Climate Master HBH018A8C40CLS HBH Series Commercial Heat Pump Condenser User guide

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Climate Master HBH018A8C40CLS HBH Series Commercial Heat Pump Condenser User guide | Manualzz

Installation, Operation & Maintenance Manual - HBH-HBV Small

Preventive Maintenance

Water Coil Maintenance - (Direct ground water applications only) If the system is installed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with the heat exchanger material and copper water lines. Generally, the more water flowing through the unit, the less chance for scaling. Therefore, 1.5 gpm per ton

[1.6 l/m per kW] is recommended as a minimum flow.

Minimum flow rate for entering water temperatures below 50°F [10°C] is 2.0 gpm per ton [2.2 l/m per kW].

Filters Filters must be clean to obtain maximum performance. Filters should be inspected every month under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.

Condensate Drain -

Compressor -

In areas where airborne bacteria may produce a “slimy” substance in the drain pan, it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem. The condensate pan may also need to be cleaned periodically to ensure indoor air quality. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect the drain twice a year to avoid the possibility of plugging and eventual overflow.

Conduct annual amperage checks to ensure that amp draw is no more than 10% greater than indicated on the serial plate data.

Water Coil Maintenance (All other water loop applications) Generally water coil maintenance is not needed for closed loop systems. However, if the piping is known to have high dirt or debris content, it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system. Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with both the heat exchanger material and copper water lines. Generally, the more water flowing through the unit, the less chance for scaling. However, flow rates over 3 gpm per ton (3.9 l/m per kW) can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Fan Motors All units have lubricated fan motors. Fan motors should never be lubricated unless obvious, dry operation is suspected. Periodic maintenance oiling is not recommended, as it will result in dirt accumulating in the excess oil and cause eventual motor failure. Conduct annual dry operation check and amperage check to ensure amp draw is no more than 10% greater than indicated on serial plate data.

Air Coil The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean.

Care must be taken not to damage the aluminum fins while cleaning. CAUTION: Fin edges are sharp.

Cabinet Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. Generally, vertical cabinets are set up from the floor a few inches [7 - 8 cm] to prevent water from entering the cabinet. The cabinet can be cleaned using a mild detergent.

Refrigerant System - To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating charts for pressures and temperatures. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.

Washable, high efficiency, electrostatic filters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air flow, resulting in poor performance. It is especially important to provide consistent washing of these filters (in the opposite direction of the normal air flow) once per month using a high pressure wash similar to those found at self-serve car washes.

50

Installation, Operation & Maintenance Manual - HBH-HBV Small

Fault

Main power problems

HP Fault

Code 2

High Pressure

LP/LOC Fault

Code 3

Low Pressure / Loss of Charge

LT1 Fault

Code 4

Water coil low temperature limit

LT2 Fault

Code 5

Air coil low temperature limit

Condensate Fault

Code 6

Over/Under

Voltage Code 7

(Auto resetting)

Unit Performance Sentinel

Code 8

Swapped Thermistor

Code 9

No Fault Code Shown

Unit Short Cycles

Only Fan Runs

Only Compressor Runs

Unit Doesn’t Operate in Cooling

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Htg Clg Possible Cause

X

X

X

X

X

X

X

X

X

X

X

X

X

X x

X Green Status LED Off

X Reduced or no water flow in cooling

X Water Temperature out of range in cooling

Reduced or no air flow in heating

Air temperature out of range in heating

X Overcharged with refrigerant

X Bad HP Switch

X Insufficient charge

Compressor pump down at start-up

Reduced or no water flow in heating

Inadequate antifreeze level

Improper temperature limit setting (30°F vs

10°F [-1°C vs -2°C])

Water Temperature out of range

X Bad thermistor

X Reduced or no air flow in cooling

X Air Temperature out of range

X

Improper temperature limit setting (30°F vs

10°F [-1°C vs -12°C])

X Bad thermistor

X Blocked drain

X Improper trap

X Poor drainage

X Moisture on sensor

X Plugged air filter

X Restricted Return Air Flow

X Under Voltage

Functional Troubleshooting

Solution

Check line voltage circuit breaker and disconnect.

Check for line voltage between L1 and L2 on the contactor.

Check for 24VAC between R and C on CXM/DXM'

Check primary/secondary voltage on transformer.

Check pump operation or valve operation/setting.

Check water flow adjust to proper flow rate.

Bring water temp within design parameters.

Check for dirty air filter and clean or replace.

Check fan motor operation and airflow restrictions.

Dirty Air Coil- construction dust etc.

Too high of external static. Check static vs blower table.

Bring return air temp within design parameters.

Check superheat/subcooling vs typical operating condition table.

Check switch continuity and operation. Replace.

Check for refrigerant leaks

Check charge and start-up water flow.

Check pump operation or water valve operation/setting.

Plugged strainer or filter. Clean or replace..

Check water flow adjust to proper flow rate.

Check antifreeze density with hydrometer.

Clip JW3 jumper for antifreeze (10°F [-12°C]) use.

Bring water temp within design parameters.

Check temp and impedance correlation per chart

Check for dirty air filter and clean or replace.

Check fan motor operation and airflow restrictions.

Too high of external static. Check static vs blower table.

Too much cold vent air? Bring entering air temp within design parameters.

Normal airside applications will require 30°F [-1°C] only.

Check temp and impedance correlation per chart.

Check for blockage and clean drain.

Check trap dimensions and location ahead of vent.

Check for piping slope away from unit.

Check slope of unit toward outlet.

Poor venting. Check vent location.

Check for moisture shorting to air coil.

Replace air filter.

Find and eliminate restriction. Increase return duct and/or grille size.

Check power supply and 24VAC voltage before and during operation.

Check power supply wire size.

Check compressor starting. Need hard start kit?

Check 24VAC and unit transformer tap for correct power supply voltage.

Check power supply voltage and 24VAC before and during operation.

Check 24VAC and unit transformer tap for correct power supply voltage.

Check for poor air flow or overcharged unit.

Check for poor water flow, or air flow.

X Over Voltage

X

Heating mode LT2>125°F [52°C]

Cooling Mode LT1>125°F [52°C] OR LT2<

40ºF [4ºC])

X LT1 and LT2 swapped

X No compressor operation

X Compressor overload

X Control board

X Dirty air filter

X Unit in "test mode"

X Unit selection

X Compressor overload

X Thermostat position

X Unit locked out

X Compressor Overload

X Thermostat wiring

X Thermostat wiring

X

Fan motor relay

X

X Fan motor

X Thermostat wiring

X Reversing valve

X Thermostat setup

X Thermostat wiring

X Thermostat wiring

Reverse position of thermistors

See "Only Fan Operates".

Check and replace if necessary.

Reset power and check operation.

Check and clean air filter.

Reset power or wait 20 minutes for auto exit.

Unit may be oversized for space. Check sizing for actual load of space.

Check and replace if necessary

Ensure thermostat set for heating or cooling operation.

Check for lockout codes. Reset power.

Check compressor overload. Replace if necessary.

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Check G wiring at heat pump. Jumper G and R for fan operation

Jumper G and R for fan operation. Check for Line voltage across BR contacts.

Check fan power enable relay operation (if present).

Check for line voltage at motor. Check capacitor.

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode

Set for cooling demand and check 24VAC on RV coil and at CXM/DXM board.

If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.

Check for ‘O’ RV setup not ‘B’.

Check O wiring at heat pump. Jumper O and R for RV coil ‘click’.

Put thermostat in cooling mode. Check 24 VAC on O (check between C and

O); check for 24 VAC on W (check between W and C). There should be voltage on O, but not on W. If voltage is present on W, thermostat may be bad or wired incorrectly.

51

Installation, Operation & Maintenance Manual - HBH-HBV Small

Performance Troubleshooting

Performance Troubleshooting Htg Clg Possible Cause

X X Dirty filter

X Reduced or no air flow in heating

Insufficient capacity/ Not cooling or heating

X Reduced or no air flow in cooling

X

X

X

X

X

X

X

X Leaky duct work

X Low refrigerant charge

X Restricted metering device

X Defective reversing valve

X Thermostat improperly located

X Unit undersized

X Scaling in water heat exchanger

X Inlet water too hot or too cold

X Reduced or no air flow in heating

High Head Pressure

X

X

X

X

X Reduced or no water flow in cooling

X Inlet water too hot

Air temperature out of range in heating

X Scaling in water heat exchanger

X Unit overcharged

X Non-condensables in system

X Restricted metering device.

X Reduced water flow in heating.

X Water temperature out of range.

Low Suction Pressure

X Reduced air flow in cooling.

Low Discharge Air Temperature in Heating

X

X

X

High humidity

X Air temperature out of range

X Insufficient charge

Too high of air flow

Poor performance

X Too high of air flow

X Unit oversized

Solution

Replace or clean.

Check for dirty air filter and clean or replace.

Check fan motor operation and airflow restrictions.

Too high of external static. Check static vs. blower table.

Check for dirty air filter and clean or replace.

Check fan motor operation and airflow restrictions.

Too high of external static. Check static vs. blower table.

Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present.

Check superheat and subcooling per chart.

Check superheat and subcooling per chart. Replace.

Perform RV touch test.

Check location and for air drafts behind stat.

Recheck loads & sizing. Check sensible clg. load and heat pump capacity.

Perform scaling check and clean if necessary.

Check load, loop sizing, loop backfill, ground moisture.

Check for dirty air filter and clean or replace.

Check fan motor operation and air flow restrictions.

Too high of external static. Check static vs. blower table.

Check pump operation or valve operation/setting.

Check water flow. Adjust to proper flow rate.

Check load, loop sizing, loop backfill, ground moisture.

Bring return air temperature within design parameters.

Perform scaling check and clean if necessary.

Check superheat and subcooling. Re-weigh in charge.

Vacuum system and re-weigh in charge.

Check superheat and subcooling per chart. Replace.

Check pump operation or water valve operation/setting.

Plugged strainer or filter. Clean or replace.

Check water flow. Adjust to proper flow rate.

Bring water temperature within design parameters.

Check for dirty air filter and clean or replace.

Check fan motor operation and air flow restrictions.

Too high of external static. Check static vs. blower table.

Too much cold vent air? Bring entering air temperature within design parameters.

Check for refrigerant leaks.

Check fan motor speed selection and air flow chart.

See ‘Insufficient Capacity’

Check fan motor speed selection and airflow chart.

Recheck loads & sizing. Check sensible clg load and heat pump capacity.

52

Installation, Operation & Maintenance Manual - HBH-HBV Small

Start-Up Log Sheet

Installer: Complete unit and system checkout and follow unit start-up procedures in the IOM. Use this form to record unit information, temperatures and pressures during start-up. Keep this form for future reference.

Model Number: Serial Number:

Unit Location in Building:

In order to minimize troubleshooting and costly system failures, complete the following checks and data entries before the system is put into full operation.

Fan Motor: Speed Tap (PSC)

Antifreeze: %

Pressures: PSIG or kPa Type:

Cooling Mode Heating Mode

Entering Fluid Temperature

Leaving Fluid Temperature

Temperature Differential

Return-Air Temperature

Supply-Air Temperature

Temperature Differential

Water Coil Heat Exchanger

(Water Pressure IN)

Water Coil Heat Exchanger

(Water Pressure OUT)

Pressure Differential

Water Flow GPM

Compressor

Amps

Volts

Discharge Line Temperature

Motor

Amps

Volts

DB

DB

WB

WB

DB

DB

Allow unit to run 15 minutes in each mode before taking data.

Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water flow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.

53

Location: ________________________

Packaged Unit Refrigeration Schematic

Date: ________________________

Customer: _____________________________________ Antifreeze: ________________________

Functional Troubleshooting

Complaint: ________________________________________________________________________

HEATING CYCLE ANALYSIS -

PSI

° F

SAT

° F

AIR

COIL

° F

SUCTION

COMPRESSOR

EXPANSION

VALVE

FILTER

DRIER*

COAX

DISCHARGE

HWG

° F

FP2: HEATING

LIQUID LINE

° F

FLASH

GAS LINE

FP1

SENSOR

° F

° F

PSI

WATER IN

° F

PSI

WATER OUT

°

F

PSI SAT

COOLING CYCLE ANALYSIS -

Refrigerant Type:

HFC-410A

° F

AIR

COIL

° F

Look up pressure drop in

I.O.M. or spec. catalog to determine flow rate.

PSI SAT

° F

SUCTION

COMPRESSOR

EXPANSION

VALVE

FILTER

DRIER*

COAX

DISCHARGE

Voltage: ________ HWG

Comp Amps: _______ ° F

Total Amps: ________

°

F

FP2: FLASH

GAS LINE

° F

OTHER SIDE

OF FILTR DR

°

F

FP1: CLG

LIQ LINE

° F

PSI

WATER IN

° F

PSI

WATER OUT

PSI SAT

Look up pressure drop in

I.O.M. or spec. catalog to determine flow rate.

Heat of Extraction (Absorption) or Heat of Rejection =

________ flow rate ( gpm) x ________ temp.

diff. ( deg. F) x ________ fluid

Superheat

Subcooling

=

=

Suction temperature - suction saturation temp.

Discharge saturation temp. - liquid line temp.

=

= factor = _____________

(deg F)

(Btu/hr)

(deg F)

  Use 500 for water, 485 for antifreeze.

Rev. 12/08

Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water flow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.

54

Date:

02/06/15

01/21/15

06/16/14

05/29/14

05/12/14

10/07/13

02/04/13

11/09/12

01/23/12

08/09/11

08/01/11

Installation, Operation & Maintenance Manual - HBH-HBV Small

Page 3

All

Pages 8, 11 & 19

Physical Data Table

Item:

Physical Data Table and Water Quality Table

Figure 10a: Vertical Condensate Drain

Electrical Table

POE Oil Warning

Water Quality Table

Condensate Drain Connection

HBV041

Unit Maximum Working Water Pressure

First Published

Action:

Changed E-Coated to Tin-Plated

Added ECM Information

Change Text - Filter “rack” to “frame”

Removed Fan Motor (hp)

Updated Ref. Charge on 024 and Unit Maximum Working

Water Pressure; Updated Water Quality Table

Updated

Miscellaneous Edits

Added

Added

Updated to Reflect New Safeties

Revision History

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1900 Wellworth Ave. • Jackson, MI 49203

517.787.2100 • www.marsdelivers.com • www.heatcontroller.com

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