Airtap Ati50 (Technical Manual)

Technical Manual
AirTap™ Hybrid Water Heater
ATI-T3.0.1
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TABLE OF CONTENTS
SPECIFICATION
Specifications 4-8
Controls & Operating Logic 9-12
Airflow: Ducting & Fan Speed 13-15
OPERATING LOGIC
Maintenance 16-18
CONTROLS &
Alarms and Errors Codes 19-20
FAQs 21-24
Appendix 25-32
Contact
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX

SPECIFICATIONS
A. SPECIFICATION TABLE
SPECIFICATION
SPECIFICATIONS (Models ATI50, ATI66 and ATI80)
Power supply 220-240V AC Single Phase

Frequency 60Hz
Electric outlet rating 30A
Heat pump output (ambient temp 68F) 2.75kW
Primary electric heater output 4kW
OPERATING LOGIC
Back-up electric heater output 4kW

CONTROLS &
Maximum water temperature 135F

Maximum current 23A
COMPRESSOR
Make Panasonic
Model 5RS080FBA21
Type Hermetic Motor (Rotary)
Current rating 3.6A
DUCTING
Refrigerant R410A (17.6 oz)

Pressure HP:4.2MPa LP:0.2MPa
Suction tube ID 9.7mm
Discharge tube ID/OD 6.53/9.53mm
Tab. 1
B. POWER CONSUMPTION DATA FOR KEY COMPONENTS

MAINTENANCE
Component Input voltage (V) Input power (W) Current (A) Max power (W)
Compressor 220 790 3.6 1100
Fan Motor 220 78 0.35 90
PCB 220 2.5 0.011 3.5
Electric Heater (Primary/Back-up) 220 4000 18.1 4200
ERRORS CODES
Tab. 2
ALARMS &
C. MAIN WIRING PORT

The unit is to be hard-wired to a 240V, 30A outlet using a flexible conduit with a conduit connector. Locate the main
wiring port. There are three 10AWG wires within the main wiring port with soldered ends: L1, L2 and G (the G or
Ground wire is the yellow/green wire).
1. Remove the main wiring port access cover.

2. Feed the external electrical wires through the wire pass through by unfastening the out cable ring.
FAQs
3. Connect these wires to the external electrical wires using insulated butt splice connectors or wing nuts (not
included). Ensure that:
A. External wires have a 10AWG rating
B. Butt splice connectors or wing nuts have the correct rating to connect two 10AWG wires. If wing nuts are used:
i. Use #10 red wing nuts for copper to copper connections or #10 purple wing nuts for copper to aluminum
connections.
ii. Clip the soldered ends of the unit’s wire and strip the insulation sheath adequately to avail unsoldered wire
APPENDIX
ends.
4. Place the wires back in the unit, replace the access cover and fasten the outer cable ring around the exiting wires.

SPECIFICATIONS
C. MAIN WIRING PORT (CONT.)
SPECIFICATION
When the main port is wired and power supply turned on, the electronic control panel is activated. A second wiring
port is located next to the main wiring port and is labeled ‘Back up heater’. Under normal operation, only the main
wiring port must be wired and the Back-up heater wiring port must remain un-wired. The back-up heater is an
emergency heating source and must be wired only when a system failure is preventing the unit from operating
normally. This procedure must be authorized by AirGenerate and performed by a qualified technician. Failure to do so
will void the warranties on the product.
OPERATING LOGIC
CONTROLS &
D. CIRCUIT DIAGRAM / WIRING SCHEME
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
Fig. 1

SPECIFICATIONS
E. DIMENSIONS & WEIGHT
SPECIFICATION
D
OPERATING LOGIC
CONTROLS &
DUCTING
H
MAINTENANCE
ATI50 ATI66 ATI80
Height (H) 59½” 70½” 75½”
Diameter (D) 25½” 25½” 25½”
Weight (lbs) 195 243 254

ERRORS CODES
ALARMS &
Fig. 2
FAQs
APPENDIX

SPECIFICATIONS
F. EXPLODED VIEW
SPECIFICATION
Top View
OPERATING LOGIC
CONTROLS &
DUCTING
MAINTENANCE
Fig. 3
1 Lid 17 Control Panel
2 Heat Pump Cover 18 Electric Box
ERRORS CODES
ALARMS &
3 Condensate Overflow Drain 19 Compressor
4 Ventilation Fan 20 Evaporator
5 Host Chassis 21 Anode Port
6 Chassis Base 22 Front Panel
7 Primary Condensate Drain 23 Temp Limiting Circuit Breaker (ATI66 & ATI80)
8 Hot Water Outlet 24 Protective Cover
9 T&P Relief Valve 25 Primary Electric Element

FAQs
10 Tank Cover 26 Back-Up Electric Element Thermostat
11 Hand Grip 27 Back-Up Electric Element
12 Cold Water Inlet 28 Back-Up Heater Wiring Port
13 Drain Valve 29 Main Wiring Port
14 Supporting Frame 30 Temp Limiting Circuit Break (ATI50)
15 Filter Access Cover 31 Hand Grip

APPENDIX
16 Exhaust Outlet 32 Air Inlet (Double Vent Version Only)

SPECIFICATIONS
G. TANK CROSS-SECTIONAL VIEW
SPECIFICATION
OPERATING LOGIC
CONTROLS &
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
Fig. 4
1 Hot Water Outlet

2 Anode Rod
3 Cold Water Inlet
4 Drain
FAQs
5 Upper Water Temp Sensor (T1)

6 Primary Electric Heater
7 Lower Water Temp Sensor (T2)
8 Back-Up Electric Heater
9 Insulation
APPENDIX
10 Condenser Coils

CONTROLS AND OPERATING LOGIC
A. TEMPERATURE AND PRESSURE SENSORS
SPECIFICATION
The following sensors are inbuilt in the unit:
Temperature sensor type Terminology How to check?

1. Water temperature (upper) A0/T1 Press 'Up' arrow key
2. Water temperature (lower) A1/T2 Default display
3. Evaporator return line A2 Press 'Down' arrow key
OPERATING LOGIC
4. Compressor discharge line A3 Press 'Up' & 'Down' arrow keys together
CONTROLS &
5. Ambient temperature A4 NA
6. Pressure sensor A5 NA
Tab. 3
DUCTING
MAINTENANCE
1 A4—Ambient Temp Sensor
2 Anode Rod Port
3 A5—Low Pressure Sensor

4 A3—Compressor Discharged Temp Sensor
5 A1—(T2) Lower Temp Sensor
ERRORS CODES
6 A0—(T1) Upper Temp Sensor
ALARMS &
7 A5—High Pressure Sensor
8 A2—Evaporator Coil Temp Sensor
9 A8—Condensate Blockage Sensor (V2.01 onwards)
FAQs
Fig. 5
APPENDIX

B. PCBA / CONTROL PARAMETERS
SPECIFICATION
Code Function Range Factory setting

F11 Water set temperature 90-135 F 130
F12 Heat pump kick-in differential* 1-54 F 20
F13 Max ambient temp for heat pump operation 42-130 F 110
F14 Min ambient temp for heat pump operation 0-40 F 32
OPERATING LOGIC
F15 Heat pump re-start ambient temp differential** 1-20 F 9

CONTROLS &
F19 T1/T2 adjustment -9-9 F 0

F21 Compressor start delay 0-10 mins 3
F31 Defrost start A2 temp -20-77 F 28
F32 Defrost stop A2 temp 0-122 F 77
F33 Defrost start delay 1-999 mins 20
F34 Max defrost time 1-99 mins 5
F41 Fan speed control + 0/1/2 (Low/High/Auto) 1
F50 Pressure alarm*** 0/2 (Off/On) 2
F51 Auto recovery attempts from F50 alarm 0-10 times 3
DUCTING
F52 Auto recovery max time from F50 alarm 0-999 mins 60
F54 Primary heater overheating alarm**** 0/2 (Off/On) 2
F55 Auto recovery attempts from F54 alarm 0-10 times 3
F56 Auto recovery max time from F54 alarm 0-999 mins 60
F57 High compressor discharge temp alarm***** 0/1 (Off/On) 1
F58 Compressor discharge high temp limit 50-257 F 230
MAINTENANCE
F59 Compressor re-start temp differential 1-54 F 18

F60 Condensate drain blockade alarm****** + 0/1 (Off/On) 1
F61 Activate memory to retain settings Yes/No Yes
F69 Communication band 24/48 BPS 24
F80 Set password Off/Set value Off
F89 Heater Mode max operating time 12-999 hours 48
F98 Force defrost Null/ADF Null
ERRORS CODES
*Heat pump on if T2<=F11-F12; Electric heater on when T1<=F11-F12-10

ALARMS &
**HP will restart when A4>=F14+F15 and A4<=F13-F15

***Error code A5 will display
****Error code A6 will display
*****Error code A7 will display
******Error code A8 will display
+ Applicable to product Version 2.01 or later
Tab. 4
FAQs
APPENDIX
10

C. HOW CAN I ACCESS AND CHANGE THE CONTROL PARAMETERS?
SPECIFICATION
You may check or change the current value of a parameter by following these steps:
1. Keep the ‘Mode’ button pressed till F11 displays on the screen
2. Press ‘Up’ or ‘Down’ arrow key to select a parameter
3. Press ‘Timer’ button to check the current value of the selected parameter
OPERATING LOGIC
4. To retain current value of the selected parameter, press the ‘Timer’ button again to access other parameters
CONTROLS &
5. To change the current value of the selected parameter, press ‘Up’ or ‘Down’ arrow key to select a new value. Press
‘Timer’ button to assign the newly selected value and access other parameters.
6. Once the parameter values have been checked/changed, let the panel remain idle for a few seconds to revert to
the default (time) display.
D. SETTING TIME AND HEAT PUMP OPERATING PERIODS

Time can be set in 24-hour HH:MM format. To set the time, press the ‘Clock’ button. The hour (HH) parameter should
DUCTING
start flashing. Press ‘Up’ or ‘Down’ arrow key to assign the hour value. Press ‘Clock’ button again. The minutes (MM)
parameter should start flashing. Press ‘Up’ or ‘Down’ arrow key to assign the minute value. Press ‘Clock’ button again.
Heat Pump Timer Function and Operating Periods
The timer function is active in ECON MODE ONLY. You may set up to three time periods (P1, P2 and P3) for the heat
pump to operate. Each time period has a user assigned start time and stop time. The heat pump will be on during the
assigned time periods only. Heat pump will turn off when water set temperature is reached, even if the unit is within
MAINTENANCE
an assigned time period (water temperature controls override timer settings). To assign or change time periods:
Ensure that the clock is set to the right time

1. Press Timer button. The start time (Hours) for P1 will start flashing – use ARROW PADS to assign Hours for P1 start
time. Press Timer button again to move to Minutes for P1 start time (EXAMPLE: If you want P1 to start at 7:15 am,
select 07 using arrow pad keys. Press Timer button and select 15 using arrow pad keys).
ERRORS CODES
2. Press the Timer button to move to P1 end time and assign values as done in Step b.
ALARMS &
3. Press the Timer button to move to P2 (and P3) time settings – repeat Steps b and c.
IMPORTANT
To activate the heat pump in Econ mode, it is necessary that at least one time period is active.
Can I override the timer settings and let the heat pump run as needed (based on water temperature settings) in Econ
mode?
FAQs
To run the heat pump independently of the timer settings, set any time period (P1, P2 or P3) to start at 00:00 and stop
at 23:59. The heat pump will now be controlled only by the water temperature sensor and the heat pump can start or
stop any time during the day based on hot water demand and temperature control settings.
Do I need to assign values to all three time periods?
No, you can choose to assign values to as many time periods as you require and leave the others as ‘inactive’. Assigning
00:00 to both start and stop times for a time period will render the time period inactive.
APPENDIX
11

E. MODES AND OPERATING CRITERIA
SPECIFICATION
Users can choose to operate the unit in one of the following modes:
AUTO MODE (Default)
Operates heat pump AND primary electric heater
Heat pump ON if T2<=F11-F12
OPERATING LOGIC
Heat pump OFF when T2=F11

CONTROLS &
Electric heater ON if T1<=F11-F12-10

Electric heater OFF when T1=F11
ECON MODE
Operates heat pump ONLY
Heat pump will activate only during the set time periods (P1, P2 and P3), every day.
During each time period,
DUCTING
Heat pump ON if T2<=F11-F12

Heat pump OFF when T2=F11
NOTE: For the heat pump to start in Econ mode, BOTH timer and temperature control conditions must be fulfilled:
i. Timer setting: Current/display time is within range of any of the three assigned heat pump operating time periods P1,
P2 or P3.
MAINTENANCE
ii. Temperature settings: Water set temperature (F11) and heat pump kick-in differential (F12) values meet the heat
pump start condition as defined above.
HEATER MODE
Operates primary electric heater ONLY
Electric heater ON if T1<=F11-10 degree F
ERRORS CODES
ALARMS &
Electric heater OFF when T1=F11
Note: The unit is programmed to run for a limited time in the Heater mode to conserve energy. Heater mode
duration is controlled by parameter F89 (default value 48 hours) as defined in Section B.
FAQs
APPENDIX
12

AIRFLOW: DUCTING & FAN SPEED
A. DUCTING EXHAUST AIR
SPECIFICATION
Can I duct the exhaust air from the unit? What are the benefits of ducting the exhaust air?
The unit has an exhaust air outlet that can be connected to a 6-inch duct. The cool exhaust air, a free by-product of
heat pump operation, can be ducted to any part of the home. It can also be used to supplement home cooling, saving
you additional energy on home cooling costs during summer months. You may vent the exhaust air out of the home
during winter months.
Ducting is especially recommended if the install area is less than 1,000 cubic feet in volume or if the unit has low
OPERATING LOGIC
overhead clearance.
CONTROLS &
WARNING:
This unit intakes ambient air in proximity to the unit and exhausts air that is cooler than the ambient air. If the exhaust air is vented
out of the install area by ducting the exhaust outlet, ensure that there is adequate air supply to the unit to avoid negative pressure.
Negative pressure occurs when the unit exhausts more air out of the install area than air allowed into the install area. Extra caution
is advised if a wood stove or combustion heater is located in the install area. Ensure that the unit does not back-draft smoke from
the operation of a wood stove or combustion heater into the home.
DUCTING
Airflow
Airflow
MAINTENANCE
ERRORS CODES
ALARMS &
Fig. 6
B. FAN SETTINGS
Starting from version 2.01, the ATI hybrid water heaters are built with a dual speed fan. Users can control fan speed
and airflow by accessing parameter F41. The default setting is '1' (high speed). By changing F41 to '0', the airflow rate
FAQs
can be reduced by 20%. The lower fan setting will also reduce the noise level.
When should the lower fan setting be used?
If the unit is installed in an unconditioned space such as a garage or attic, high speed setting should be retained. Switch
to the lower speed setting if the unit is installed in a conditioned space. Lower speed setting is also recommended if
there is a negative pressure concern at the high speed setting.
APPENDIX
13

B. FAN SETTINGS (CONT.)
SPECIFICATION
High Speed Fan Low Speed Fan

Measurement Measurement
No. of Airflow Measurement Point
Duct Configuration [Ft] Airflow [CFM] Airflow [CFM]
Elbow [Ft]
5 2.5 216.00 169.00
OPERATING LOGIC
1 10 7.5 216.00 169.00

CONTROLS &
25 22.5 204.00 161.00

5 2.5 204.00 161.00
2 10 7.5 210.00 161.00
25 22.5 198.00 153.00
5 2.5 198.00 153.00
3 10 7.5 198.00 153.00
25 22.5 198.00 153.00
Tab. 5
DUCTING
*The airflow rates above apply to rigid ducting having a smooth inner surface. Airflow rates will be impacted by turns and length at a significantly higher rate if the
ducting is flexible and has a ridged surface. For duct lengths longer than 10 feet, rigid ducting is recommended.
C. DUCTING INTAKE AIR

The AirTap Hybrid water heater is also available in a double vent version. The DV series can be ducted for both exhaust
and intake air.
MAINTENANCE
Airflow Airflow
ERRORS CODES
ALARMS &
FAQs
APPENDIX
Fig. 7
14

D. DIMENSION, SPACE REQUIREMENT AND VENTILATION
SPECIFICATION
1’
OPERATING LOGIC
CONTROLS &
DUCTING
Fig. 8
Please check dimensions of the model you intend to install and ensure that the unit has a minimum of 1 feet of
clearance from the top. If the unit is ducted to vent the exhaust air, ensure that sufficient clearance is available.
MAINTENANCE
Ensure that air intake to the unit is not blocked or obstructed. It is recommended that the unit be strapped to a wall
for safety.
If the unit is installed in an enclosed room:
a. The room size must exceed 1,000 cubic feet OR
b. The room must have a louvered door or similar ventilation OR
c. The unit must be ducted to vent the exhaust air out of the enclosed area.
ERRORS CODES
ALARMS &
FAQs
APPENDIX
15

MAINTENANCE
WARNING: RISK OF ELECTRIC SHOCK
SPECIFICATION
MAKE SURE THE UNIT IS COMPLETELY SHUT OFF AND UNPLUGGED FROM POWER SOURCE.
A. T&P / RELIEF VALVE

OPERATING LOGIC
CONTROLS &
The relief valve is an important safety feature and must be checked at least once a year. You may lift the lever handle
to release water from the unit and ensure that the valve is operating normally.
CAUTION:
Since the relief valve may release hot water from the unit, the water must be released directly into a suitable drain.
The relief valve must not be removed, plugged or obstructed under any circumstance.
B. FILTER
DUCTING
The unit is equipped with air filters that must be checked periodically (preferably every six months) for dirt or debris
that may impede airflow. Please refer to the Exploded View on page 7. These filters are itemized as 15 and 16 (for dou-
ble vent version, filter itemized as 32 should also be checked). Filter 15 is removable and should be washed or rinsed
annually. This filter can be pulled out by unscrewing the filter slot screws on top of the unit.
C. ANODE ROD
MAINTENANCE
The unit comes pre-attached with a sacrificial anode rod to counter corrosive elements in the tank. Anode rods deplete
over time and it is recommended that the anode rod in the unit be checked every 5 years. If the anode rod is found to
be depleted, replace the anode rod. A DEPLETED ANODE ROD WILL RESULT IN TANK FAILURE. Please follow Fig. 14
instructions to access the anode rod.
D. SEDIMENT BUILD-UP
ERRORS CODES
ALARMS &
Sediment build-up is a common occurrence on all water heaters. Since sediment deposits in the tank of the unit can
affect performance and compromise safety, it is recommended that the tank is drained periodically. AirGenerate™
recommends draining a few quarts of water every month and draining the unit completely every year.
CAUTION:
Shut off the power to the unit before draining the unit, even if you are draining a few quarts of water only. To drain
the unit completely, shut off the cold water supply and open hot water faucet(s). Unit must be drained by opening
the drain valve located at the bottom of the unit.
FAQs
APPENDIX
16

MAINTENANCE
E. CONDENSATE DRAIN TUBE
SPECIFICATION
The unit is equipped with two condensate water drains – a primary drain and an overflow drain. A monthly check is
recommended to ensure that these drains are not blocked. Blockage at the primary condensate water will trigger an
alarm and shut the heat pump off.
IMPORTANT
If the primary condensate drain is clogged the unit will sound an alarm and display error code A8. The unit will also
OPERATING LOGIC
switch from Auto or Econ mode to Heater mode until the condensate block is cleared. The unit will run an auto check
CONTROLS &
every 48 hours (default – can be changed by accessing parameter F89 in the control panel) for condensate clearance.
If the condensate has cleared, the unit will revert to Auto mode. Else, the unit will continue to operate in Heater
mode.
F. EXTENDED SHUTDOWN
If you will not be using the unit for an extended period of time, shut off the power and water supply to the unit. It is
recommended that the unit and water piping be drained completely. Drainage is necessary if the unit is exposed to
DUCTING
freezing temperatures. Ensure that the controls are checked by qualified personnel and the unit is completely filled
with water before restarting the unit after an extended shutdown.
G. MAINTENANCE SCHEDULE
AirGenerate™ recommends the unit be inspected annually by qualified service personnel to check electrical wiring,
controls and heating elements.
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
17

MAINTENANCE
I. ACCESS TO CRITICAL PARTS
SPECIFICATION
Please follow the steps below to gain access to heat pump components (including filter), anode rod, temperature
limiting reset button and electric heating elements (primary and back-up).
OPERATING LOGIC
CONTROLS &
DUCTING
MAINTENANCE
Fig. 9
ERRORS CODES
ALARMS &
1. Slide the control panel upwards to expose control panel docking connector
2. Remove connector and slide out the control panel completely
3. Unfasten decorative panel screws (2 places)
4. Unfasten metal bracket screws (2 places)
5. Unfasten heat pump enclosure base screws (4 places)
6. Remove the external electrical wires by following these steps:
FAQs
A. Remove the main wiring port access cover

B. Separate the external wires from the unit’s internal wires by removing wing nuts/butt splice
connectors
C. Unfasten outer cable ring and pull out the external electrical wires
7. Remove heat pump enclosure
If an exhaust air vent is attached to the unit, ensure that the vent is temporarily removed before heat pump
APPENDIX
enclosure is taken off.
18

ALARMS AND ERROR CODES
The unit will sound an alarm and display an error code in the event of a malfunction. If the unit is sound-
SPECIFICATION
ing an alarm, note the flashing error code and turn off the unit by pressing the ‘Off’ button. Contact
support at AirGenerate before attempting to turn on the unit. Error codes range from A0 to A8.
Codes A0 to A4 are specific to inbuilt sensors in the unit:

A0: Upper water temperature sensor (T1) malfunction. Since this sensor controls the primary electric heater, you will not be
able to run the unit in Auto or Heater modes. Switch to Econ mode or activate Back-up heater by following the ‘Activating Back-
OPERATING LOGIC
up Heater’ procedure. Obtain new sensor from AirGenerate and follow sensor replacement procedure.
CONTROLS &
A1: Lower water temperature sensor (T2) malfunction. Since this sensor controls the heat pump, you will not be able to run the
unit in Auto or Econ modes. Switch to Heater mode or activate Back-up heater by following the ‘Activating Back-up Heater’
procedure. Obtain new sensor from AirGenerate and follow sensor replacement procedure.
A2: Evaporator coil temperature sensor (A2) malfunction. Since this sensor affects heat pump performance, you will not be able
to run the unit in Auto or Econ modes. Switch to Heater mode or activate Back-up heater by following the ‘Activating Back-up
Heater’ procedure. Obtain new sensor from AirGenerate and follow sensor replacement procedure.
A3: Compressor discharge temperature sensor (A3) malfunction. Since this sensor affects heat pump performance, you will not
DUCTING
be able to run the unit in Auto or Econ modes. Switch to Heater mode or activate Back-up heater by following the ‘Activating
Back-up Heater’ procedure. Obtain new sensor from AirGenerate and follow sensor replacement procedure.
A4: Ambient temperature sensor (A4) malfunction. Since this sensor affects heat pump performance, you will not be able to run
the unit in Auto or Econ modes. Switch to Heater mode or activate Back-up heater by following the ‘Activating Back-up Heater’
procedure. Obtain new sensor from AirGenerate and follow sensor replacement procedure.
A5: Operating pressure outside normal range. Check the following:
MAINTENANCE
1. Ensure that the tank is completely full with water (especially if this is a new install and you are turning the unit on for the
first time). Check this by opening a hot water faucet – water must flow in a steady, uninterrupted manner.
2. If the ambient temperature is close to the low or high ambient temperature operating limit, switch to Heater mode tempo-
rarily. Revert to Auto or Econ mode when ambient temperature has normalized.
3. If the unit is ducted, remove the duct and operate the unit.
4. If the alarm is still not resolved, follow these steps and report findings to AirGenerate support.
ERRORS CODES
a. Deactivate alarm & let the unit run in Econ mode (to de-activate A5 alarm, set parameter F50 to zero)
ALARMS &
b. Check amperage (place a clamp meter around one of the live/hot wires)
c. Check exhaust temperature
d. Check evaporator coil temperature (A2) by pressing the ‘Down’ arrow button
e. Check compressor discharge temperature (A3) by pressing ‘Up’ and ‘Down’ arrow keys together.
IMPORTANT: Do not run the unit for more than 15 minutes in Econ mode. After taking these readings, switch to Heat-
er mode again. Re-activate alarm A5 by setting parameter F50 to 1.
f. If AirGenerate support recommends a refrigerant recharge, follow ‘Refrigerant Recharge’ procedure.
AirGenerate support may also request that additional troubleshooting measures or temperature readings be taken.
FAQs
A6: Primary electric element over-heating. Switch to Econ mode or activate back-up heater temporarily. Obtain new sensor (T1)
and new primary electric element from Airgenerate. Follow sensor and element replacement procedures.
APPENDIX
19

ALARMS AND ERROR CODES
A7: Compressor discharge temperature (measured by sensor A3) over limit (limit set by parameter F58 – default
SPECIFICATION
setting 230’F). Check the following:

1. If the water set temp (F11) is above 125’F, reduce it to 125’F temporarily.
2. If the ambient temperature is close to the high ambient temperature operating limit, switch to Heater mode
temporarily. Revert to Auto or Econ mode when ambient temperature has normalized.
3. If the alarm is still not resolved, follow these steps and report findings to AirGenerate support.
OPERATING LOGIC
a. Deactivate alarm & let the unit run in Econ mode (to de-activate A7 alarm, set parameter F57 to zero)
CONTROLS &
b. Check amperage (place a clamp meter around one of the live/hot wires)
c. Check exhaust temperature
d. Check evaporator coil temperature (A2) by pressing the ‘Down’ arrow button
e. Check compressor discharge temperature (A3) by pressing ‘Up’ and ‘Down’ arrow keys together.
IMPORTANT: Do not run the unit for more than 15 minutes in Econ mode. After taking these readings,
switch to Heater mode again. Re-activate alarm A7 by setting parameter F57 to 1.
f. If AirGenerate support recommends a refrigerant recharge, follow ‘Refrigerant Recharge’ procedure.
DUCTING
AirGenerate support may also request that additional troubleshooting measures or temperature readings be
taken.
A8: Condensate drain blockade alarm. Turn the unit off and check condensate drain/hose to ensure condensate wa-
ter is draining properly. Re-start unit.
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
20

FAQS
A. PERFORMANCE / GENERAL
SPECIFICATION
1. How efficient is the unit? How does it compare to gas, electric or tankless water heaters?
The Energy Factor rating on the unit is 2.35 (in Auto or hybrid mode). Electric, gas and tankless water heaters have an
Energy Factor of less than 1.
2. What is the payback on the unit?
Payback is dependent on a number of factors such as hot water usage, operating environment (including ambient
OPERATING LOGIC
temperature), local electricity tariffs, availability of rebate or incentive programs, etc. This unit could save on average
CONTROLS &
$300 yearly compared to standard electric water heater. This does not factor additional savings if the cool exhaust air
is ducted to supplement home cooling during warmer months.
3. What is the hot water delivery rate?
The First Hour Rating on the 66 gallon unit is 75 gallons (in Auto or hybrid mode).
4. What is the ambient temperature operating range for the unit? Can I adjust the range?
The default setting for the ambient temperature operating range is 32 – 110’F. You can change the range by accessing
parameters F13 (maximum ambient temp for heat pump operation) and F14 (minimum ambient temp for heat pump
DUCTING
operation).
5. What is the heat loss rate or thermal efficiency of the unit?
The insulation rating on the unit is amongst the best in the industry. A unit starting with 130’F water will lose less than
10’F over a 24-hour period. In BTU terms, the heat loss for ATI 66 is approx. 3.4 Btu/hr-F
6. What are the recommended settings (mode, water set temperature and kick-in differential)? Should I switch the
MAINTENANCE
mode based on seasonal changes or if hot water demand is higher than usual?
Settings are determined by hot water consumption patterns. It is recommended that users start with lower water temp
setting (120-125’F) and higher kick-in differential (20’F). For households with high hot water demand, the water temp
setting maybe increased to 130’F and kick-in differential reduced to 10’F. Recommended mode is Auto (hybrid). If you
are running the unit in Econ mode (heat pump only) during summers and notice a drop in hot water delivery in winter,
switch the unit to Auto mode.
7. How many amperes does the unit draw in each mode?
ERRORS CODES
ALARMS &
Heat pump amperage varies with ambient and water temperatures. Indicative amperage for each mode is as follow:
1. Econ mode: 4-5
2. Auto mode: 22-23
3. Heater mode: 17-18
8. What is the exhaust air flow rate (CFM)? Can I lower the air flow rate?
The exhaust air flow is approx. 250 CFM. Starting with version 2.01, you can lower the airflow to approx. 200 CFM by
setting parameter F41 to 1.
FAQs
APPENDIX
21

FAQS
A. PERFORMANCE / GENERAL (CONT.)
SPECIFICATION
9. What are the benefits of ducting the exhaust air? Can I duct the exhaust air to any part of the home? Is there a
restriction on the duct length?
The cool exhaust air from the unit maybe ducted to supplement home cooling in warmer months. You may duct the
exhaust air to any part of the home. For more information, refer to Airflow: Ducting &Fan Speed section.
10. Can I duct intake air to the unit?
OPERATING LOGIC
ATI hybrid water heaters are also available in a Double Vent version (DV series). This version has a vent adapter for air
CONTROLS &
intake in addition to the vent adapter for exhaust air.

11. I am concerned that the exhaust air will offset home heating during winter. How can I manage this?
If the unit is installed in an unconditioned space such as a garage or attic, this is not a concern. If the unit is installed in
a conditioned space, you may duct the exhaust air outside or to an unconditioned area. You may operate the unit in
the lower fan speed setting to minimize home heating offset. . For more information, refer to Airflow: Ducting &Fan
Speed section.
12. How much noise does the unit produce when running?
DUCTING
The noise produced when running is comparable to a new domestic dishwasher.

13. Can the unit be transported or moved lying down/horizontally?
To avoid damage to the unit, do not transport the unit horizontally at any time. When moving the unit for installation,
please keep the unit as upright as possible.
14. Is it ok to use a re-circulating pump in conjunction with the unit?
MAINTENANCE
A recirculation pump maybe used with the water heater. The warranty will remain unaffected. The following directions
are strongly recommended when a recirculation pump is being used:
A. Water lines are adequately insulated to minimize heat loss
B. Use of recirculation pump should be optimized to prevent offset of energy gains from operating the ATI hybrid
water heater. Operation of the recirculation pump maybe optimized by setting a higher kick-in differential for
the recirculation pump and/or minimizing operating frequency of the recirculation pump by choosing fewer
ERRORS CODES
operating periods if the recirculation pump is timer-controlled.

ALARMS &
WARNING: The ATI hybrid water heater has internal thermostats to control its operations. Do not attempt to bypass
the water heater’s internal sensors by attaching an external device/thermostat. Such an action will void the warran-
ty on the unit.
15. Will using a water softener affect unit operation?
Using water softener is not expected to affect unit operation. Please note that extreme pH levels will void the lifetime
warranty on the tank.
FAQs
APPENDIX
22

FAQS
B. TROUBLESHOOTING
SPECIFICATION
1. I am running out of hot water. How can I increase hot water recovery?
Increase the set temperature, make sure it is in Auto Mode, and change the kick-in differential to a lower number.
2. How can I check if the heat pump is running?
When the heat pump is running, the HTG icon will be lighted on the display panel.
OPERATING LOGIC
3. How can I check if the electric element is running?
CONTROLS &
When the electric element is running, the HTR icon will be lighted on the display panel.
4. How can I check if the heat pump is operating normally?
A healthy heat pump that is working properly will be quiet. One of the main ways you can tell if your heat pump is
working well is to listen to it. You should be able to hear it when it turns on, when the fans start and stop working and
when air passes through the ductwork, but the pump itself should be relatively noiseless. There should be no groaning,
creaking, or popping sounds. The motors should not sound as though they are working too hard or straining to
complete a task.
DUCTING
5. If the heat pump is not operating normally, what steps can I take?
Record the following and send the data to AirGenerate Support
A. Set unit to Auto Mode
B. What is the set temperature:
C. What is the lower sensor temperature (temp is displayed on screen below set temp.):
MAINTENANCE
D. What is the upper sensor temperature (hold up arrow):
E. What is the evaporator sensor temperature (hold down arrow):
F. What is the compressor discharged temperature (hold up and down arrow):
G. How many amps is the unit drawing (use clamp meter):
Wait 15 minutes and repeat steps 1–7
ERRORS CODES
6. How can I re-charge refrigerant into the unit?
ALARMS &
See appendix A
7. How can I access the fan?
See appendix B
8. The control panel display does not seem to be working. How can I change the control panel?
See appendix C
9. How can I turn on the back-up heater?
FAQs
See appendix D
APPENDIX
23

FAQS
B. TROUBLESHOOTING (CONT.)
SPECIFICATION
12. How can I change the primary electric element?

See appendix E
13. How can I change a temperature sensor?
See appendix F
OPERATING LOGIC
14 What are the available parts?

CONTROLS &
See appendix G
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
24

APPENDIX A: REFRIGERANT
RE-CHARGE REFRIGERANT
SPECIFICATION
1. CAUTION: Recharge procedure must only be carried out by a certified HVAC technician
2. CAUTION: Procedure must be carried out in an open or vented space, with unobstructed air flow. Ensure there are
no flammable objects in the vicinity. Refrigerant must not be inhaled.
3. Remove AirTap case. (Section A: Access To Critical Parts, Fig. 1)
4. Locate refrigerant return line in the system. (Please refer to Fig. 2)
5. Install a Schrader valve, size 3/8”, to the return line. (Please refer to Fig. 3)
OPERATING LOGIC
6. Recover R410A refrigerant from unit. Vacuum the lines to ensure that the lines are refrigerant free and ensure
CONTROLS &
there is no leakage.
7. Charge the unit with 17.6 oz of R401A.
8. Use sniffer to detect leaks.
9. Seal the Schrader valve.
10. Put the unit cover back on.
A. ACCESS TO CRITICAL PARTS
DUCTING
MAINTENANCE
B. Separate the external wires from the unit’s internal wires by re-
moving wing nuts/butt splice connectors
ERRORS CODES
C. Unfasten outer cable ring and pull out the external electrical wires
ALARMS &
Fig. 1
If an exhaust air vent is attached to the unit, ensure that the vent is
temporarily removed before heat pump enclosure is taken off.
FAQs
APPENDIX
Fig. 2 Fig. 3
25

APPENDIX B: CONTROL PANEL
REPLACING PCB / CONTROL PANEL
SPECIFICATION
The AirTap water heater has an advance PCB to control it’s operations. Please follow the instruction to replace the PCB.
Safety Information
Please read this section carefully to prevent accidents or injuries. All the warning and safety procedures written in
OPERATING LOGIC
AirTap’s main installation guide applies here.

CONTROLS &
The following precautions are recommended to prevent electrical shocks:

• Disconnect power from AirTap and Electrical Water Heater before replacing the PCB.
DUCTING
Steps in Installation
Removing the control panel:
 Remove the control panel by sliding it upwards to expose the control panel docking connector
MAINTENANCE
ERRORS CODES
ALARMS &
 Disconnect the panel docking connector.

FAQs
APPENDIX
26

APPENDIX B: CONTROL PANEL
 Unfasten protective cover screws.
SPECIFICATION
OPERATING LOGIC
CONTROLS &
 Unfasten PCB screws.
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
 Replace defective PCB with new PCB .
 Screw all screws back , connect the panel docking connector, and slick the display panel back into its place.
FAQs
APPENDIX
27

APPENDIX C: FAN
ACCESSING THE FAN
SPECIFICATION
OPERATING LOGIC

CONTROLS &

B. Separate the external wires from the unit’s internal wires by re-
moving wing nuts/butt splice connectors
C. Unfasten outer cable ring and pull out the external electrical
DUCTING
wires
If an exhaust air vent is attached to the unit, ensure that the vent is
temporarily removed before heat pump enclosure is taken off.
MAINTENANCE
1. Unfasten marked screws

ERRORS CODES
ALARMS &
2. Tighten or replace screw

FAQs
APPENDIX
28

APPENDIX D: BACK-UP HEATER
CHANGING THE BACK-UP HEATER
SPECIFICATION
1. Remove the power source from the primary heater wiring port.
2. Remove plate cover and connect the power source to the back-up heater wiring port.
OPERATING LOGIC
CONTROLS &
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
29

APPENDIX E: ELEMENT
A. ACCESSING THE ELEMENT
SPECIFICATION
3. Unfasten decorative panel screw
4. Unfasten protective cover
OPERATING LOGIC
CONTROLS &
DUCTING
B. REMOVING DEFECTIVE ELEMENT

1. Cut the thermostat wire (ensure there is enough wire for reconnection)
2. Unfasten ground connector
MAINTENANCE
3. Unfasten L1
4. Unfasten L2
ERRORS CODES
ALARMS &
C. INSTALLING NEW ELEMENT

1. Link the new thermostat wire with the previous cut wire
2. Fasten ground connector
3. Fasten L1
4. Fasten L2
FAQs
APPENDIX
30

APPENDIX F: TEMPERATURE SENSOR
CHANGING TEMPERATURE SENSOR
SPECIFICATION
To change the temperature sensor, the motherboard will need to be replace. Please follow the circuit diagram and re-
place all connections in the wiring scheme.
OPERATING LOGIC
CONTROLS &
DUCTING
MAINTENANCE
ERRORS CODES
ALARMS &
FAQs
APPENDIX
31

APPENDIX F: PARTS
AVAILABLE PARTS
SPECIFICATION
Part Number
1. Fan 100434
2. T&P relief valve 100599
3. Drain valve 100891
OPERATING LOGIC
4. Filter 100673
CONTROLS &
5. Control panel display 100631

6. Mother board fuse 100880
7. Mother board 100890
8. 4-way reversing valve 100350
9. Thermal expansion valve 100016
10. Evaporator 100424
11. Anode rod 100379
DUCTING
12. High temp limit sensor (TCO) 100315

13. Primary electric element 100597
14. Back-up electric element 100556
15. Thermostat (Back-up element) 100752
16. Temperature sensor (A0/T1 & A1/T2) 100999
17. Temperature sensor (A2, A3, A4) 100164
MAINTENANCE
18. Pressure sensor (High) 100167

19. Pressure sensor (Low) 100177
20. Condensate blocking sensor 100603
21. Capacitor 100255
22. Compressor 100325
ERRORS CODES
ALARMS &
FAQs
APPENDIX
32

CONTACT
CUSTOMER SUPPORT
Please contact AirGenerate™ Support Department for any technical assistance or questions.
Register your unit at: www.airgenerate.com
AirGenerate™
8500 Commerce Park Dr. Suite 105

Houston, TX 77036
Phone: 1(713) 574-6729Fax: 1(281) 520-3987
Email: support@airgenerate.com, for support or to query about a new purchase.
www.airgenerate.com

Airtap Ati50 (Technical Manual)

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Technical Manual

AirTap™ Hybrid Water Heater

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SPECIFICATIONS (Models ATI50, ATI66 and ATI80)

Power supply 220-240V AC Single Phase

Back-up electric heater output 4kW

Maximum water temperature 135F

Refrigerant R410A (17.6 oz)

B. POWER CONSUMPTION DATA FOR KEY COMPONENTS

C. MAIN WIRING PORT

1. Remove the main wiring port access cover.

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ATI50 ATI66 ATI80

Height (H) 59½” 70½” 75½”

Diameter (D) 25½” 25½” 25½”

Weight (lbs) 195 243 254

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1 Lid 17 Control Panel

2 Heat Pump Cover 18 Electric Box

4 Ventilation Fan 20 Evaporator

5 Host Chassis 21 Anode Port

6 Chassis Base 22 Front Panel

8 Hot Water Outlet 24 Protective Cover

9 T&P Relief Valve 25 Primary Electric Element

10 Tank Cover 26 Back-Up Electric Element Thermostat

11 Hand Grip 27 Back-Up Electric Element

12 Cold Water Inlet 28 Back-Up Heater Wiring Port

13 Drain Valve 29 Main Wiring Port

14 Supporting Frame 30 Temp Limiting Circuit Break (ATI50)

15 Filter Access Cover 31 Hand Grip

16 Exhaust Outlet 32 Air Inlet (Double Vent Version Only)

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1 Hot Water Outlet

5 Upper Water Temp Sensor (T1)

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Temperature sensor type Terminology How to check?

2 Anode Rod Port

3 A5—Low Pressure Sensor

5 A1—(T2) Lower Temp Sensor

8 A2—Evaporator Coil Temp Sensor

9 A8—Condensate Blockage Sensor (V2.01 onwards)

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Code Function Range Factory setting

F15 Heat pump re-start ambient temp differential** 1-20 F 9

F19 T1/T2 adjustment -9-9 F 0

F59 Compressor re-start temp differential 1-54 F 18

*Heat pump on if T2<=F11-F12; Electric heater on when T1<=F11-F12-10

**HP will restart when A4>=F14+F15 and A4<=F13-F15

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D. SETTING TIME AND HEAT PUMP OPERATING PERIODS

Ensure that the clock is set to the right time

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Heat pump OFF when T2=F11

Electric heater ON if T1<=F11-F12-10

Heat pump ON if T2<=F11-F12

Electric heater OFF when T1=F11

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