to the installation manual

Transcription

Geothermal
Installation
Geothermal Installation
Manual
Manual
Water To Water
Water To Water
January 2013
January
2012
Document
Revision 1
Document Revision 1
January 2013
Rev. 1
ii
Spectrum Manufacturing LLC
Water to Water Heat Pump
Table of Contents
Table of Contents
iii
Getting Started with the Unit
1
Safety Considerations
3
Electrical
5
January 2013
Rev. 1
iii
Table Of Contents
Condensate Drain Setup
16
Duct Work
17
System Piping
21
Importance of Water Quality
26
Desuperheater Installation
28
Smart Relay Features and Functions
30
January 2013
Rev. 1
iv
Table Of Contents
Safety Guidelines and Functions
34
Maintenance Requirements
38
Troubleshooting Tips
39
Unit Components
44
January 2013
Rev. 1
v
Table Of Contents
Unit Checkout Sheet
50
Strip Heat
51
Heating and Cooling Refrigeration
56
January 2013
Rev. 1
vi
Getting Started with the Unit
Initial Inspection
Moving and Storage
January 2013
Rev. 1
1
Getting Started With The Unit
Model Configuration Nomenclature
Tag
Type
Tag
Capacity
Tag
WA
Water to Air
024
2 Ton
U
Up-flow
WW
Water to Water
036
3 Ton
D
Down-flow
HFC
Hydronic Fan Coil
048
4 Ton
H
Horizontal
DX Fan Coil
060
5 Ton
S
Split
072
6 Ton
D
Domestic HWG
Tag
Voltage
Tag
DXFC
Tag
Return Air
Configuration
Desuperheater
L
Left
1
Single Phase
1
Yes
R
Right
3
Three Phase
0
No
Tag
Heat Exchanger
Tag
Backup Heat Element
Tag
Warranty
C
Copper
0
None
10
10 Year
N
CuproNickel
1
5 KW
5
5 Year
CD
Copper Double Wall
2
10 KW
ND
CuproNickel Double
Wall
3
15 KW
4
20 KW
January 2013
Rev. 1
2
Pre-Installation




Location



January 2013
Rev. 1
3
Equipment Installation
January 2013
Rev. 1
4
Electrical
Loop Pumping Flow Centers
Electrical
DHW
Model
Voltage
Compressor
External Loop Pump
Pump
FLA
WW-024
WW-036
WW-048
WW-060
WW-072
240/1
Ø
240/1
Ø
240/1
Ø
240/1
Ø
240/1
Ø
RLA
LRA
11.7
58.3
15.3
Total Unit
FLA
Min Circuit
Ampacity Max Fuse
(MCA)
Min
AWG
QTY
FLA
Total
0.4
2
1.8
3.6
15.7
19.6
25
12
83
0.4
2
1.8
3.6
19.3
24.1
35
10
21.2
99
0.4
3
1.8
5.4
27
33.8
45
10
27.1
118
0.4
3
1.8
5.4
32.9
41.1
50
8
29.7
150
0.4
4
1.8
7.2
37.3
46.6
60
8
Water to Water Electrical Data
January 2013
Rev. 1
5
Electrical
Model
HFC-024
HFC-036
HFC-048
HFC-060
HFC-072
Voltage
240/1
Ø
240/1
Ø
240/1
Ø
240/1
Ø
240/1
Ø
Fan Blower
Total Unit FLA
Min. Circuit
Ampacity
(MCA)
Min. Breaker
Size
Min
AWG
FLA
HP
2.3
1/3
4.3
5.4
10
14
2.5
1/3
4.5
5.6
10
14
4.3
1/2
6.3
7.9
10
14
5.5
3/4
7.5
9.4
10
14
6.1
1
8.1
10.1
10
14
Hydronic Fan Coil Electrical Data
January 2013
Rev. 1
6
Electrical
Legend
Model
WW
Water to Water
HFCH
Hydronic Fan Coil Horizontal
HFCV
Hydronic Fan Coil Vertical
Weight (lbs.)
Shipping Weight
Shipping Dimensions
Refrigerant Charge
WW 024
WW 036
WW048
WW 060
WW 072
4 Lbs 6 Oz
HFCH 024
HFCH 036
HFCH 048
HFCH 060
HFCH 072
HFCV 024
HFCV 036
HFCV 048
HFCV 060
HFCV 072
Unit Weights/Refrigerant Charge
January 2013
Rev. 1
7
Electrical
Wiring Diagram Ladder
January 2013
Rev. 1
8
Electrical
Wiring Diagram Pictorial
January 2013
Rev. 1
9
Electrical
Wiring Diagram Ladder Air Handler
January 2013
Rev. 1
10
Electrical
Wiring Diagram Pictorial Air Handler
January 2013
Rev. 1
11
Electrical
SelecTech Motor Connections
January 2013
Rev. 1
12
Electrical
Control Connections
Wall Stat Connections
Function
24V
24 Volt
G
Fan Circulate Speed
Y1
Fan Med-High Speed
Y2
O
Fan High Speed
Reversing Valve (default is energized in Cooling)
AUX
Auxiliary Heat
Com
Common
L
Fault Light
Wall Thermostat Connections
Aqua Stat Connections
Function
24V
24 Volt
Y1
Compressor Operation
Y2
C
Compressor Second Stage
Common
NC
Normally Closed-Energized in Heating
NO
Normally Open- Energized in Cooling
Aqua Stat Connections
Note: The Normally Open And Normally Closed terminals are to be used with a Heating and Cooling Aqua Stats or
Controller, to avoid Overheating or Freezing the Tank.
January 2013
Rev. 1
13
Electrical
Air Handler Connections 240 Volt
Function
Fan Breaker
Line Voltage From Building Panel
Motor
Fan Blower Motor
Opt. Load Pump
Optional Pump Output For Pumping Water
To the Air Handler
GND
Ground
Air Handler Connections From
24Volt
Pan
Function
Condensate Pan Level Switch
Aux
Auxiliary Heat
EMH
Fan 1
Emergency Heat
Fan Speed Low
Fan 2
Fan Speed Med/High (or where the installer
prefers)
Fan 3
Fan Speed High (or where the installer prefers
COM
Common
GND
Ground
Air Handler Connections
January 2013
Rev. 1
14
Electrical
January 2013
Rev. 1
15
Condensate Drain Setup
January 2013
Rev. 1
16
Duct Work
Design Requirements



Flex Duct
Building Cavities and Ducts
Static Losses
January 2013
Rev. 1
17
Duct Work
Maximum Velocities
Location
Supply
Main Ducts
900 FPM
Branch Ducts
600 FPM
Supply Outlet Face Velocity
700 FPM
Return Grill Face Velocity
500 FPM
Filter Grill Face Velocity
300 FPM
Maximum Air Velocities
Duct Connections
Zonal Pressure Relief
January 2013
Rev. 1
18
Duct Work
Duct Installation
Insulation
Air Tightness
January 2013
Rev. 1
19
Duct Work
System Air Flow
January 2013
Rev. 1
20
System Piping
Open Loop Systems (Ground Water)
January 2013
Rev. 1
21
System Piping
January 2013
Rev. 1
22
System Piping
Closed Loop Systems (Ground Loop)
January 2013
Rev. 1
23
System Piping
Pressurized Flow Center Installation



Non-Pressurized Flow Center Installation
January 2013
Rev. 1
24
System Piping
January 2013
Rev. 1
25
Antifreeze Overview
January 2013
Rev. 1
26
Antifreeze Characteristics




Antifreeze Charging



January 2013
Rev. 1
27
Desuperheater Package
January 2013
Rev. 1
28
Desuperheater Piping
January 2013
Rev. 1
29
Sequence of Operations
January 2013
Rev. 1
30
January 2013
Rev. 1
31
Unit Checkout Sheet
Short Cycle Protection
January 2013
Rev. 1
32
Component Delays
Manual (24 Volt Disconnect Switch Inside Panel)
Electronic Condensate Overflow Protection
January 2013
Rev. 1
33





High Pressure
Low Pressure
January 2013
Rev. 1
34
Flow Switch
Condensate Overflow
Fault Retry Mode


Soft Reset
January 2013
Rev. 1
35
Hard Lockout
System Checkout







Unit Startup
January 2013
Rev. 1
36
January 2013
Rev. 1
37
Maintenance Requirements
Annual Maintenance
Lockouts




January 2013
Rev. 1
38
Troubleshooting
Problem/Issue
Entire unit will not
run.
Possible Cause
Power supply is off
Actions and Corrections
Apply power and close disconnect.
Circuit breaker
reset circuit breaker.
Voltage supply low
If voltage is below minimum voltage specified on unit
data plate, contact local power company.
Thermostat/Aquastat Set the fan to On. The fan should run. Set thermostat
to Cool and lowest temperature setting, the unit
should run in the cooling mode. Set unit to Heat and
the highest temperature setting, the unit should run in
the heating mode. If neither the blower nor
compressor run in all three cases, the thermostat or
Aquastat could be wired incorrectly or faulty. To
ensure correct wiring or faulty Aquastat, verify 24
volts is available on the low voltage terminal strip in
the compressor section between "R" and "C", "Y" and
"C", and, if in cooling mode, "O" and "C". When
utilizing an air handler, and the blower does not
operate, verify 24 volts between terminals "G" and
"C". Replace the thermostat if defective.
January 2013
Rev. 1
39
Problem/Issue
Compressor does
not run.
Possible Cause
Wiring
Check for loose or broken wires at compressor,
capacitor, or contactor.
Safety controls
Check Smart Relay screen for faults.
Capacitor
Check capacitor and replace if defective.
Compressor
overload open
If the compressor has cooled down and the overload
will not reset, replace compressor.
Compressor motor
grounded
Internal winding grounded to the compressor shell.
Replace compressor. If compressor burnout has
occurred, install suction filter dryer.
Compressor
windings open
After compressor has cooled, check continuity of the
compressor windings. If the windings are open,
replace the compressor.
PLC reads High
Discharge pressure
Pressure Check Unit too high
Or
HARD LOCKOUT
HI PRESSURE
January 2013
Rev. 1
In Cooling mode, check:

Lack of or inadequate water flow

Entering water temperature too warm
 Scaled or plugged condenser
In Heating mode check:

Lack of or inadequate air flow

Blower is inoperative, clogged filter or
restrictions in ductwork
Refrigerant charge
The unit is overcharged with refrigerant. Reclaim
refrigerant, evacuate and recharge with factory
recommended charge.
High pressure
Check for defective or improperly calibrated high
pressure switch.
40
Problem/Issue
PLC reads:
Low Pressure
Check Unit, or
Possible Cause
Suction pressure too
low
HARD LOCKOUT
LOW PSI.
In Cooling mode, check:

Lack of or inadequate air flow

Entering water temperature too cold

Blower is inoperative, clogged filter or
restrictions in ductwork
In Heating mode check:

Lack of or inadequate water flow

Entering water temperature too cold

Scaled or plugged condenser
Check refrigerant charge.
Always charge to nameplate.
Unit Short Cycles
Insufficient cooling
January 2013
Rev. 1
Refrigerant charge
The unit is low on refrigerant. Check for refrigerant
leaks. Repair, evacuate and recharge with factory
recommended charge.
Low pressure switch
Check for defective low pressure switch.
TXV Bulb may be
defective/severed,
TXV valve stuck
shut, or moisture in
the refrigerant
system
TXV bulb and TXV control diaphragm can be replaced
after removing the charge, replacing the control
device and bulb, and properly recharging the unit to
nameplate value.
Unit oversized
Adjust deadband on aquastats
Wiring and controls
Loose connections in the wiring or a defective
compressor contactor.
Unit undersized
Recalculate heating and or cooling loads.
41
Problem/Issue
Insufficient heating
Possible Cause
Loss of conditioned
air by leaks
Check for leaks in duct work or look for entering
ambient air through doors or windows.
Airflow
Lack of adequate air flow or improper distribution of
air. Replace dirty filter.
Refrigerant charge
Low on refrigerant charge causing poor operation.
Compressor
Check for defective compressor. If discharge is too
low and suction pressure is too high, compressor is
not pumping properly. Replace compressor.
Reversing valve
Defective reversing valve creates a bypass of
refrigerant from discharge to suction side of
compressor. Replace reversing valve.
Operating pressures
Compare unit operating pressures to a pressure/
temperature chart for the refrigerant used.
TXV
Check TXV for restriction or defect. Replace if
necessary.
Moisture,
noncondensables
The refrigerant system may be contaminated with
moisture or noncondensables. Reclaim refrigerant,
evacuate and recharge with factory recommended
charge.
NOTE: A liquid line dryer may be required.
Loss of conditioned
air by leaks
Check for leaks in duct work or entering ambient air
through doors or windows.
PLC Reads: HARD
LOCKOUT FLOW
SWITCH
Inadequate or no
water flow
Check for water flow. Check flow switch by
temporarily bypassing it. Make sure all air is purged
from lines. Make sure flow center is purged and
functional. Check for proper flow direction.
PLC Reads: HARD
LOCKOUT PAN
LEVEL
Pan level switch
Check condensate drain for blockage. Make sure
condensate drain is properly installed. Check Pan level
switch by temporarily bypassing it. Make sure unit is
on a level surface.
PLC Reads: HARD
LOCKOUT
CURRENT SENS
Current sensor
Refer to compressor does not run. Check current
sensor by temporarily bypassing it.
January 2013
Rev. 1
42
January 2013
Rev. 1
43
Unit Components
Compressor (Copeland)
Flow Switch
High Pressure Switch
Low Pressure Switch
Low Voltage Breaker
High Voltage Breakers
January 2013
Rev. 1
44
Unit Components
Master Contactor
Reversing Valve
Smart Relay
Terminals
Transformer
Remote Fan Coil Components
Pump Relay
January 2013
Rev. 1
45
Unit Components
High Voltage Breaker
Blower Motor (Selectech)
Electric Heater
Terminals
January 2013
Rev. 1
46
Unit Components
Unit Dimensions
January 2013
Rev. 1
47
Unit Components
January 2013
Rev. 1
48
Unit Components
January 2013
Rev. 1
49
Unit Checkout Sheet
Customer Data
Name:
Date:
Address:
Phone:
Make:
Model:
Serial #:
Refrigerant Charge (OZ):
Compressor RLA:
Compressor LRA:
Blower FLA/HP:
Maximum Fuse Size (A):
Maximum Circuit Ampacity (A):
Operating Conditions
EAT/LAT
EWT/LWT
January 2013
Rev. 1
Cooling Mode
/
Heating Mode
/
/
/
50
Strip Heat
Model
KS-05-1
KS-10-1
KS-15-1
KS-20-1
KW
4.8
9.6
14.4
19.2
Amps
20
40
60
80
Max Overcurrent
Protection
Single
Multi-Feed
Feed
Min.
CFM
SCCR
Min. Supply
Ampacity
300
10 KA
250V
MAX.
30
N/A
30 A
760
10KA
250V
MAX.
50
N/A
50 A
1140
10 KA
250V
MAX.
80
#1
30 A
#2
50 A
80 A
1520
10 KA
250V
MAX.
100
#1
30 A
#2
50 A
100 A
240 Volts Single Phase
Note: When using multi-feed, metal jumpers in the screw connection terminals must be removed
January 2013
Rev. 1
51
Strip Heat
January 2013
Rev. 1
52
Strip Heat
January 2013
Rev. 1
53
Strip Heat
January 2013
Rev. 1
54
Strip Heat
January 2013
Rev. 1
55
When the Compressor (1) is energized, it starts to pump refrigerant through the system. Because of the
compressor increasing the pressure of the refrigerant, it therefore increases the temperature and has
compressed it into a high pressure HOT vapor, (Superheated Gas) Then, in systems equipped with a
Desuperheater (2), (hot water generator) the high pressure vapor will go through and release some of its
superheat into the home's Potable Water. The hot vapor then goes to the Reversing valve (3). In the Heating
Cycle, the reversing valve will direct the hot vapor to a Water to Refrigerant Heat Exchanger (4) (Condenser),
where it will be condensed to a liquid. This Heat Exchanger is typically connected to an insulated storage tank
inside the home. As it travels through the Heat Exchanger, the hot vapor will release its stored heat into the
Water from the storage tank. This is considered condensing, (the action of changing a vapor or gas, to a
liquid). At the end point of the Water to Refrigerant Heat Exchanger (Condenser), the refrigerant is a high
pressure sub-cooled liquid. Sub-cooling is the cooling of liquid refrigerant below its condensing temperature.
The high pressure liquid then enters the Expansion Valve (5). This device reduces the pressure from the high
side to the low side in a refrigeration system. This is accomplished by metering the liquid refrigerant into the
evaporator coil. This rapid decrease in pressure lowers the temperature of the refrigerant considerably. In the
Heating Cycle of a Water to Water Heat Pump, the Evaporator (6) is also a water to refrigerant heat
exchanger. This Heat Exchanger is typically connected to a ground loop. The refrigerant at the start point of
the evaporator is in a low pressure, cold, vapor and liquid mixture. As it travels through the evaporator (water
to refrigerant heat exchanger) it begins to collect heat from the ground water that is also traveling through
the coil. As the refrigerant absorbs heat, it will start to vaporize (changing from a liquid to a gaseous state).
When it has left the evaporator, the refrigerant is a 100% saturated vapor. At this point, it will enter the
compressor to begin the cycle again.
January 2013
Rev. 1
56
When the Compressor (1) is energized, it starts to pump refrigerant through the system. Because of the
compressor increasing the pressure of the refrigerant, it therefore increases the temperature and has
compressed it into a high pressure HOT vapor, (Superheated Gas). Then, in systems equipped with a
Desuperheater (2), (hot water generator) the high pressure vapor will go through and release some of its
superheat into the home's Potable Water. The hot vapor then goes to the Reversing Valve (3). In the Cooling
Cycle, the reversing valve directs the hot vapor to the Water to Refrigerant Heat Exchanger (4) (Condenser)
that is connected to the ground water, where it will be condensed to a liquid. As it travels through the Heat
Exchanger, the hot vapor will release its stored heat into the Water from the ground. This is considered
condensing, (the action of changing a vapor or gas, to a liquid). At the end point of the Water To Refrigerant
Heat Exchanger (Condenser) the refrigerant is a high pressure sub-cooled liquid. Sub-cooling is the cooling of
liquid refrigerant below its condensing temperature. The high pressure liquid then enters the Expansion Valve
(5). This device reduces the pressure from the high side to the low side in a refrigeration system, by metering
the liquid refrigerant into the evaporator coil. This rapid decrease in pressure lowers the temperature of the
refrigerant considerably. In the Cooling Cycle of a Water to Water Heat Pump, the Evaporator (6) is also a
Water To Refrigerant Heat Exchanger. Because we have directed the HOT vapor to the Ground Water Heat
Exchanger for the condensing cycle, the storage tank in the home is now connected to the Evaporator Coil
(also a Water to Refrigerant Heat Exchanger). The refrigerant at the start point of the evaporator is in a low
pressure, cold, vapor and liquid mixture. As it travels through the evaporator (water to refrigerant heat
exchanger) it begins to collect heat from the water that has come from storage tank. As the refrigerant
absorbs heat it will start to vaporize (changing from a liquid to a gaseous state). When it has left the
evaporator, the refrigerant is a 100% saturated vapor. At this point it will enter the compressor to begin the
cycle again.
January 2013
Rev. 1
57
January 2013
Rev. 1
58

to the installation manual

Transcription

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