP, and MENU. It also includes status LEDs: PWR (Green), HP ON (Yellow), and FAULT (Red).

Button Functions:

• BOOST key: Normal Mode: Boost Toggle; Menu Mode: Exit Menu; Data Change Mode: Increment (⬆️)
• TEMP key: Normal Mode: Sensor °C; Menu Mode: Next Setting; Data Change Mode: Decrement (⬇️)
• MENU key: Normal Mode: Menu Mode; Menu Mode: Enter; Data Change Mode: Accept setting

Controller Status LEDs:

• Green LED (PWR): Flashing in standard mode, Steady on in Boost mode.
• Yellow LED (HP ON): Indicates the Heat Pump is on. If flashing, it signifies Boost mode.
• Red LED (FAULT): Solid light displays a fault code on the digits. Flashing indicates a sensor fault.

Modes of Operation

Time Control Mode:

The temperature control mode can be enabled and disabled during certain periods within the 24-hour cycle, as outlined in the options page. Users can select to permanently enable, four preset time periods, or opt for two adjustable time periods.

Boost Mode:

The Boost mode can be turned on and off via a momentary press of the Boost button. When activated, temperature control mode is enabled, allowing the heat pump to turn on until the temperature reaches 59°C (plus 3 seconds), or the 6-hour period has elapsed. The On Call LED will start flashing. If inadvertently pressed, boost mode can be turned off by pressing the Boost button again.

Temperature Control Mode:

The "temperature control" turns the heat pump on at the T-on setting (37°C) and off at the T-off setting (59°C). On first start, the heat pump turns on if the temperature is less than 59°C. On subsequent starts, it turns on when the temperature drops to the T-on setting (37°C) and turns off when it reaches the T-off setting (59°C).

Legionella Time Cycle Check:

For the effective elimination of Legionella, the system control will automatically heat the temperature to 59°C at least once every 24 hours.

Details of Operational Modes:

The temperature mode can be enabled by various time switch modes, selectable in the "User Menu". Whenever the temperature mode is enabled by one of these options, the Power ON LED will flash.

Note: If a faulty temperature sensor is detected (e.g., Eg-8 or Eg-9), the Boost function will still operate and turn the heat pump on for 6 hours.

Please note with activation/closure of a dry contact, the one-shot boost function will be activated, so the system will stop once the temperature reaches 59°C. The boost function is triggered by a change in state from open to closed contact. If the dry contact remains closed, the system will go under the "temperature mode" and the green light will be flashing. The next time the system will be running if the temperature drops below 37°C. With option 6, if the dry contact does not get closed in an 18-hour cycle, the system will automatically run to meet the legionella requirement 18 hours after the last time that 59°C was reached.

Heat Pump Purge Mode

On occasion, the heat pump needs to be purged of air in the system.

To activate Purge Mode, perform the following steps:

1. Ensure the module is in the Normal Display mode, displaying either Time of day or Temperature.
2. Press and hold down the Menu button for approximately 5 seconds.
3. The Display will commence flashing "Purg".
4. The heat pump output will be disabled.
5. The Purge output will be enabled.
6. Purge mode will remain active for 5 minutes.
7. All menu and display modes are disabled during Purge Mode.
8. After 5 minutes has elapsed, the purge output will turn off.
9. All control functionality will resume.

Note: Purge mode can be turned off at any time by again pressing and holding the Menu button for 5 seconds. Purge mode is automatically turned off if the module is currently displaying a heat pump error code.

User Access

This section describes the menu structure for accessing and setting various parameters:

• Menu Navigation: Use the MENU, TIME, OPTN, and STAT options.
• Button Functions:
• Push Buttons: Boost (Exit/Up ⬆️), Temperature (Move/Down ⬇️), Menu (Accept).
• Options (OP-1 to OP-6):
• OP-1: Heat Pump Enabled for 24hrs (Default)
• OP-2: Preset Time Switch Setting - 2
• OP-3: Preset Time Switch Setting - 3
• OP-4: Preset Time Switch Setting - 4 (P.V.)
• OP-5: Two user adjustable time blocks (e.g., Time Switch Setting - User 1, Run Time Setting - User 1)
• OP-6: Remote Control Input (CON2, Term 3 & 4) (e.g., Time Switch Setting - User 2, Run Time Setting - User 2)
• Notes:
• 1. 'x' = Current Value.
• 2. In Data Change mode, when "Adj" is toggled on the display, the value can be changed by using the UP button or the DOWN button.

Button Functions

This section details the functions of the controller's buttons in different modes:

Boost Button:

Press to switch the Heat Pump into boost mode. The On Call LED will start flashing. If inadvertently pressed, boost mode can be turned off by pressing the Boost button again. After one-shot boost is complete, the controller reverts back to the last programmed setting.

Temperature Button:

Press to display the current tank temperature (latches on for 20 sec). The current control option is also briefly displayed. The temperature is displayed for 4 seconds, then the currently selected user option is displayed for 4 seconds, before reverting back to the tank temperature for a remaining 12 seconds. This feature is disabled whilst in Menu Mode, during Purge Mode, or whilst displaying a heat pump fault code or temperature sensor fault.

Examples: Setting the Time

NOTE: There is a 12-second no button press timeout.

1. Press MENU ENTER button, "Menu" appears on display.
2. Press TEMP ⬇️ button, "time" appears on display.
3. Press MENU ENTER button, the time and ADJ alternatively flash on the display.
4. Press BOOST ⬆️ EXIT to increase the time or TEMP ⬇️ to decrease time.
5. When finished, press MENU ENTER, "time" appears on display.
6. Wait 12 seconds for menu timeout. New time will appear.

Changing an Option – Mode of Operation

NOTE: There is a 12-second no button press timeout.

1. Press MENU ENTER button, "Menu" appears on display.
2. Press TEMP ⬇️ button, "time" appears on display.
3. Press TEMP ⬇️ button, "optn" appears on display.
4. Press MENU ENTER button, the option and ADJ alternatively flash on the display.
5. Press BOOST ⬆️ EXIT to increase the option number or TEMP ⬇️ to decrease the option.
6. When finished, press MENU ENTER, "optn" appears on display.
7. Wait 12 seconds for menu timeout. New time will appear.

Setting the Control Option

With reference to the Menu Structure, carry out the following steps:

1. Press MENU ENTER: "Menu" is displayed.
2. Press TEMP ⬇️ (to move to next parameter): "TIME" is displayed.
3. Press TEMP ⬇️ (to move to next parameter): "OPtn" is displayed.
4. Press MENU ENTER: The option currently set "OP-X" is displayed, alternatively with "AdJ-", indicating you are in data change or adjust mode.
5. Use the BOOST ⬆️ EXIT button to increment the Option UP, or the temperature button to decrement the Option DOWN. Note that the "AdJ-" prompt is not displayed whilst the up/down buttons are pressed.
6. If setting Option 1 to 4, then press MENU ENTER to return to the main menu loop.
7. If the Option is set to Option 5, then this is the User Selectable time switch settings. Press BOOST ⬆️ EXIT: "Menu" to enter User Time-ON-1, "onu1" is displayed.
8. This is the time of day you want the heat pump temperature mode enabled.
9. Press MENU ENTER to display the current time-On setting. The "AdJ-" prompt will again appear.
10. Use the BOOST ⬆️ EXIT to increment the Time-ON UP, or the temperature button to decrement the Time-ON DOWN. Note that the "AdJ-" prompt is not displayed whilst the up/down buttons are pressed.
11. Press MENU ENTER: Once the correct time-ON is displayed, press the Menu button to Accept.
12. Press TEMP ⬇️ button to move to the User Hours-Run-1, "hru1" is displayed.
13. Press MENU ENTER button to display the current Hours Run setting. The "AdJ-" prompt will again appear.
14. Use the BOOST ⬆️ EXIT button to increment the Hours Run UP, or the temperature button to decrement the Hours Run DOWN. Note that the "AdJ-" prompt is not displayed whilst the up/down buttons are pressed.
15. Press MENU ENTER: Once the correct Hours Run is displayed, press the Menu button to accept.
16. Press TEMP ⬇️: A second user selectable time switch setting is also available. Press the Temperature button to move to the User Time-ON-2, "onu2" is displayed. Repeat steps 9 to 11 to adjust, but if not required, move to the next step.
17. Press TEMP ⬇️ button to move to the User Hours-Run-2, "hru2" is displayed.
18. Press MENU ENTER button to display the current Hours Run setting. The "AdJ-" prompt will again appear.
19. Use the BOOST ⬆️ EXIT button to increment the Hours Run UP, or the temperature button to decrement the Hours Run DOWN. Note that the "AdJ-" prompt is not displayed whilst the up/down buttons are pressed. If the second user selectable time switch is not required, it can be disabled by setting the user hours run-2 period to 00 hrs.
20. Press MENU ENTER: Once the correct Hours Run is displayed, press the Menu button to accept.
21. Press BOOST ⬆️ EXIT: Once finished, simply press the Boost button (exit) to revert to the normal display or wait 30 seconds for auto exit.

Status of Operation LED and Button Function Summary

The controller status is indicated by LEDs and button functions:

• PWR (Green LED): Solid when power is on. Flashing in standard mode, steady on in Boost mode.
• HP ON (Yellow LED): Indicates the Heat Pump is on. Flashing signifies Boost mode.
• FAULT (Red LED): Solid light displays a fault code on the digits. Flashing indicates a sensor fault.

Controller Status LEDs:

Eg, during Options 2-6: When heating is disabled due to the time period, the Green LED will be solid. When temperature mode is enabled due to the time, the Green LED will flash.

IMPORTANT

Temperature control mode is disabled if a faulty temperature sensor is detected (Eg-8 and Eg-9), although the boost mode is still operational.

Heat Pump Faults

Should the heat pump unit go into fault mode, it will generate a fault code which this module will display. The Fault LED will turn on, and one of the error code categories on Table 10 will be displayed. Each error code on the external controller has been synced with a corresponding fault condition on the heat pump PCB board. When an error is showing on the external controller, the piping cover on the left side of the heat pump needs to be removed to access the heat pump PCB display.

IMPORTANT

1. If the tank is cold and no hot water is available at taps after a consecutive 24-hour cycle and no error codes on display, this may indicate a faulty RJ45 PATCH cable. Check connections at both ends or replace the cable.
2. Temperature control mode is disabled for Eg-8 and Eg-9 faults; however, boost mode is still operational.
3. Eg-8 and Eg-9 faults have a fixed 3-second time delay for both fault on and fault off occurrences. Details of error codes and troubleshooting procedures are summarized in Table 11. ONLY a licensed installer should conduct the troubleshooting process per instructions given in the "Service Manual".

Communication/Temperature Sensor Cable Extension Guide

The RJ45 and sensor cables can be extended up to 15 metres.

Note: There are 2 different RJ45 wiring sequences for all RJ45 cables (CAT5 or CAT6). Take special note of the SEQUENCE of the wires and the associated plug pin positions of your replacement cable. These 2 wiring standards are known as T-568A and T-568B.

In this example, the photo of the controller is using T-568B. Take note of the replacement (longer) cable you select and determine if it is type A or B. Then wire into the controller to match the type you have. Note: Positions 1, 2, 3, and 6 are the only differences.

Note: Isolate the mains power before removing the cover and performing this modification.

Lengthening Sensor Wire

15 Metre sensor cables are available and are the best option for extending the sensor cable. Note: The controller will only accurately measure Sensors Specification: NTC 10K @25°C Beta 3435K. Do not use other sensors.

Replacing a Sensor

Note: Isolate the mains power supply during this procedure.

1. Remove the four screws that hold the lid on.
2. Unscrew the existing sensor from the terminal block.
3. Loosen the cable gland for the sensor lead.
4. Carefully pull the wire back through the opening in the bottom case.
5. Thread the new sensor wire back through where the old one came from.
6. Place the wires of the new sensor into the terminal block where the old sensor came from.
7. Do not allow the sensor cable to come within 10mm of the high voltage components inside the enclosure. Tighten the cable clamp.
8. Replace the lid, replace the four screws and tighten.
9. Reconnect the Reclaim controller and turn on the power.
10. Check that the sensor is reading correctly.

RJ45 Pinout Configurations:

Sensor Probe T10K

Temperature Versus Resistance Table [ITS-90]

Resistance: 10.0k ohms at 25 deg. C B Value: 3435K at 25/85 deg. C