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Rheem W2W Series, Owner'S Manual And Installation Instructions

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Rheem W2W Series Owner'S Manual And Installation Instructions Download Page 3

 

3 

CONTENTS 

 
 

RESPONSIBLE OFFICER

 

– We recommend you read pages 4 to 18. 

The other pages are intended for the installer but may be of interest.

 

 
 

Contents ....................................................................................... 3

 

About Your Water Heater ............................................................ 4

 

How Your Water Heater Works ................................................... 8

 

Regular Care .............................................................................. 12

 

Water Supplies ........................................................................... 14

 

Save A Service Call ................................................................... 16

 

Installation .................................................................................. 19

 

Heat Pump And Tank Assembly .............................................. 31

 

Manifold Installations ................................................................ 35

 

Connections 

– Plumbing .......................................................... 38

 

Commissioning .......................................................................... 56

 

Draining The Water Heater ....................................................... 68

 

TROUBLE SHOOTING ............................................................... 68

 

Rheem Heat Pump Water Heater Warranty  - Australia & New 
Zealand Only - ............................................................................ 70

 

 

Summary of Contents for W2W Series

Page 1: ...heater must be installed and serviced by an qualified person Please leave this guide with a responsible officer Owners Guide and Installation Instructions Commercial Water to Water Heat Pump Water Heater WMKA21549 ...

Page 2: ...dustry Commission This water heater must be installed by a licensed person as required by the Victorian Building Act 1993 Only a licensed person will give you a Compliance Certificate showing that the work complies with all the relevant standards Only a licensed person will have insurance protecting their workmanship for 6 years Make sure you use a licensed person to install this water heater and ...

Page 3: ... 3 About Your Water Heater 4 How Your Water Heater Works 8 Regular Care 12 Water Supplies 14 Save A Service Call 16 Installation 19 Heat Pump And Tank Assembly 31 Manifold Installations 35 Connections Plumbing 38 Commissioning 56 Draining The Water Heater 68 TROUBLE SHOOTING 68 Rheem Heat Pump Water Heater Warranty Australia New Zealand Only 70 ...

Page 4: ...ter temperature before use such as when entering a shower or filling a bath or basin to ensure it is suitable for the application and will not cause scald injury We recommend and it may also be required by regulations that an approved temperature limiting device be fitted into the hot water pipe work to the bathroom and ensuite when this water heater is installed This will keep the water temperatu...

Page 5: ...afety switch and flow switch Additionally the compressor is fitted with thermal overload protection the condenser heat exchanger is fitted with a pressure relief valve and the storage tanks are supplied with a combination temperature pressure relief valve These devices must not be tampered with or removed The water heater must not be operated unless each of these devices is fitted and is in workin...

Page 6: ...tect the compressor from damage This may take up to 20 minutes to 2 hours The auxiliary booster will operate instead of the heat pump if the heat pump is in fault or sufficient energy is not available from the chiller HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY Installation requirements are shown on page 19 The water heater must be installed by a qualified person and in accordance wit...

Page 7: ...ide and Installation Instructions Refer to Regular Care on page 12 If this water heater is to be used where an uninterrupted hot water supply is necessary for your application or business you should ensure that you have back up redundancy within the hot water system design This should ensure the continuity of hot water supply in the event that this water heater were to become inoperable for any re...

Page 8: ...re heat is transferred to a refrigerant fluid The fluid is compressed and passes to the condenser double wall heat exchanger where heat is transferred into the potable water The pump circulates water from the bottom of the storage tanks through the heat exchanger and the heated water is circulated back into the storage tanks This process continues until the water in the storage tanks reaches the s...

Page 9: ...e heat pump and switches to an auxiliary gas or electric water heater if installed and activated in the menu A pump circulates water from the storage tanks through the auxiliary water heater until the set temperature is reached When the cold side outlet temperature and hot side outlet temperature rises to 10 C the auxiliary heating mode is deactivated and the heat pump starts operating again For i...

Page 10: ...ctly to the mains water supply If the mains supply pressure in your area exceeds that shown on page 21 a pressure limiting valve must be fitted THERMAL CUT OUT The refrigeration circuit is protected by thermal sensors These will activate a thermal cut out in the event of excessive heat in the refrigeration system If the thermal cut out has activated the heat pump will not operate for a period of 2...

Page 11: ...4 Chilled water outlet temperature sensor 5 Hot water inlet temperature sensor 6 Hot water outlet temperature sensor 7 Refrigerant suction side temperature superheat 8 Suction pressure transducer 9 Discharge pressure transducer 10 Cold water flow switch 11 Low temperature cut out switch The output of these sensors are displayed on the user friendly control panel to ensure correct system operation ...

Page 12: ... condensate drain for blockages clear if necessary 7 Isolate power to heat pump and check all electrical connections for signs of overheating due to poor connection 8 Check for vibration or excessive noise from compressor and hot and cold water pumps 9 Check refrigerant pressures and adjust refrigerant charge if required Visually check system for any potential problems 10 Confirm correct system op...

Page 13: ...ve once every six months It is very important you raise and lower the lever gently Warning Exercise care to avoid any splashing of water as water discharged from the drain line will be hot Stand clear of the drain line s point of discharge when operating the valve s lever DANGER Failure to do this may result in the water heater heat exchanger failing If water does not flow freely from the drain li...

Page 14: ...upply desalinated water supply public reticulated water supply or water brought in from another supply then water chemistry information should be sought from the supplier or it should be tested to ensure the water supply meets the requirements given in these guidelines for the Rheem warranty to apply SATURATION INDEX The saturation index SI is used as a measure of the water s corrosive or scaling ...

Page 15: ...metropolitan area is likely to be corrosive due to the dissolution of atmospheric contaminants SUMMARY OF WATER CHEMISTRY ADVICE AFFECTING THE RHEEM WARRANTY The water heater is not suitable for certain water chemistries Those chemistries are listed below If the water heater is connected at any time to a water supply with the following water chemistry Rheem s warranty will not cover any resultant ...

Page 16: ...m button Phone your nearest Rheem Service Department or Accredited Service Agent or Service Centre in NZ to inform about the alarm Is the timer set If the timer has been set ensure sufficient time has been allowed to reheat the storage tanks Are you using more hot water than you think Are outlets especially the showers using more hot water than you think Very often it is not realised the amount of...

Page 17: ...stead The total storage tank capacity will be heated to 60 C during these periods Heating of the water by the heat pump will occur when the freeze protection deactivates Thermal cut out activated Has the thermal cut out for the heat pump compressor activated If the thermal cut out has activated the heat pump will not operate for a period of 20 minutes to 2 hours and display alarm on the control pa...

Page 18: ...check the following points Is the relief valve in the storage tanks running excessively Are outlets especially the showers using more hot water than you think Refer to Not Enough Hot Water on page 16 Is there a leaking hot water pipe dripping hot water tap etc Even a small leak will waste a surprising quantity of hot water and energy Replace faulty tap washers and have your plumber rectify any lea...

Page 19: ...m design This should ensure the continuity of hot water supply in the event that this water heater was to become inoperable for any reason We recommend you provide advice to the system owner about their needs and building backup redundancy into the hot water supply system COMPONENTS The heat pump water heater system is modular and comprises three main components the heat pump water heater storage ...

Page 20: ...nd vertically upright Clearance must be allowed for servicing of the water heater The water heater must be accessible without the use of a ladder or scaffold You must be able to read the information on the rating plate Remember you may have to remove the entire water heater later for servicing A clearance of 850 mm is required from the side of water connections and the front of the heat pump SAFE ...

Page 21: ...ng the storage tank Care must be taken to avoid air locks The cold water line to the storage tank should be adequately sized and fitted with a full flow gate valve or ball valve HOT WATER DELIVERY This water heater can deliver water at temperatures which can cause scalding It is necessary and we recommend that a temperature limiting device be fitted between the storage tanks and the hot water outl...

Page 22: ...ng as a temperature boosting water heater is not installed downstream of the heat pump If a temperature boosting water heater is installed the circulated hot water flow and return system must return to the inlet of the temperature boosting water heater and not the heat pump to avoid potential nuisance tripping Temperature Limiting Device A temperature limiting device cannot be installed in circula...

Page 23: ...iling Under either condition the operation and performance of the device cannot be guaranteed INSULATION To minimise heat loss and provide protection from freezing the cold water line to and the hot water line from the heat pump water heater must be insulated in accordance with the requirements of AS NZS 3500 4 The insulation must be weatherproof and UV resistant if exposed SADDLING PIPE WORK To p...

Page 24: ...INSTALLATION 24 Typical Installation with Recirculation ...

Page 25: ...INSTALLATION 25 Typical Installation with Inline Auxiliary Boost ...

Page 26: ...INSTALLATION 26 Typical Installation with Rheem Guardian Warm Water System ...

Page 27: ...INSTALLATION 27 Dimensions and Technical Data RHEEM W2W Model 15kW 95401500 ...

Page 28: ...INSTALLATION 28 Dimensions and Technical Data RHEEM W2W Model 35kW 95403500 ...

Page 29: ...INSTALLATION 29 Dimensions and Technical Data RHEEM W2W Stackable Model 15kW 9540150S ...

Page 30: ...INSTALLATION 30 Dimensions and Technical Data RHEEM W2W Stackable Model 35kW 9540350S ...

Page 31: ... the heat pump water heater storage tanks and primary circulators An auxiliary booster and circulator may also be employed as part of the system The water heater must not be operated until all components are assembled HEAT PUMP Locate the heat pump s in the appropriate position observing the required clearances for operation and servicing Refer to page 31 Indoor Installations To comply with AS1677...

Page 32: ...low manifold system to ensure even distribution of the stored energy Up to ten tanks can be manifolded together in a single bank More than one bank can be used Follow the diagram on page 36 when manifolding the tanks Refer to the installation instructions supplied with the storage tanks for specific information relating to the installation of the storage tanks PRIMARY CIRCULATORS Each side cold an...

Page 33: ...ame as any other To achieve this the following is necessary 1 The inlet manifolds must be designed to balance the flow to each heat pump i e each branch line must be the same diameter and length 2 The outlet manifolds must be designed to balance the flow from each heat pump i e each branch line must be the same diameter and length 3 The first heat pump in must be the last heat pump out Note Inlet ...

Page 34: ... depending on system design Consult the Application Guide for details on the auxiliary boost function designed for this system In Line Boosting Only Where the auxiliary water heater is required to ensure sufficient hot water is available for periods after the main peak or to boost the temperature of the water produced by the heat pump for other purposes eg high temperature for kitchen and laundry ...

Page 35: ...nks must be of the same model 4 The cold water line cold and hot headers and hot water line must be sized to meet the requirements of both AS NZS 3500 4 and the application 5 A non return valve isolation valve and if required a pressure limiting valve and expansion control valve must be installed on the cold water line to the system 6 A full flow gate valve or ball valve not a stop tap as used on ...

Page 36: ...MANIFOLD INSTALLATIONS 36 Manifold Arrangement Hot Manifold Assembly Cold Manifold Assembly Primary Hot Water Flow Manifold Assembly HOT WATER FLOW RETURN FROM HEAT PUMPS FLOW TO HEAT PUMPS ...

Page 37: ...etween wall and back of water heater is 100 mm A minimum of 900 mm E F should be left in front of the water heater for access servicing and water heater removal Installation Layout Minimum Dimensions Model A B C D E F 610 430 935 685 300 100 1685 900 RT1000 1250 1000 300 100 2100 1000 RT2000 1550 1300 300 100 2700 1300 RT3000 1700 1450 300 100 3000 1450 RT4000 1850 1600 300 100 3300 1600 RT5000 20...

Page 38: ...stem An acceptable arrangement is shown in the diagram Refer also to Hot Water Delivery on page 21 and to Mains Water Supply on page 21 Disconnection unions are provided at the cold side and hot side water inlets and outlets on the water heater to allow for disconnection of the water heater Use a spanner on the back nut when tightening unions to prevent the pipe from rotating or twisting within th...

Page 39: ...n should be as short as possible and fall all the way from the water heater with no restrictions It should have no more than three right angle bends in it Use DN15 pipe The outlet of the drain line must be in such a position that flow out of the pipe can be easily seen refer to AS NZS 3500 4 but arranged so hot water discharge will not cause injury damage or nuisance The drain line must discharge ...

Page 40: ...with the Wiring Rules AS NZS 3000 and local authority requirements Heat Pump The heat pump water heater must be directly connected to a 415 V AC 50 Hz mains power supply The heat pump must be on its own circuit with an isolating switch installed at the switchboard A secondary isolating switch must be installed within reach of the water heater A conduit is required for the electrical cable to the h...

Page 41: ...or the electrical cable between the water heater and each pump The conduit is to be connected to the water heater with a 20 mm terminator Holes are provided on the electrical panel for cabling Tank Sensor Installation Connect one of the supplied temperature sensors to the connection terminal on the heat pump marked Tank Sensor Run out the sensor to the nearest storage tank For 610 series tanks a t...

Page 42: ...on terminal on the heat pump marked Building Flow Sensor Run out the sensor to the building flow pipe Fit a thermostat well not supplied in the pipe ensuring the end of the sensor is in the flow of water To prevent the sensor dislodging from the well secure the sensor to the insulation using a cable tie Alternatively clamp the sensor to the outside of the pipe using a pipe clamp prior to the insul...

Page 43: ...f a single auxiliary boost element is supplied by Rheem remove bridging wire at the terminals marked A7 and A9 behind the element controller cover and connect the terminal A7 and A9 to the voltage free terminal marked VF in the heat pump enclosure to control the operation of the boost element Electric Heating Unit Wiring Diagram ...

Page 44: ...l of the auxiliary boost elements will be via the Master heat pump using an intermediary relay arrangement Refer to Application Guide for more detail Auxiliary Boost Heater external to storage tank Depending on the installation an auxiliary heater and or boost pump may be supplied Refer to Application Guide for auxiliary boost options In the heat pump enclosure terminals marked SA N and GND provid...

Page 45: ...LAN cables Determine the 1st heat pump as Master Route the cables neatly to prevent damage and trip hazards Do not route across access panels Note Any of the two LAN connections will be acceptable Step 2 In 2nd heat pump enclosure Connect DI3 with DIC1 Connect DIC1 with the existing wire as shown in the picture Note Terminal plug can be removed for ease of making connections by pulling downwards a...

Page 46: ...temperature sensor for the Master heat pump must be connected otherwise the heat pumps will not operate due to fault There is no need to connect tank temperature sensors for Slave heat pumps 2 Building temperature sensor for the Master heat pump must be connected There is no need to connect building temperature sensors for Slave heat pumps 3 Ignore the values for tank and building temperature sens...

Page 47: ...eat pumps each heat pump will have its own BMS card Insert the BMS card into the connector for each heat pump taking care that the card is firmly placed as shown in red circle If the system is comprised of multiple heat pumps for Master Slave operation only master heat pump will have a BMS card and the slave heat pumps will be connected via LAN cables Follow the instruction on page 45 for Intercon...

Page 48: ...15KW HEAT PUMP INTERNAL WIRING DIAGRAM ...

Page 49: ...CONNECTIONS ELECTRICAL 49 35KW HEAT PUMP INTERNAL WIRING DIAGRAM ...

Page 50: ...CONNECTIONS ELECTRICAL 50 Controller and Display Information ...

Page 51: ... Press up or down to turn unit on or off Press enter to confirm Press down key to display type of circulating pump control Default AUTOMATIC ON TEMP Press esc to return to Menu Master B Set Point displays the tank maximum set point at which the compressor will be deactivated Cursor will be on the set temperature Pressing the up and down keys will adjust the setting in 0 1 increments Hold down for ...

Page 52: ...rature to be maintained during a specified date range Enabling the Special Event to Yes allows user to program in the desired date range set point and differential to be maintained during the Special Event period ii Enabling Tariff to Yes will open the Tariff Time Band pages which allows the user to program which hours are off peak shoulder and peak in 12 hour blocks as Weekday AM Weekday PM Weeke...

Page 53: ...Lo pressure switches closed or open circuit HP1 switch OK Flow switch On Off Flow switch in non potable chilled water circuit activated W2W heat pump Comp O Load On Off Compressor overload activated Remote On Off Remote control of heat pump activated Compressor 1 On Off Compressor status Rev valve On Off Reversing valve status NA Fan On Off Fan status A2W heat pump Circ Pump On Off Primary pump s ...

Page 54: ...22 a Change display do not use b Information software version information c Summer Winter not applicable to this product d Working Hours i Circ Pump reset counter ii Compressor 1 reset counter iii Outdoor Fan 1 reset counter e BMS configuration will time out after 5 minutes if no buttons pressed Address 1 Protocol CAREL Speed 19200 Change the protocol if Modbus BACnet is used as required ...

Page 55: ...arel NTC Carel NTC Thermoregulation 06 Enable unit On Off By digital input No Screen N A By supervisor No Screen N A By flow switch No Screen N A Dig input 6 is for Comp O Load 4 Screen N A I O Config 06b Storage tank temp Yes No Sensor type Carel NTC Carel NTC Building flow temp Yes No Sensor type Carel NTC Carel NTC Thermoregulation 07 HP LP Safety LP trip set 0 1 Bar 0 1 Bar HP trip set 27 5 Ba...

Page 56: ... forget the shower s and supply cock s and valve s in the system Open the isolation valves fully on the cold return and hot water branches to the storage tank s installed in a bank Open the cold water isolation valve on the cold water line to the storage tank s Air will be forced out of the taps Close each tap as water flows freely from it Check the pipe work for leaks Switch on the electrical sup...

Page 57: ...f the installation and commissioning of the water heating system leave this guide with the responsible officer Commissioning Procedure Multiple Heat Pump Master Slave Configuration Perform this procedure if the system is comprised of multiple heat pumps to be configured for Master Slave operation Open all of the hot water taps in the building don t forget the showers and supply cocks and valves in...

Page 58: ...enter the setup menu Use Up or Down buttons to set values Press and release Enter to move curser to next line Change the following values as shown below Menu Slave 1 Slave 2 Slave 3 Master Example Screen Image of Slave 1 Display address setting 17 18 19 16 I O board address 02 03 04 01 trm1 32 32 32 32 trm2 17 18 19 16 trm3 None Ok Yes Yes Yes Yes Press Enter to confirm settings The screen will ch...

Page 59: ... Storage tank temp Yes No Sensor type Carel NTC Carel NTC Building flow temp Yes No 5 Turn OFF the Slave heat pump If there is only 1 slave proceed directly to step 6 If there are 2 or 3 Slave heat pumps repeat step 3 to step 5 for Slave 2 and Slave 3 respectively using the values for respective Slave heat pumps 6 Turn ON Master heat pump and set the master address as stated in step 3 7 After comm...

Page 60: ... turn on immediately when it is first switched on if it is switched on within 20 minutes to 2 hours of it having been switched off at the isolating switch or the heat pump has just completed a heating cycle The water heater will wait until the conditions for start up are favourable in order to protect the compressor from damage This may take up to 20 minutes to 2 hours The auxiliary booster if ins...

Page 61: ...heat pumps for Master Slave operation perform this procedure for only master heat pump Only master heat pump will have a BMS card and the slave heat pumps will be connected via LAN cable Configure BMS settings from the display of the heat pump After commissioning the Master heat pump go to the Service menu Service password 0022 BMS config Refer to page 50 to see the chart for navigating Service me...

Page 62: ...276 7 R Probe_Value_12 13 Virtual Analoge Output 1 0 Default 0 3276 7 R VAOut_1 14 Virtual Analoge Output 2 0 Default 0 3276 7 R VAOut_2 15 Virtual Analoge Output 3 0 Default 0 3276 7 R VAOut_3 16 Virtual Analoge Output 4 0 Default 0 3276 7 R VAOut_4 17 Virtual Analoge Output 5 0 Default 0 3276 7 R VAOut_5 18 Virtual Analoge Output 6 0 Default 0 3276 7 R VAOut_6 19 Superheat valve Comp 1 0 Default...

Page 63: ...ek end 0 Default 0 2 R W trfw_2 24 type of tariff timeband 3 week end 0 Default 0 2 R W trfw_3 25 type of tariff timeband 4 week end 0 Default 0 2 R W trfw_4 26 type of tariff timeband 5 week end 0 Default 0 2 R W trfw_5 27 type of tariff timeband 6 week end 0 Default 0 2 R W trfw_6 28 type of tariff timeband 7 week end 0 Default 0 2 R W trfw_7 29 type of tariff timeband 8 week end 0 Default 0 2 R...

Page 64: ...t 0 999 R Comp_T_Hours_L_3 75 Compressor 3 Hour run counter high 0 Default 0 999 R Comp_T_Hours_H_3 76 Compressor 4 Hour run counter low 0 Default 0 999 R Comp_T_Hours_L_4 77 Compressor 4 Hour run counter high 0 Default 0 999 R Comp_T_Hours_H_4 78 Pump Hour run counter low 0 Default 0 999 R Pump_T_Hours_L 79 Pump Hour run counter high 0 Default 0 999 R Pump_T_Hours_H 86 Outdoor Fan 1 Hour run coun...

Page 65: ...0 1 R Din_1 2 Digital Input 2 0 Default 0 1 R Din_2 3 Digital Input 3 0 Default 0 1 R Din_3 4 Digital Input 4 0 Default 0 1 R Din_4 5 Digital Input 5 0 Default 0 1 R Din_5 6 Digital Input 6 0 Default 0 1 R Din_6 7 Digital Input 7 0 Default 0 1 R Din_7 8 Digital Input 8 0 Default 0 1 R Din_8 9 Digital Input 9 0 Default 0 1 R Din_9 10 Digital Input 10 0 Default 0 1 R Din_10 11 Digital Input 11 0 Def...

Page 66: ...ce enable of compressor 1 1 Default 0 1 R W Comp1_En 36 remote maintenance enable of compressor 2 1 Default 0 1 R W Comp2_En 37 remote maintenance enable of compressor 3 1 Default 0 1 R W Comp3_En 38 remote maintenance enable of compressor 4 1 Default 0 1 R W Comp4_En 41 Actual status of compressor 1 0 Default 0 1 R Device_Status_Comp_1 42 Actual status of compressor 2 0 Default 0 1 R Device_Statu...

Page 67: ...probe on input 7 0 Alarms 0 1 R Al_probe_7 128 Alarm from probe on input 8 0 Alarms 0 1 R Al_probe_8 129 Alarm from probe on input 9 0 Alarms 0 1 R Al_probe_9 130 Alarm from probe on input 10 0 Alarms 0 1 R Al_probe_10 131 Alarm from probe on input 11 0 Alarms 0 1 R Al_probe_11 132 Alarm from probe on input 12 0 Alarms 0 1 R Al_probe_12 133 Alarm_comp1 0 Default 0 1 R Device_Alarm_comp1 134 Alarm_...

Page 68: ...e all hot water taps Operate the relief valve release lever on one of the storage tanks do not let the lever snap back or you will damage the valve seat Operating the lever will release the pressure in the water heater Close the isolation valves at the inlets and outlets of the water heater cold and hot side and place a bucket under each inlet side Undo the unions at the inlets and outlets of the ...

Page 69: ... pump starts then turns off soon after This could be caused by a Insufficient water flow rate through heat exchanger Check pipe sizing per chart check obstructions check lines and pump are bled check pump is operating Note Tanks and heat pumps are to be manifolded in Equa Flow It is important that the branches to each storage tank ONLY contain a gate or ball valve and union Fitting of loose jumper...

Page 70: ...rranty period will remain effective The replacement does not carry a new Rheem warranty 2 3 Where the water heater is installed outside the boundaries of a metropolitan area as defined by Rheem or further than 25 km from either a regional Rheem branch office or an Accredited Rheem Service Agent s office the cost of transport insurance and travelling between the nearest branch office or Rheem Accre...

Page 71: ...atutory provisions to the contrary this warranty excludes any and all claims for damage to furniture carpet walls foundations or any other consequential loss either directly or indirectly due to leakage from the water heater or due to leakage from fittings and or pipe work of metal plastic or other materials caused by water temperature workmanship or other modes of failure 3 WHAT IS COVERED BY THE...

Page 72: ...ater heater or if that s unavailable the date of manufacture and serial number from the rating label on the water heater b Rheem will arrange for the water heater to be tested and assessed on site c If Rheem determines that you have a valid warranty claim Rheem will repair or replace the water heater in accordance with this warranty 5 2 Any expenses incurred in the making of a claim under this war...

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