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440-2506 (11/12/COM/WEB)

Continuing Education Course Approval Application Department of Consumer and Business Services Building Codes Division 1535 Edgewater NW, Salem, Oregon Mailing address: P.O. Box 14470, Salem, OR 97309-0404 503-373-1268 • Fax: 503-378-2322 Web: bcd.oregon.gov

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Northwest Energy Efficiency Alliance Alyssa Baker-Blanc

421 SW 6th Ave #600OR 97204Portland

[email protected] www.neea.org(503) 467-2150

2

Advanced Heat Pump Water Heater Training

7/6/20

Course Outline


Course Description

This course will train plumbers and HVAC contractors in the Northwest on heat pump water heater

(HPWH) technology with specific focus on space requirements, venting and ducting and

condensate management. The training will provide an overview of code related requirements that

pertain to these subjects.

Course Objectives and Learning Outcomes

The objective of this course is to comprehensively address areas of confusion that exist among

water heater installers through thorough explanation of best practices, code and real-world

creative solutions. Topics and the time spent on each are as follows:

• Introduction to Advanced Topics – 5 minutes

• Space requirements – 30 minutes

• Venting and ducting – 45 minutes • Condensate – 30 minutes

• Q&A – 10 minutes

By the end of this 2-hour training, attendees will feel confident in their ability to optimally install

HPWHs, satisfy their customers and answer questions pertaining to common issues with HPWHs.

Course Outline

1. Introduction: who are we?

2. Introduction to NEEA and the Hot Water Solutions program

3. Landscape of the market in the Northwest

a. Provide an overview of the market and why this matters to attendees’ business

4. Understand experience in the audience

a. Describe your business

i. Raise your hand to show what type of company you represent

b. Experience selling HPWHs

i. Raise hand to show experience with HPWH

c. Goal: assist the attendees in reaching a deeper technical understanding of HPWHs

so as to be able to have expertise needed for a variety of installation elements as

well as when discussing HPWH’s with homeowners

5. Introduction: goals for this training

a. Introduce learning outcomes as a road map for the course

i. This training is designed to meet the following outcomes. When the training

is complete, installers should be able to demonstrate their ability to

overcome HPWH installation barriers related to small spaces, understand

best practices for condensate management, size a HPWH to meet a

customer’s needs and demonstrate proficiency with operational modes and

error codes.

b. Learning Outcomes:

i. Overcome HPWH installation barriers related to small spaces

ii. Establish best practices for condensate management

iii. Size a HPWH to meet customer needs

iv. Build proficiency with operational modes and error codes

6. HPWH space requirements and solutions

a. Space: basic requirements

i. Review installs in confined spaces and discuss make up air requirements

1. 700 cubic feet of space

2. Garages and basements ideal

3. If basic space is not available compensate by adding louvered doors

or venting

ii. 50-gallon tank may need to be rotated for proper function of T&P Valve

iii. Tank is required to be insulated when tank is on a slab

iv. Drain pans are required for all HPWH installs unless tank is on a slab

v. Different manufacturers have different specific requirements

b. Space requirements of major brands

i. Review manufacturers requirements for spacing of the tank

1. Bradford White

a. Corner installs requirements

b. Alcove installs requirements

2. A. O. Smith

a. 6” of clearance considered best practice

b. 0” acceptable on right and left side if right side has at least 3”

c. No exhaust air into solid surfaces

3. Rheem

a. Zero clearance required if two rules are followed

i. Allow 6” from top to remove and clean filter

ii. Do not face discharge air directly into a wall

c. Space: when there’s not enough

i. Significant temperature drop (15 degrees) in the room where a HPWH is

installed can be an indicator of inadequate space.

d. Space: overcoming small spaces

i. Introduce concept of net free area (NFA)

1. Calculated space between metal components of the louver

2. Usually printed on the louver

3. If not present on louver follow formulas for calculation

ii. Louvered doors are one option

iii. Venting is the second, with some requirements

1. Inside to inside venting (Best option)

2. Inside to outside venting

3. Outside to outside venting (Worst option)

e. Space: ducting a HPWH – maximum duct runs

i. Process for total equivalent length (TEL) calculations

1. Follow manufacturer guidelines (see chart)

ii. Code requirements for well caps and termination hoods

1. Size and screening requirements are based on air flow

iii. Code requirements for intakes from attics and exhausts into attics

1. Screened if in the attic

2. No dampers

3. Minimum height above insulation level

f. Accessories: example

i. Comparison between 8-inch flex and 6-inch rigid ducting

g. Clogged condensate alarm

1. If evaporator drain main becomes clogged, compressor will shut off

2. HPWH will communicate the issue through alarm, light or error code

h. Venting: duct condensation

i. Vapor barrier requirements on duct installation carrying cool air

1. Flex duct should cover all exposed metal on exhaust duct to prevent

condensation on exposed metal parts

i. Venting attaching the duct work

i. Proper technique of attaching duct work with tensioning tools and ties

1. Can’t be hand tightened, tensioning tool is required

2. Ties should be secured and tensioned with tool

j. Victor, Montana case study

i. A case study of an HPWH install in Victor, Montana with limited space

1. Basement layout over-view with square footage of rooms

2. Accessories and considerations

a. 3 feet of flex ducting with 90-degree bend

b. 8-inch to 6-inch reducer

c. Within duct limits

d. 6-inch intake grille

3. Overview of intake room

a. 6” hole for intake duct

b. Installed intake grille

k. Summary of space requirements & solutions

i. 6-inch clearance on top of HPWH needed for filter cleaning

ii. No clearance from wall required

iii. 700 cubic feet of space required for efficient functionality

iv. Louvers and venting can be used to overcome space requirements

v. Keep venting simple (inside to inside is best)

1. Use tension ties

2. Cover all exposed metal parts on exhaust ducting

3. Do the math

vi. Don’t exhaust air directly against solid surfaces

7. Condensate Management

a. Condensate production

i. Condensate is produced when water vapor in the air condenses on the cold

evaporator coil while the compressor is running

ii. Condensate is not produced in electric mode

iii. Condensate is not produced when incoming air temperature is below a

certain threshold:

1. A. O. Smith - 46 F⁰

2. BW - 36 F⁰

3. RHEEM - 36 F⁰

b. Condensate: cleanout

i. Install a “T” connector to allow for easy condensate line cleanout (a code

requirement)

c. Condensate draining options

i. List of code allowable places for condensate drainage

1. Floor drains

2. Outside

3. Laundry tubs

4. Washing machine vent

ii. Tank must be level for drain pan to drain properly

d. Condensate quantity + pumps

i. Amount of condensate produced depends on the amount of moisture in the

air

ii. Average production of about 2 quarts per day

iii. An existing AC condensate pump can handle extra load

iv. A 2-gallon per minute pump is sufficient

v. If installed in basement, double the available lift

e. Wiring condensate pump to HPWH

i. Some HPWHs allow for the wiring of a condensate pump to the HPWH

ii. If the pump fails, the controls will automatically disable the heat pump and

run as an electric water heater to prevent condensate overflow

f. Condensate Ph

i. Unlike condensing gas water heaters, condensate from HPWHs is non-acidic

ii. Neutralizers are not necessary

g. Condensate codes and practices

i. Drain sizing

1. IMC 307.2.2 tells us that an A/C condensate drain inside diameter

should not be smaller than 3/4″ and should not be smaller than the

drain pan outlet diameter

2. 3/4″ is sufficient for up to 20 tons according to the IMC unless the

drain outlet size is larger than 3/4″

ii. Drain pitch

1. The IMC dictates a 1% minimum pitch of the drain which is equal to

1/8″ fall for every 12″ (foot) of horizontal run

2. In practice, it is safer to use 1/4″ of fall per foot to ensure proper

drainage and provide some wiggle room for error

iii. Support

1. Drains can be made out of many materials, but PVC is by far the most

common

2. When a drain line is PVC, the IMC dictates that it should be supported

every 4′ when horizontal (while maintaining proper pitch) and every

10′ vertically

iv. Cleanout

1. IMC 307.2.5 states that the condensate assembly must be installed in

such a way that the drain line can be “cleared of blockages and

maintained” without cutting the drain

2. Placing a “T” or a trap, not an elbow, at the start of the condensate

line is one way to achieve this

h. Where not to run condensate

i. Sidewalks or any walking surfaces

ii. Above/near foundation of the house

iii. On a roof

iv. Directly into a sewer line

v. Anywhere subject to freezing temperatures

i. Condensate management summary

i. Condensate is only produced when compressor is running

ii. Condensate is not acidic

iii. 2 gallons is an appropriate size for a condensate pump

iv. Follow applicable code for condensate line and drainage

v. Installing a “T” connector rather than elbow at the start of the condensate

line allows the line to be cleared of blockages and maintained

8. Sizing, modes & troubleshooting

a. Sizing: first hour rating

i. How to size according to code to First Hour Rating (FHR)

ii. FHR is largely defined by tank size

iii. Hybrid heater have higher ratings

iv. Test is done with a tank setpoint temperature

1. Chart listing FHR by brand

b. Sizing: maximize savings

i. The larger the tank, the more hot water can be drawn using the compressor

only

ii. The compressor draws between 300 to 500 watts depending on brand

iii. The heating element draws 4500-5000 watts depending on brand, 12-16

times more energy

c. Sizing: Usage considerations

i. Size of household will impact the size of the water heater

ii. The third shower dilemma – size HPWH tanks appropriately

1. Many households are likely to have three or more back-to-back

showers

2. Consider the following guidelines when bidding a HPWH:

Number of

consecutive 8-minute

showers

Appropriate tank size

1-2 50 gallon

3 65 gallon

4+ 80 gallon

iii. Based on the HPWH logic model: in hybrid mode, the electric elements do

not kick on until the third shower is underway, by which time the unit may

not be able to catch up with the hot water demand.

d. Uncontrolled recirculation pump

i. The Taco Smart Plug addresses the issue that uncontrolled recirculation

pumps present for HPWHs.

1. Solution to address the fact that uncontrolled recirculation pumps can

waste up to 3,000 kWh per year.

2. The Taco Smart plug requires no plumbing and no electrical work

3. The penalty of an uncontrolled recirculation pump is higher for HPWHs

as it will cause the HPWH to switch the electrical element on to meet

the extra demand.

e. Modes of operation

i. Hybrid Mode - Uses both the heat pump and electric elements

ii. Efficiency mode – Most efficient, only uses the heat pump

iii. Electric mode - Least efficient, only uses the elements

iv. Vacation mode - allows length of time where the water heater is off, but then

turns back on so homeowner can have hot water when they return

f. Access through the app

i. Some manufacturers offer HPWH control via an app

ii. Benefits can include:

1. Change setpoint temperature

2. Change operating mode

3. Leak detection notification

4. Shutoff valve control

5. Utility Time of Use (TOU) programming

6. Energy usage reports

7. Available hot water in the tank

8. Review service codes

g. Size modes and troubleshooting summary

i. Size to maximize savings – larger households will derive bigger savings from

larger tanks

ii. Four operational modes allow for different levels of efficiency and heat

recovery

iii. Display allows tech to review error codes and possible resolutions

9. Resources

a. List of Hot Water Solutions web pages

b. List of major manufacturer web pages

10. Q&A Session


Course Materials

• PowerPoint presentation; please see the following slide deck

Advanced Heat Pump Water Heater (HPWH) Training

Helping Your Customers Make the Best Water Heating Decisions

Who Are We?

Overcome HPWH installation barriers related to

small spaces

Goals for this Training

Establish best practices for condensate

management

Build proficiency with operational modes and

error codes

Size a HPWH to meet customer needs

HPWH Space Requirements & Solutions

Space: Basic Requirements

• ~700 cubic feet of space (roughly an 8x9x10 room.)

• Garages and open basements are ideal.

• Don’t have 700 cubic feet? Compensate by adding louvered doors or venting.

• Venting is usually not needed. If it is, it can be done in a manner that does not compromise the building envelope.

8’

9’

10’

Example: 8x9x10=720 cubic ft.

It is important to check the clearance requirements for the specific Brand of HPWH you are installing as each brand has its own unique set of specific measurements

Clearance: Requirements are based on Brand

Clearance: Requirements for Bradford White - Corner

50-gallon tank 65 and 80-gallon tanks

Note: 8 inches of clearance on top of the unit is still required for filter maintenance.

Clearance: Requirements for Bradford White - Alcove

Note:• 8-inch clearance on

top of unit is required for top water/electric and filter maintenance.

• Rotating the 50-gallon model allows air to bounce to the front.

• Zero clearance left side and rear for 65 and 80-gallon models

• Use full louvered door in front or leave open.

50-gallon tank 65-gallon tank

Clearance: Minimum Requirements – A. O. Smith

• While a 6-inch clearance is considered best practice, zero clearance on the back and left side and 3 inches on the right side is allowed.

• 6 inches of clearance required on top of the unit for filter maintenance.

• Do not blow the exhaust air directly into a solid surface.

50-gallon models may need to be rotated clockwise slightly to provide clearance for the condensate drain elbow. This is not necessary for the 66 or 80-gallon models.

Minimum required Clearances

Rear Left Side Right Side Top

0” 0” 3” 6”

…as long as these two rules are followed:

1. Allow room to remove and clean filter (6 inches from top of the HPWH)

2. Do not face the discharge air directly into a wall (the air will get colder and colder)

Clearance: Rheem HPWHs Require Zero Clearance…

Space: When There’s Not Enough

If the temperature in the room drops more than 15 degrees Fahrenheit, it is an indication of inadequate space in the room.

Normal temperature drop is only 3-5 degrees.

Space: Overcoming Small Spaces

Finding air elsewhere

• Louvered doors.

• Outside to outside venting (avoid if at all possible.)

• Inside to outside venting (may cause negative pressure in tight homes.)

• Inside to inside venting (usually the best solution.)

Louvered Door Ducting Kit

Space: Ducting a HPWH - Maximum Duct Runs

Accessories: Example

8-inch flex and 6-inch rigid comparison

Max length

8” Flex duct 125

Length of duct 15

Termination 5

Two elbows 10

Balance 95

Max Length

6” Rigid duct 65

Length of duct 15

Termination 5

Two elbows 10

8”-6” reducer 15

Balance 20

Clogged Condensate

• If evaporator drain main becomes clogged, compressor will shut off.

• Alarm may sound, warning light will illuminate, and/or error code will display.

Pull flex duct over all exposed metal on exhaust duct to prevent condensation on exposed metal parts.

Venting: Duct Condensation

Tensioning Tool Tensioning Ties

Venting: Attaching the Duct Work

Tape can work, but tensioning ties pulled tight with a tensioner work better.

Case Study: Victor, Montana HPWH Install

Case Study: Basement Layout

Water heater closet 4X4

BathroomPlay room 15X20

Bathroom8-inch 3 foot duct on intake

Conditioned basement

Conditioned basement

Case Study: Accessories and Considerations

• 3 feet of flex ducting with 90-degree bend.

• 8-inch to 6-inch reducer.

• Within duct limits.

• 6-inch intake grille.

Case Study: View from the Intake Room

Cut 6-inch hole for intake duct from playroom

Installed intake grille

Space Requirements & Solutions Summary

• 6-inch clearance on top of HPWH needed for filter cleaning.

• No clearance from wall required.

• 700 cubic feet of space required for efficient functionality .

• Louvers and venting can be used to overcome space requirements.

• Keep venting simple (inside to inside is best.)

• Use tension ties.

• Cover all exposed metal parts on exhaust ducting.

• Do the math.

• Don’t exhaust air directly against solid surfaces.

HPWH Condensate Management

25

Condensate Production

Condensate is produced when water vapor in the air condenses on the cold evaporator coil while the compressor is running.

Condensate is not produced when incoming air temperature is below a certain threshold:• A. O. Smith - 46 F⁰• BW - 36 F⁰ • RHEEM - 36 F⁰

Condensate: Cleanout “T” the Condensate Line to Allow For Easy Clean Out (Code Requirement)

Condensate Drainage Options

Condensate drainage locations:

• Floor drains

• Outside

• Laundry tubs

• Washing machine vent

Tank must be level for drain pan to drain properly.

Condensate Quantity + Pumps

• Amount of condensate produced depends on the amount of moisture in the air.

• Average production of about 2 quarts per day.

• An existing AC condensate pump can handle extra load.

• A 2-gallon per minute pump is sufficient

• If installed in basement, double the available lift.

Wiring the Condensate Pump to the HPWH

• Some HPWHs allow for the wiring of a condensate pump to the HPWH.

• If the pump fails, the controls will automatically disable the heat pump and run as an electric water heater to prevent condensate overflow.

Condensate pH (Non-Acidic)

HPWH condensate is like condensate from an air conditioner.

Not like condensate from a condensing gas water heater.

Range of acidity for combustion produced condensate

Neutralizers

HPWH Condensate

Condensate Code and Practices

Drain Sizing• IMC 307.2.2 tells us that an A/C condensate drain inside diameter should not be

smaller than 3/4″ and should not be smaller than the drain pan outlet diameter. 3/4″ is sufficient for up to 20 tons according to the IMC unless the drain outlet size is larger than 3/4″.

Drain Pitch• The IMC dictates a 1% minimum pitch of the drain which is equal to 1/8″ fall for

every 12″ (foot) of horizontal run. In practice, it is safer to use 1/4″ of fall per foot to ensure proper drainage and provide some wiggle room for error.

Support• Drains can be made out of many materials, but PVC is by far the most common.

When a drain line is PVC, the IMC dictates that it should be supported every 4′ when horizontal (while maintaining proper pitch) and every 10′ vertically.

Cleanout• IMC 307.2.5 states that the condensate assembly must be installed in such a way

that the drain line can be “cleared of blockages and maintained” without cutting the drain. Placing a “T” or a trap, not an elbow, at the start of the condensate line is one way to achieve this.

Where Not to Run Condensate Drainage

• Sidewalks or any walking surfaces

• Above/near foundation of the house

• On a roof

• Directly into a sewer line

• Anywhere subject to freezing temperatures

Condensate Management Summary

• Condensate is only produced when compressor is running.

• Condensate is not acidic.

• 2 gallons is an appropriate size for a condensate pump.

• Follow applicable code for condensate line and drainage

• Installing a “T” connector rather than elbow at the start of the condensate line allows the line to be cleared of blockages and maintained

HPWH Sizing, Modes & Troubleshooting

Sizing: First Hour Rating (FHR)

First Hour Rating is mostly defined by tank size - the larger the tank the higher the rating. There are slight

variations between manufacturers.

Hybrid water heaters have higher first hour rating than

standard tanks in certain operating modes.

The test is done with a tank at setpoint temperature -

hot water is drawn until the delivered water

temperature starts to decrease.

Heater type 40-Gallon 50-Gallon 65 or 66-Gallon 80-Gallon

Hybrid Heat Pump

60 65-67 75-79 84-89

Standard electric N/A 62 N/A 80

First Hour Rating (Based on Brand)

Sizing: Maximize Savings

• The larger the tank, the more hot-water can be drawn using the compressor only.

• The compressor draws between 300 to 500 watts depending on brand.

• The heating element draws 4500-5000 watts depending on brand, 12-16 times more energy.

Sizing: Usage Considerations

The third shower dilemma

Many households are likely to have three or more back-to-back showers.

Consider the following sizing guidelines when bidding a HPWH:

# of consecutive 10 minute showers

Appropriate tank size

1-2 50 gallon

3 65 gallon

4+ 80 gallon

The functionality of the heat pump in addition to electric elements means a HPWH offers the same, or better responsiveness than a standard electric tank.

Uncontrolled Recirculation Pumps

An uncontrolled recirculation pump results in high energy use because it keeps a HPWH using the electric element. The Taco Smart Plug is an easy and smart solution.

Modes Of Operation Overview – Control Panels

RheemA. O. Smith

Bradford White

Operational Modes: Hybrid Mode

In Hybrid Mode, the primary means of heating is the heat pump which moves heatinstead of creating heat. The heat pump (compressor) draws between 370-550watts of power and can heat the tank up to 140 degrees just like standard electric water heaters.

Should the heat pump need help, as a result of nearly draining the tank with long showers for example, one of the backup heating elements will turn on for faster reheating of the tank.

Hybrid Mode is often the default and recommended mode. It prioritizes the use of the compressor over the heating element and allows for faster recovery time than Efficiency Mode.

Operational Modes: Heat Pump only

Different brands have different names for Heat Pump Only mode, but they all have a mode that operates where the heat pump handles all of the water heating to maximize energy efficiency. Recovery in this mode will take longer but will a use fraction of the energy compared to if the water were to heat using the electric elements only.

If the ambient conditions leave the heat pump’s operating range ( an average of 45-120°F ambient air or average water temperature in the tank is 59°F or less) the controls will seamlessly disable the heat pump and turn on the backup electric elements to protect the heat pump while still producing hot water. Once the ambient conditions are back in the safe range the controls will resume standard Efficiency Mode operation.

Operational Modes: Electric only Mode

The Electric Mode operates the same as any standard electric tank and uses only

the heating elements without help of the heat pump. This is the least efficient

operating mode.

This mode is intended for temporary use only and by default the water heater will

automatically revert to Hybrid Mode operation after 48 hours in Electric Mode to

ensure you are getting high efficiency heat pump operation.

Operational Modes: Vacation Mode

Vacation Mode is used when you will be away from the home for an extended period and hot water is not needed. In this mode, the unit will drop the water temperature down to 60-65 ºF and will use the most efficient heating mode to conserve energy while the heater is sitting idle.

Different brands have different length of days for vacation mode. However, after the length of time has been reached, the water heater will resume normal operation. This allows the homeowner to save energy while they are away, and still come home to a full tank of hot water.

App Enablement

Some manufacturers provide an app for

enhanced customer experience. Benefits

can include*:

• Change setpoint temperature

• Change operating mode

• Leak detection notification

• Shutoff valve control

• Utility Time of Use (TOU) programming

• Energy usage reports

• Available hot water in the tank

• Review service codes

App availability and features vary by

manufacturer

Sizing, Modes & Troubleshooting Summary

• Size to maximize savings – larger households will derive bigger savings from larger tanks.

• Four operational modes allow for different levels of efficiency and heat recovery.

• Display allows tech to review error codes and possible resolutions. HP.WH

Resources

Utility HPWH Programs

https://hotwatersolutionsnw.org/partners

Download a utility rebate flyer for your state here.

Hot Water Solutions

http://hotwatersolutionsnw.org

A.O. Smith

https://university.hotwater.com/

Rheem

https://my.rheem.com/

Bradford White

https://www.bradfordwhite.com/for-the-pro/

Q&A - Thank You

[email protected]

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