A.O. Smith PHPT-60 Service Handbook Download Page 1

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RESIDENTIAL HYBRID ELECTRIC HEAT PUMP WATER HEATER

Service Handbook

PRINTED IN THE U.S.A. 0511

321547-000

SERVICE SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN

FOR MODELS:

PHPT-60 (60 GAL.)
PHPT-80 (80 GAL.)

INSTALLATION CONSIDERATIONS -

PREVENTIVE MAINTENANCE -

OPERATION & SERVICE - TROUBLESHOOTING

Summary of Contents for PHPT-60

Page 1: ...R Service Handbook PRINTED IN THE U S A 0511 321547 000 SERVICE SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN FOR MODELS PHPT 60 60 GAL PHPT 80 80 GAL INSTALLATION CONSIDERATIONS PREVENTI...

Page 2: ...ection B 16 Control Board Section C 17 Control Board Section D 18 Wiring Diagrams 19 20 Accessing Maintenance Display 21 Element Test Continuity Check 22 Element Test Ohm s Check 23 Heating Element Re...

Page 3: ...tial that you return the unit to a safe condition before you leave the site All original components must be re installed and all safety measures must be implemented In addition the recommended water t...

Page 4: ...ed The volume and pressure of water increases when it is heated in a closed system IE Water heated from 90 F to 140 F in a 40 gallon water heater will expand by approximately one half gallon Minerals...

Page 5: ...SHUO VL HG WHPSHUDWXUH SUHVVXUH UHOLHI YDOYH PXVW EH LQVWDOOHG LQ RSHQLQJ SURYLGHG DQ UHVXOW LQ RYHUKHDWLQJ DQG H FHVVLYH WDQN SUHVVXUH DQ FDXVH VHULRXV LQMXU RU GHDWK WARNING Excessive Weight Hazard...

Page 6: ...ll piping properly installed and free of leaks Heater completely filled with water see Water Piping System section p 9 Closed system pressure buildup precautions installed see Closed System Thermal Ex...

Page 7: ...ser Interface Module UIM The unit is in Standby the power button on the UIM is RED Press the power button it should turn green and the display should light up If the power button does not turn green r...

Page 8: ...erode over time and become less effective until they stop working all together another type of protective device is a powered anode A powered anode is an active device that counteracts galvanic corros...

Page 9: ...of joint compound and be certain that all fittings are tight IMPORTANT DO NOT over apply joint compound Piping Installation 1 Install the water piping and fittings as shown Figure 2 Connect the cold...

Page 10: ...sure Relief Valve Drain Line 3 4 19mm ID Minimum Drain Figure 3 Temperature and Pressure Relief Valve Installation For protection against excessive pressures and temperatures a temperature and pressur...

Page 11: ...upper thermostats Routine Preventive Maintenance At least monthly a visual inspection should be made of the following Air Filter Remove and inspect clean if needed and reinstall Condensate drain pan...

Page 12: ...sed in this mode The key advantage of using this mode is that it eliminates the cool air exhausted from the heat pump During cold weather months this may be desirable Hot water delivery and operating...

Page 13: ...upon completion of service work Selecting Operating Mode The operating mode can be changed by touching the desired mode icon on the User Interface Module Figure 4 NOTE While vacation mode is on the o...

Page 14: ...d reports any errors through the User Interface Module UIM Based on the inputs from the sensors and or the manual inputs from the UIM the Control Board determines which heating mode the unit should be...

Page 15: ...onnect to lower heating element Pin 2 Connect to L1 behind ECO switch CN 206 Compressor Pin 1 Compressor power L1 Pin 2 Unused Pin 3 Unused Pin 4 Compressor power L2 CN 207 Fan Low high Pin 1 Fan powe...

Page 16: ...l 1 COM Connects to L1 behind the ECO Switch Terminal 2 NO Connects to the upper heating element CN 203 Powered Anode Pin 1 Powered anode signal Pin 2 Ground Figure 7 Terminal 1 Terminal 2 Pin 2 Pin 1...

Page 17: ...Pin 3 Lower water temperature sensor on tank Pin 4 Lower water temperature sensor on tank CN 212 Temperature Sensors Pin 1 Ambient temperature sensor Pin 2 Ambient temperature sensor Pin 3 Discharge t...

Page 18: ...verflow optional Note Pin 9 and 10 are connected by a jumper wire This wire should be cut and wired in series to the overflow switch of the field supplied condensation pump optional SW 201 Dip Switch...

Page 19: ...ER ELEMENT OVERLOAD DETECTION ANODE POWERED HP TEMP TANK TEMP COMPRESSOR DISPLAY USER INTERFACE UPPERELEMENT 4 5 KW NOTES 1 THEFUNCTIONOF CN211 AND CN215 IS THE SAME EITHER CN211 OR CN215 SHOULD BE CO...

Page 20: ...ring Diagram for Non Relay Models L1 L2 Red Black Approved Connectors Junction Box Overload Protectio To 240v 1 Phase Power supply Electrical Service ground Circui Breaker Ground Wire Green n t FIigur...

Page 21: ...temperatures and the final four 4 show the fault code history The down arrow can be used to access previous screens Table 2 Maintenance Display Screen Message Meaning 1 Ambient Temperature Air tempera...

Page 22: ...for a Grounded Element IIB Testing for a Grounded Element 1 Complete Preparing for the Test before you proceed 2 Check for continuity as follows A Place a test probe on one of the element terminals an...

Page 23: ...grounded If either test shows less than infinite resistance the element is defective and should be replaced p 24 D Proceed to Completing the Test III Completing the Test 1 Replace the element s if ne...

Page 24: ...element by loosening the screws Figure 14 Remove the screw in element by turning the element counterclockwise with a 1 1 2 inch socket wrench Remove the existing gasket 8 Clean the area where the gas...

Page 25: ...and the water heater should return to normal operation If resetting the ECO does not clear the error the ECO will need to be checked Follow the procedure below NOTE Tank temperature must be less than...

Page 26: ...it measures 25uF 5 it is good If the value is outside this tolerance the capacitor is bad and should be replaced If a capacitance meter is not available use an Ohm meter to check the condition of the...

Page 27: ...ded period of time If power must be turned off drain the tank completely to minimize corrosion Removing the Powered Anode 1 Press the power button on the UIM to place the water heater in Standby Mode...

Page 28: ...ress power button and verify that unit is in efficiency mode Raise set point 10 Wait ten 10 seconds for compressor to turn on Perform voltage and current checks Fan on Hot Cool No Fan on No Yes Yes Ta...

Page 29: ...Done No Bad Good Check resistance from anode center tab to tank 1M Bad Remove anode and check resistance from threaded portion of anode to the tab 1M Bad Replace anode Good Check that upper element i...

Page 30: ...es Hot Yes No Replace fan Check filter and evaporator for dirt and dust build up Bad 100 Good Motor thermal switch may be open allow to cool Repeat resistance check Replace fan 100 49 61 Reconnect CN2...

Page 31: ...e Yes No Check resistance on fan cable connector pin 1 to 3 Good 49 61 Bad 100 Is case of motor hot No Yes Thermal switch may be open allow to cool Check resistance of cold motor Bad 100 Good 49 61 Re...

Page 32: ...ed and the fault is cleared NOTE After the problem is resolved a fault must be cleared by turning off power to the unit at the breaker or fuse panel for ten 10 seconds and then turning it back on Temp...

Page 33: ...120 140 160 180 200 220 Temperature F Resistance k Ohms Chart 1 Resistance vs Temperature for Tank and Discharge thermistors 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 0 20 40 60 80...

Page 34: ...40 41 42 43 44 45 47 49 51 52 54 56 PSIG 54 56 58 60 62 64 66 68 70 72 74 76 78 F 57 59 60 62 64 65 66 68 69 71 72 73 75 PSIG 80 85 90 95 100 105 110 115 120 125 130 135 140 F 76 79 82 85 88 90 93 96...

Page 35: ...re below for best results 1 Shut off power to the unit at the breaker or fuse box prior to servicing the unit 2 Remove the air inlet and outlet grills Important Do not spray cleaner on the fan motor F...

Page 36: ...st procedure p 32 replace sensor if defective Inlet or outlet water valves at the water heater closed Insure valves are fully open INSUFFICIENT HOT WATER SLOW HOT WATER RECOVERY Temperature set point...

Page 37: ...ntinue use of re circulation system Hot water leak at faucet or piping Repair hot water leaks Sediment or scale build up in tank Drain and flush tank Water conditioning may be required to minimize bui...

Page 38: ...cing the water heater DRIPPING DRAIN VALVE Valve may be slightly open Check to see if the drain valve is closed tightly If the leakage cannot be stopped by tightening the valve replace it WATER DISCOL...

Page 39: ...er and void the warranty Control board faulty If the error still persists this problem may be caused by the control board Replace the control board Heat Pump Connect Fault Heat pump compressor circuit...

Page 40: ...lue If the measured resistance is 200k or 0 the thermisitor is faulty Replace thermisitor assembly Control board faulty Replace control board If replacing the control board doesn t resolve the issue c...

Page 41: ...Lower pressure switch is open Low suction pressure Use a service gage set to check system pressures high and low sides The low side pressure switch opens if suction pressure drops below 7 3 psi and wi...

Page 42: ...OM Fault Main board failure Faulty control board Replace the control board If replacing the control board doesn t resolve the issue contact technical support Main Control Board EEPROM Fault Main board...

Page 43: ...shorted the ECO is good if not the ECO is faulty and should be replaced Condensate Drain Alarm The installed condensate pump is not working Condensate pump not operating Check to see if condensate pum...

Page 44: ...lowchart p 29 Low water level Check water level fill the tank if necessary Power Anode No Current Sense Powered anode circuit not working Faulty control board Replace the control board If replacing th...

Page 45: ...he tank open the cold water inlet valve and restart the heater IMPORTANT Do not turn on power to the water heater unless it is completely filled with water To ensure that the tank is full open a hot w...

Page 46: ...midity in the air If the relative humidity is high the amount of condensate can exceed 20 oz per hour The condensate is collected in a plastic pan under the evaporator Two drain ports are provided for...

Page 47: ...ls 9007324005 14 Air Filter 9007482005 15 Compressor Wiring Harness 409171 000 16 Fuses 2 Input power to control board 3 Amp 250V slow blow 20mm X 5mm 9007485015 17 T P Valve 9000728015 18 Drain Valve...

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A.O. Smith PHPT-60, Service Handbook

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