Heat Pump Water Heater Durabliltiy Testing - Phase II

Ten heat pump water heaters (HPWH) were placed in an environmentally controlled test facility and run through a durability test program of approximately 7300 duty cycles (actual cycles accumulated ranged from 6640 to 8324 for the ten units). Five of the units were upgraded integral types (HPWH mounted on storage tank, no pump) from the same manufacturer as those tested in our first durability program in 2001 (Baxter and Linkous, 2002). The other five were ''add-on'' type units (HPWH with circulation pump plumbed to a separate storage tank) from another manufacturer. This durability test was designed to represent approximately 7-10 years of normal operation to meet the hot water needs of a residence. The integral units operated without incident apart from two control board failures. Both of these were caused by inadvertent exposure to very hot and humid (>135 F dry bulb and >120 F dew point) conditions that occurred due to a test loop failure. It is not likely that any residential water heater would be installed where such conditions were expected so these failures are not considered a long-term reliability concern. Two of the integral HPWHs featured a condensate management system (CMS) option that effectively eliminated any need for an evaporator condensate drain, but imposed significant efficiency penalties when operating in high humidity ambient conditions. The add-on units experienced no operational failures (breakdowns with loss of hot water production) during the course of the testing. However, their control systems exhibited some performance degradation under the high temperature, high humidity test conditions--HPWHs would shut off with tank water temperatures 15-20 F lower than when operating under moderate ambient conditions. One unit developed a refrigerant leak during the test program and lost about 50% of its charge resulting in reduced efficiency. Efficiency measurements on all the integral units and four of the add-on units showed significantly higher efficiencies than conventional electric water heaters (EWH). DOE Simulated Use Tests conducted prior to starting the durability testing resulted in energy factors (EF) of about 2.3 for the integral design and 1.4 for the add-on design compared to the minimum value of 0.86 prescribed for EWHs. Based on the experience from this and the previous durability testing, there is no evidence that strongly suggests that any of the HPWHs suffered significant performance degradation after undergoing over 7000 water heat cycles