Subscribe to Our Youtube Channel
Related Manuals for CGC IKV008
Summary of Contents for CGC IKV008
- Page 1 Installation Operation Maintenance Hybrid Vertical Stack Heat Pump Innkeeper/Homekeeper Models: IKV008 – IKV018 HKV020 – HKV036 R090303 July 7 , 2010 ...
-
Page 2: Table Of Contents
Condensate Hose Connection ........................ 4 Location/Placement/Riser Bundle ........................ 5 Finish ................................ 6 3. OPERATION (IN SUITE) ........................ 7 Fan Operation ............................... 7 Standard Heating Operation ......................... 7 Cooling Operation ............................ 8 Time Delays .............................. 8 Recommendations ............................ 8 4. OPERATION (DETAILED) ........................ 10 Board Description ............................ 10 Fan ................................ 11 Cool Start Up ............................... 11 Cool Operation ............................ 12 Operational Algorithm .......................... 14 Thermostat Connection .......................... 14 Shutdown Output ............................ 15 Fault Alarms .............................. 15 5. COMMISSION & START UP ...................... 17 6. MAINTENANCE .......................... 19 IKV008 ‐ IKV018 Wiring Diagram......................... 20 HKV020 ‐ HKV036 Wiring Diagram ...................... 21 R090303 July 7 , 2010 ... -
Page 3: Information
Hybrid Vertical Stack – Installation Operation Maintenance Manual INFORMATION Handling Care must be taken in handling the cabinet, chassis, risers and other accessories to ensure that this equipment does not sustain any damage. It is recommended that the chassis and cabinet be transported individually on a two‐wheel cart. The protective shipping packaging should remain on the chassis and cabinet until they are ready for installation. During construction, the unit must not be run and shall be sheltered from contaminants and debris such as drywall dust, wood chips, and paint that could damage the fan or block the cooling/heating coil which may result in diminished performance. Storage The chassis must be stored in an upright position at all times with the compressor section towards the ground and the fan section oriented upwards. Failure to maintain the chassis in an upright position may result in permanent damage to the unit. Dropping the chassis or exposing it to extreme shock or vibration may also result in permanent damage to the interior components and piping. Both the chassis and cabinet should be stored in a non‐corrosive environment sheltered from conditions of extreme temperature or humidity. Subjecting the unit to conditions of this nature may result in significantly reduced performance, reliability, and operational life. The unit is intended for interior use only and should be stored indoors at all times to protect it from the elements and to help eliminate the potential growth of indoor air quality (IAQ) contaminants. If indoor storage is not possible, the equipment may be stored outdoors during the summer months only, if the following provisions are met: 1. The equipment must be placed on a dry surface, or raised off the ground in a manner which allows for air‐circulation beneath the unit. 2. A waterproof tarp must be used to cover the equipment in order to provide protection from the elements. 3. Continuous ventilation to the units must be provided to help prevent moisture accumulation on the interior and exterior surfaces. Moisture buildup on, or within the ... -
Page 4: Weight/Dimension/Clearances
Hybrid Vertical Stack – Installation Operation Maintenance Manual INFORMATION 5. The individual units shall not be stacked on top of one another. 6. If the unit was previously in use, ensure that all water in the coil has been blown out and that all hose connections are plugged during storage. Weight/Dimension/Clearance Unit Weight: Model 008 010 012 015 018 020 024 030 036 Weight 115 120 120 135 145 210 225 225 240 (lb) Unit Dimension: Models 008 ‐ 018 Models 020 ‐ 036 ... -
Page 5: Installation
Hybrid Vertical Stack – Installation Operation Maintenance Manual INSTALLATION The information below details the correct installation procedure for a vertical stack unit. Please read this document in its entirety prior to proceeding with unit installation. Specific site conditions may warrant variations in locations and dimensions. GENERAL INSTALLATION CHECKLIST 1. Remove packaging and inspect the unit. Carefully check for shipping damage or material shortage; file a freight claim and notify appropriate sales representative if damage is found. NOTE: The chassis, front panel, and return air boot ship separately from the cabinet and risers. 2. Verify the correct model and voltage as indicated by the model number. 3. Verify the installation location of the unit using the sheet metal template that is provided. 4. Verify that the power supply complies with the nameplate specification. 5. Connect properly sized and protected power supply wiring to the electrical receptacle in the cabinet. 6. Install proper grounding wires to an earth ground. Figure 3 R090303 Installation Operation Maintenance Manual is subject to change without notice Page 3 ... - Page 6 Hybrid Vertical Stack – Installation Operation Maintenance Manual INSTALLATION R090303 Installation Operation Maintenance Manual is subject to change without notice Page 4 ...
- Page 7 Hybrid Vertical Stack – Installation Operation Maintenance Manual INSTALLATION LOCATION 1. Determine cabinet location using the manufacturer‐supplied template. 2. As depicted in Figure 4, locate core holes for risers using supplied template. 3. Locate the unit in an indoor area. The ambient temperature surrounding the Figure 4 unit must not be less that 45°F (7°C). Do not locate the unit in areas that may be subjected to freezing temperatures. PLACEMENT 1. Review the riser schedule to identify cabinet type and location. 2. Position cabinet and fasten to floor. 3. To level the unit, loosen the four bolts that are located at the bottom of the cabinet on the left and right hand sides (refer to Figure 5). Level and plumb the unit and then tighten the Figure 5 four bolts to hold the cabinet in position. 4. Connect risers ‐ shown in Figure 6 ‐ using 95/5 tin‐antimony solder, or braze with Sil‐Fos. 5. Perform leak test on risers. 6.
-
Page 8: Finish
Hybrid Vertical Stack – Installation Operation Maintenance Manual INSTALLATION FINISH 1. Attach drywall to cabinet (left side) or install drywall studs (right side). Fasten cabinet to studs. Installation of acoustic insulation in stud wall is recommended. 2. Glue or attach drywall with screws to stud wall and front of cabinet, as shown in Figure 7. 3. Mount thermostat and connect to thermostat wire. Ensure that the thermostat is not mounted in direct sunlight, or within the supply airstream of the heat pump unit. 4. Install and connect chassis. Wire Figure 7 thermostat to control board. 5. Connect supply/return hoses and condensate line to risers. 6. Perform a leak test and ensure that the hose clamp on the condensate line is tight. 7. Hang return air boot on lower clips, shown in Figure 8. 8. Connect power cord at cabinet electrical box. 9. Hang acoustically insulated front panel on upper clips. ... -
Page 9: Operation -In Suite
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION –IN SUITE CAUTION: To avoid fouled machinery, extensive unit clean up, and void warranty, do not operate units without air filters in place, and do not operate units during the construction process. The CGC Group hybrid heat pump provides year round cooling and heating controlled by your in‐suite wall mounted thermostat. The CGC Group hybrid heat pump provides DX cooling with a water‐cooled refrigeration circuit, and hydronic heating with a hot water coil. The compressor operates in the cooling mode only and shuts down during the heating mode, providing for quieter operation, extended compressor life, and a reduction in energy consumption. To ensure correct operation, centralized equipment located within the building mechanical room is automatically controlled to provide each heat pump unit with water that is at the proper temperature. Fan Operation: Each heat pump has two‐speed fan operation. The fan operates as follows: LOW Speed ‐First stage of heating mode (Thermostat Setting: Fan Automatic) ‐Fan only operation (Thermostat Setting: Fan On) HIGH Speed ‐The second stage of heating mode ‐Cooling mode Standard Heating Operation: Each heat pump has two stages of heat operation. The compressor does not operate in either stage. To enable heating operation, Manual Change Over thermostats (MCO) must be set to “Heat” mode. Automatic Change Over (ACO) thermostats should be set to “Auto” mode. To start heating operation, the suite temperature must fall below the heat set‐point temperature. ... -
Page 10: Cooling Operation
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION –IN SUITE Stage 1 Heating: Fan operates at low speed for 10 minutes with minimal noise in an attempt to elevate suite temperature to desired level. Stage 2 Heating: After 10 minutes, if set‐point temperature is not reached, fan will automatically step up and operate at high speed. Cooling Operation: Each heat pump has a water cooled refrigeration circuit that operates only during the cooling mode. To enable cooling operation, MCO thermostats must be set to “Cool” mode. The ACO thermostats should be set to “Auto” mode. In order for the cooling operation to become activated, the suite temperature must rise above the cool set‐point temperature. The thermostat will automatically stop cooling once the space temperature drops below the cool set‐point temperature. Cooling: The fan always operates at high speed during the cooling operation. The compressor also operates during the cooling operation. Time Delays: ‐ Thermostat time delay up to 5 minutes upon initial power up. ‐ Thermostat time delay up to 5 minutes when switching between heat/cool/off modes. ‐ Heat pump time delay up to 5 minutes upon initial start up. ‐ Heat pump time delay up to 5 minutes from the end of a cooling operation to the start of the next cooling operation. Recommendations: 1. Set the thermostat fan to ON for continuous fan operation while your suite is occupied. This will help to ensure that the temperature is uniform throughout the suite. ... - Page 11 Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION –IN SUITE 3. When away for a short duration, set the thermostat as follows: a. Set fan to AUTO b. Set thermostat to appropriate heat or cool mode (based on seasonal conditions). c. Set heat or cool set‐point to your desired suite temperature (ie. 72°F or 22°C). 4. When away for an extended period, set the thermostat as follows: a. Set fan to AUTO b. Set thermostat to appropriate heat or cool mode (based on seasonal conditions). c. During cooler seasons set your thermostat to a minimum set point of 65°F (18°C) d. During warmer seasons set your thermostat to a maximum set point of 78°F (26°C) This will help to ensure the unit operates minimally; preventing your suite from becoming excessively cold or hot. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 9 ...
-
Page 12: Operation -Detailed
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED The unit circuit board incorporates six relay outputs with the following uses: • K1 – Auxiliary relay for cooling valve on a two‐valve unit or heat valve on a dehumidification unit. • K2 – Heating Relay • K3 – Alarm Relay • K4 – Compressor Relay • K5 – Low Fan or Fan Relay for belt drive units • K6 – High Fan or Compressor #2 on belt drive units Each of these relays have in parallel, a green LED indicator that lights up when the relay is energized. The board incorporates digital inputs that are opto‐coupled to a 24V AC source. These inputs have amber LED indicators that will light up when an input is present. These inputs include: •... -
Page 13: Fan
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED FAN A call on “G” for fan on the thermostat terminal strip will cause the fan to operate continuously on low fan speed through K5 on multi speed units. A call on “W” for heat on the thermostat terminal strip will also cause the fan to operate on low speed. After 10 minutes of a continuous heating call, the multi speed units will be switched to high speed through Relay K6. A call on “Y” for cooling on the thermostat terminal strip will cause the fan on multi speed units to step up to high speed through Relay K6. Fan operation will terminate whenever heating or cooling calls are dropped. Both relays and their associated LED’s are energized when the fan is in high speed. HEAT A call on “W” for heat will turn on the fan at low speed. Simultaneously, it will energize the heat relay K2 and it’s LED. The relay K2 will provide 24V AC fused power directly to the heat valve. COOL START UP 1. A call on “Y” for cooling initiates a series of checks prior to the start up of the compressor. These checks include: a. Power ON timer – Compressor operation is delayed for approximately 5 minutes after restoration of power. This prevents all units coming on‐line at the same time once power is restored. It also prevents compressor jolting as a result of intermittent power. b. Anti‐Recycle timer – There is a 5‐minute anti‐recycle delay timer that allows the refrigeration cycle to achieve pressure equalization so that the compressor is unloaded upon start up. c. High Pressure Switch – The high refrigerant pressure switch must be closed prior to start. LED 11 will be ON. d. -
Page 14: Cool Operation
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED start‐up. If the switch does not remake within the 5 minute ignore period, the compressor will be immediately stopped. e. Air Temperature Sensor Ta – Sensor Ta will prevent compressor operation if the air flowing through the unit is below 60°F (15°C). f. Water Temperature Sensor Tw – Sensor Tw will prevent compressor operation if the outgoing system fluid temperature is above 140°F (60°C). g. Refrigerant Temperature Sensor Tr – Sensor Tr will prevent compressor operation if the coil temperature is below 35°F (2°C). h. Any of the above faults will be indicated with the Diagnostic Code described under DIAGNOSTICS COOL OPERATION 2. Monitoring of the refrigerant cycle continues during operation of the compressor. The following malfunctions will cause the compressor to shutdown: a. If the head pressure exceeds the set point of the high pressure switch, it will open, and the control board will terminate the compressor operation within 10 seconds. At this time the flash code 6 will be initiated on the red diagnostic LED. Compressor operation will be restored in accordance with the “Intelligent Reset” algorithm. b. If the suction pressure drops below the set point of the low pressure switch, the switch will open and if it remains open beyond the 5 minute ignore period after start up, compressor operation will be terminated within 10 seconds. Compressor operation will be restored in accordance with the “Intelligent Reset” algorithm. A flash code of 5 on the red diagnostic LED will be initiated at this time. c. Intelligent Reset Algorithm – If a low or high pressure switch opens, the compressor will be shut down. There is a 20 minute delay before the system is automatically reset, after which if there is a cool call in place and all other ... - Page 15 Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED operation until the controls are powered down for at least 20 seconds, while a soft lockout is a compressor shutdown that will be restored once the conditions causing the shutdown have been rectified. d. During compressor operation, refrigerant temperature, system fluid temperature and discharge air temperature are continuously monitored. If the refrigerant temperature drops below 35°F, compressor operation will be disabled. After 10 minutes an auto reset occurs and the compressor will be enabled as soon as the temperature rises above 60°F. Actual compressor restart will be delayed a minimum of 5 minutes by the anti‐recycle timer. A flash code of 2 will be initiated upon a low refrigerant temperature shutdown. e. If the outgoing system fluid temperature rises above 140°F, compressor startup will be disabled. After 10 minutes an auto reset occurs and the compressor will be enabled as soon as the temperature drops below 115°F. The outgoing system fluid sensor is mounted on the leaving fluid pipe. Actual compressor restart will be delayed a minimum of 5 minutes by the anti‐recycle timer. A flash code of 3 will be initiated upon a high outgoing system fluid temperature shutdown. f. If the discharge air temperature drops below 50°F compressor operation will be disabled. After 10 minutes an auto reset occurs and the compressor will be enabled as soon as the temperature rises above 60°F. The discharge air temperature sensor is mounted on the fan housing. Actual compressor restart will be delayed a minimum of 5 minutes by the anti‐recycle timer. A flash code of 4 will be initiated upon a low discharge air temperature shutdown. g. The condensate level sensor is a 100 ohm thermistor that is heated for 15 seconds every 4 minutes. Its temperature is measured at the beginning of the heat cycle, and again at the end of the heating cycle. If the condensate level rises above the sensor it will not warm up during the warm up cycle, and the temperature change will be insignificant. It is this lack of temperature change that the controller sees as an impending condensate overflow. When high condensate level is detected, compressor operation is immediately terminated, and at the same time the fan is stopped for 30 seconds, and then restarted. At this time a flash code of 7 will be intiated. The 4 minute cycle will continue until the cooling call is no longer in place. If the condensate level drops below the sensor, compressor operation will be returned to normal. However, if the ...
-
Page 16: Operational Algorithm
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED Note: The last flash code will be maintained in memory for 1 week or until the unit controls are powered down. The flash code will continue until the problem has cleared and the compressor has been put into operation. If a cooling call is in place, it must be disengaged before the cause of the last alarm shutdown can be identified. OPERATION ALGORITHM There are several control algorithms to prevent cycling and problematic operation. These are: 1. Double Call – If thermostat connections or set up is incorrect resulting in a simultaneous call for both heating and cooling, the unit will not operate. This condition can be observed on the thermostat connection LEDs. (Note: A heat pump thermostat will present this scenario) 2. Reverse Cycle Call – Poorly located automatic changeover thermostats (ie. thermostats mounted on a wall opposite a discharge grill, or a thermostat in a doorway to outside) can trigger heating and cooling mode changes many times an hour. The CGC controller has a 10‐minute anti‐mode change timer for both heating and cooling mode changes. The controller will not accept a change in mode until 10 minutes have elapsed since termination of the opposite call. THERMOSTAT CONNECTIONS The CGC control board has been designed to operate with most standard 24V AC thermostats. These are powered from the CGC board with 24V AC and simply switch power ON to each of the Heat (W), Cool (Y), Fan (G) or Aux (A). While most present day thermostats operate in this manner there are others that may or may not work properly. The following should be checked out for satisfactory performance prior to installation: 1. Heat Pump Thermostat – Some heat pump units do not have heat relays (therefore are not compatible with standard thermostats) and require “Heat Pump Thermostats”. These thermostats call for both heating and cooling on one of the signal wires. These thermostats are completely incompatible with CGC’s controller. 2. Mercury bulb thermostat ‐ This type is problematic but can be used. Unfortunately, the anticipators are a problem. Heat anticipators must be in series with a high current relay ... -
Page 17: Shutdown Output
Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED thermostats required 5 wires. These will work with a CGC board, although CGC does not recommend them. They require periodic battery replacement, which is something that should be avoided if possible. 4. Power stealing thermostats – This type of thermostat is electronic and was also developed as a replacement for old mercury bulb thermostats. These too are problematic in that they bleed a small amount of current down the signal wires and this may be interpreted as a signal for heat or cool. 5. Triac switched controllers – This is a commonly used switching device and all controllers tested to date have functioned flawlessly. CGC recommends that prior to installation of a third party supplied controller, it be checked for compatibility. CGC can confirm this. 6. Relay switched controllers – This type of controller works well with CGC devices. SHUTDOWN OUTPUT The CGC board has an optional input terminal strip that allows for two types of remote shutdown. These are a) compressor shutdown and b) unit shutdown. The advantage of these inputs is that many units can be connected in parallel and when powered by an independent 24V AC signal one or both of these actions can be implemented. Common uses are: Duty cycling for demand control Global night setback Heating only mode during emergency power periods The CGC controller is also set up so these shutdown functions can be initiated individually with on board 24V power. This capability allows unit or compressor shutdown based on a door switch, a light switch, or occupancy switch. A separate 24V power supply is required if two or more units are being shutdown. FAULT ALARM OUTPUT The CGC board is provided with a fault alarm indication and output. The fault alarm relay provides normally open and normally closed contacts for use in transmitting fault conditions. ... - Page 18 Hybrid Vertical Stack – Installation Operation Maintenance Manual OPERATION ‐DETAILED Other fault conditions are: Hard lockout due to high or low pressure switch being open for 10 minutes or longer. Hard lockout due to three high or low pressure shutdowns in a 24 hour period. High level condensate for a period in excess of 15 minutes. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 16 ...
-
Page 19: Commission & Start Up
Hybrid Vertical Stack – Installation Operation Maintenance Manual COMMISSION & START UP System Flushing: Proper system cleaning and flushing is an important aspect of the commissioning and start up procedure for hybrid units. Ensure the system has been flushed properly. This prevents fouling of the unit’s heat exchangers. NOTE: Hydronic coils are not 100% drainable. System Fluid: Ensure that system water temperature is within an acceptable range to facilitate start‐up (80‐ 120°F) for cooling and (100 – 140°F) for heating. System Water pH: System water should have a neutral pH balance of approximately 7.5 which will extend the life of the hoses, heat exchangers, and other water side accessories. Water Flow Rate: Open all isolation valves to the unit. Ensure that the entering and leaving fluid temperatures of the hybrid unit in operation are acceptable. There is typically an 8 to 12 degree drop or rise in temperature, depending on whether the unit is in cooling or heating. Under extreme conditions, slight variances in the temperature may be noted. Freeze Protection from Water System: Ensure that freeze protection is provided for the outdoor portion of the loop water system. Inadequate freeze protection can lead to coil damage. NOTE: A potential issue may arise during construction where the system fluid loop is drained after being cleaned, flushed and tested. Hybrid vertical stack units will not completely drain and may hold fluid in the condenser or heating coil. Extensive damage may result to internal components if the system fluid freezes unless adequate glycol is added. Remove Air from System Fluid Loop: Air in the system impairs unit operation and can cause erosion in the system piping. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 17 ... - Page 20 Hybrid Vertical Stack – Installation Operation Maintenance Manual COMMISSION & START UP Clean Unit Filters: Confirm that the unit filters that are being used are clean. This contributes to the proper operation of the unit by ensuring that there is adequate air flow across the coil. Fan Rotation: Inspect the fan section to ensure that it is free and clear of any debris and that the fan rotates freely. NOTE: This equipment is designed for indoor installation ONLY. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 18 ...
-
Page 21: Maintenance
Hybrid Vertical Stack – Installation Operation Maintenance Manual MAINTENANCE WARNING: To prevent injury or death due to electrical shock or contact with moving parts, disconnect the power to unit before servicing. Inspect Filters: Establish a regular maintenance schedule. Clean filters frequently and replace as required. A vacuum can be used to clean filters, as well as the surface of coil components. To remove the filter from the unit, remove the front service entrance and slide out the filter component. Check Fan Motors Annually: Make sure to inspect fan motors for unusual signs of wear. All CGC hybrid heat pump fan motors are permanently lubricated when shipped from the factory. Do not oil the fan motors. Amperage Check on Compressor and Fan Motor: Current draw on this equipment should not exceed normal full load or rated load amps by more than 10 percent of the values noted on the unit nameplate. Safety Control Reset: All CGC hybrid heat pumps include high and low pressure switches to prevent the machine from operating under abnormal conditions of temperature or water flow. If multiple pressure alarms occur in 24 hours, the compressor operation will be permanently locked out until the unit is reset, or power is disconnected for 20 seconds. NOTE: If the heat pump must be reset more than twice, check the unit for a dirty air filter, abnormal entering water temperature, inadequate water flow (delta T method), or internal malfunctions that may be causing high or low pressure conditions. If the unit continues to alarm, contact a trained service technician and ensure the problems are resolved before re‐ setting the unit again. Drain Pan and Condensate Hose: Make sure to inspect and clean if necessary, the condensate hose and drain pan on a regular basis. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 19 ... - Page 22 Hybrid Vertical Stack – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 20 ...
- Page 23 Hybrid Vertical Stack – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 21 ...
Need help?
Do you have a question about the IKV008 and is the answer not in the manual?
Questions and answers