Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INFORMATION Handling Care must be taken in handling the horizontal unit and other accessories to ensure that this equipment does not sustain any damage. It is recommended that the horizontal unit be transported individually on a two – wheel cart The protective shipping packaging should be kept on until ready for installation. During construction, the equipment must be sheltered from contaminants and debris such as drywall dust, wood chips, or paint that could damage the fan, or block the cooling / heating coil and diminish unit performance. Storage The unit must at all times be stored in an upright position with the compressor section down and the fan section oriented up. Failure to maintain the unit in a vertical position may result in damage to interior unit piping and components possibly causing permanent unit damage. Damage of this nature may also result from dropping the unit. Both, Unit should be stored in a corrosive free environment sheltered from extreme temperature and humidity conditions. Subjecting the unit to these conditions could result in significantly reduced performance, reliability and operation life. The unit is intended for indoor use only. To protect the unit from damage due to the elements, and to prevent possible Indoor Air Quality (IAQ) contaminant sources from growing, the unit should be stored indoors. If indoor storage is not possible, the following provisions for outdoor storage must be met: 1. Place the unit(s) on a dry surface or rise above the ground to assure adequate air circulation beneath the unit. 2. Cover the unit(s) with a water proof tarp to protect them from the elements. 3. Make provisions for continuous venting of the covered units to prevent moisture from accumulating on unit(s) surfaces. Wet interior unit insulation can become a site for microbial growth which has been determined to be a cause of odors and serious health ...
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION The Installation of all horizontal Product and components and accessories must be in accordance with local codes and all regulations of all governing authorities having jurisdiction. The following installation procedures are recommended by the Manufacturer. It is the responsibility of the installing contractor to comply with all applicable codes and regulations. . R090303 Installation Operation Maintenance Manual is subject to change without notice Page 3 ...
Page 6
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION GENERAL INSTALLATION CHECK The list below summarizes the steps required to successfully install a horizontal unit. This checklist should define the scope of the installation procedures required to install the unit. 1. Remove packaging and inspect the unit. Check for shipping damage or material shortage; file a freight claim and notify appropriate sales representative, if damage is found. 2. Verify the correct model. 3. Verify the power supply complies with the nameplate specification. 4. Connect properly sized and protected power supply wiring to the disconnect (not supplied). 5. Install proper grounding wires to an earth ground. Figure 1 R090303 Installation Operation Maintenance Manual is subject to change without notice Page 4 ...
Page 7
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION LOCATION 1. Determine future horizontal mount location with clearances shown, in appendix A. 2. Locate the unit in an indoor area. The ambient temperature surrounding the unit must not be less that 45F (7C). Do not locate the unit in areas subject to freezing. PLACEMENT 1. Position the unit and fasten to Ceiling ensuring the unit is level. Extension Rods and Rubber isolators are to be used (if supplied). 2. Provide access for fan and fan motor maintenance and for servicing the compressor and coils without removing the unit. 3. Provide access to water valves and fittings and screwdriver access to the unit side panels, discharge collar and all electrical connections. PIPING CAUTION: Piping must comply with all applicable Figure 2 codes. 1.
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION NOTE: Insulation of the water piping loop is not required except where piping runs through unheated areas or outside the building. The Normal loop operating temperature is between 85F (29C) and 120F (49C). Wiring 1. Wire Room temperature sensor to electrical panel as indicated by the wiring diagram. 2. Connect power. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 6 ...
Page 9
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION CAUTION: To avoid fouled machinery, extensive unit clean up and void warranty, do not operate units without filters in place or use as a temporary heat source during construction. The CGC Group hybrid heat Pump provides year round cooling and heating as controlled by your system DDC control panel. The CGC hybrid heat pump provides cooling with a water cooled compressor refrigeration circuit and provides heating with warm water. The compressor operates during cooling operation only and does not operate during heating operation providing quieter operating sound levels and energy cost savings. Central equipment located within the building mechanical room is automatically controlled to ensure the water supplied to each heat pump unit in each suite at the proper temperature ensuring correct operation. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 7 ...
Page 10
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION 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 too have amber LED indicators located near the input locations. These light up when the input is closed. These inputs include: ...
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION 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 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 advance to high speed through Relay K6. Fan operation will terminate whenever all calls are dropped. Both Relays and their LED’s are energized on High Speed. HEAT OPERATION A call on “W” for heat will turn on the fan at low speed. Simultaneously it will energize the heat relay K2 and its LED. The relay K2 will provides 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 are: 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 that power is restored. It also prevents compressor jolting with intermittent power. b. Anti‐recycle timer – There is a 5‐minute anti‐recycle delay timer that gives the refrigerant cycle time after shutdown to achieve pressure equalization to allow for an unloaded compressor start. c. High Pressure Switch – The high refrigerant pressure switch must be closed prior to start. LED 11 lamp will be ON. ...
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION situations, particularly when the unit is cold, the pressure switch will open during start‐up. If the switch does not remake with 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 system fluid temperature is above 125°F (52°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 operation continues during operation of the compressor. The following malfunctions will cause compressor 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 15. 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 5 flash on the red diagnostic LED 15 will be initiated at this time. c. Intelligent reset algorithm – If a low or high pressure switch opens and remains open for more than 10 minutes, a hard lockout will be initiated and the cooling mode will be locked off until the controls are manually reset. At the same time ...
Page 13
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION power down to reset. If two or less switch open shutdowns occur within a 24 hour period, they will be erased from memory and will not contribute to a future hard lockout. (A hard lockout will prevent compressor operation until the controls are powered down for at least 20 seconds, the green power light goes out, while a soft lockout is a compressor shutdown that will be restored once the condition causing the shutdown returns to normal.) 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. It 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 2 flash code will be initiated with a low refrigerant temperature shutdown. e. If the system fluid temperature rises above 125°F compressor startup will be disabled. It will be enabled as soon as the temperature drops below 120°F. Once compressor operation is established, the shut down temperature will be increased to 145°F. The 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 3 flash code will be initiated with a high system fluid temperature shutdown. f. If the discharge air temperature drops below 50°F compressor operation will be disabled. It will be enabled as soon as the temperature rises above 60°F. The discharge air temperature sensor is mounted on the fan scroll. Actual compressor restart will be delayed a minimum of 5 minutes by the anti‐recycle timer. A 4 flash code will be initiated with a low 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 ...
Note: Last flash code will be maintained in memory for 1 week or until unit controls are powered down. Flash code will continue unless the problem has cleared and the compressor has been put into operation. If a cooling call is in place one must remove that call in order to check the cause of the last alarm shutdown. 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 (thermostats mounted on a wall opposite a discharge grille that is exposed to discharge air temperatures will switch from heat to cool continuously, or a thermostat in a doorway to outside) can cause 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 for 10 minutes after the opposite call was terminated. 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 installing: 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 ...
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION than normal temperature swings. The cool anticipator if oversized can bleed enough current to indicate a cooling call even after it has been terminated. 3. Battery powered thermostats – These thermostats were developed as replacements for old mercury bulb thermostats that had 4 wire connections while 24V electronic 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. 4. Power stealing thermostats – This type 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. ...
Page 16
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION not powered, if the board fuse is blown, or if the electronics are damaged, a fault condition will be indicated. The fault relay is paralleled with the Fault LED which will be ON when no fault condition exists. 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 in excess of 15 minutes. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 14 ...
Hybrid Horizontal Spackeeper – 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 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‐ 120F) for cooling and (100 – 140F) 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 exchange, 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. 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 situation may occur during construction where the system fluid loop is drained after being cleaned, flushed and tested. Hybrid horizontal unit 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 15 ...
Page 18
Hybrid Horizontal Spackeeper – Installation Operation Maintenance Manual COMMISSION & START UP Clean Unit Filters: Check to ensure the unit filters are clean. This contributes to the proper operation of the unit by ensuring adequate air flow across the coil. A Vacuum may be used to remove any debris or dirt lodged in or on the units. Fan Rotation: Inspect fan section to ensure it is clean of any debris and that the fan rotates freely as well as belt tension. NOTE: This equipment is designed for indoor installation ONLY. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 16 ...
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE WARNING: To prevent injury or death due to electrical shock or contact with moving parts, disable the unit using the disconnect before servicing. Inspect Filters: Establish a regular maintenance schedule. Clean filters frequently and replace as needed. To remove the filter from the unit lift the filter up and pull it out of the unit at the bottom. Replace the old filter by sliding the top edge of a new filter up into the rack, then pushing in the bottom of the filter until it drops in place. Check Fan motors annually: All hybrid heat pumps are permanently lubricated when shipped from the factory. Do not oil fan motors. Check belt tensions, wheel spins freely, and not excessively dirty. Visual Inspection: Visually inspect units giving special attention to hose assemblies. Note any signs of deterioration or cracking and repair leaks immediately. 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 hybrid heat pumps include high and low pressure cutouts to prevent the machine from operating at abnormal conditions of temperature or water flow. To reset alarm lockout, power unit down for 20 seconds. NOTE: If the unit must be reset more than twice, check the unit for a dirty filter, abnormal entering water temperature, inadequate water flow (delta T method) and internal malfunctions. If the unit continues to cutout, contact a trained service technician. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 17 ...
Page 20
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 18 ...
Page 21
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 19 ...
Page 22
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual APPENDIX A R090303 Installation Operation Maintenance Manual is subject to change without notice Page 20 ...
Page 23
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 21 ...
Page 24
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 22 ...
Page 25
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 23 ...
Need help?
Do you have a question about the SKH060 and is the answer not in the manual?
Questions and answers