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Summary of Contents for CGC SpaceKeeper SKH008
- Page 1 Installation Operation Maintenance Hybrid Horizontal Heat Pump Spacekeeper Models: SKH008 – SKH060 July 7 , 2010...
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Page 2: Table Of Contents
Table of Contents 1. INFORMATION .......................... 1 Handling/Storage ............................ 1 Weight/Dimension/Clearances ........................ 2 2. INSTALLATION .......................... 3 General Install Checklist .......................... 5 Location/Placement/Piping .......................... 6 Condensate Drain Connection ........................ 7 Wiring ................................ 8 3. OPERATION ............................ 9 Board Description ............................ 10 Fan ................................ 11 Heat Operation ............................ 11 Cool Start Up ............................... 11 Cool Operation ............................ 12 Operational Algorithm .......................... 14 Thermostat Connection .......................... 14 Shutdown Output ............................ 15 Fault Alarm Output ............................. 15 4. COMMISSION & START UP ...................... 17 5. MAINTENANCE .......................... 20 SKH008 ‐ SKH018 Wiring Diagram ...................... 21 SKH020 ‐ SKH060 Wiring Diagram ...................... 22 ... -
Page 3: Information
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. The protective shipping packaging should remain on the unit until it is 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 unit must be stored in an upright position at all times. Failure to maintain the unit 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. The unit 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 unit’s insulation may result in microbial growth that can lead to odors and serious ... -
Page 4: Weight/Dimension/Clearances
Hybrid Horizontal Spacekeeper – 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/Dimensions/Clearances Weight: Model 008 010 012 015 018 020 024 030 036 042 048 060 Weight 130 130 135 150 160 205 235 235 235 375 300 375 ... -
Page 5: Installation
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION R090303 Installation Operation Maintenance Manual is subject to change without notice Page 3 ... - Page 6 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION The Installation of Hybrid Horizontal SpaceKeeper units and accessories must be in accordance with local codes and all regulations of all relevant 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 4 ...
- Page 7 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION DELIVERY AND GENERAL INSTALLATION CHECKLIST The list below summarizes the steps required to successfully install a CGC Horizontal SpaceKeeper unit. 1. Remove packaging and inspect the unit. Check for shipping damage or material shortage; file a freight claim and notify your sales representative if damage or deficiency is found. 2. Verify the model. 3. Verify that 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. ARR. 3 BACK ARR. 1 RIGHT SUPPLY AIR SUPPLY AIR COMPRESSOR AND CONTROL ACCESS PANEL FRONT LEFT RETURN AIR FILTER Figure 1 ...
- Page 8 INSTALLATION LOCATION 1. Determine future horizontal mount location with clearances shown in appendix A. 2. Locate the unit in an indoor area. The air temperature surrounding and being supplied to the unit must be above 45°F (7°C) at all times. Do not locate the unit in areas subject to freezing. PLACEMENT 1. Position the unit and fasten to ceiling ensuring the unit is leveled. Extension Rods (not supplied by CGC) and Rubber isolators are to be used. DO NOT block access panels with mounting rods. 2. Meet specified clearances to provide room for removal of all access panels. 3. Provide access to water valves and fittings, as well as screwdriver access to the unit side panels, discharge air collar, and all electrical connections. PIPING CAUTION: Piping must comply with all applicable Figure 2 codes and regulations. 1. Install isolation valves at each unit to permit unit removal for servicing. ...
- Page 9 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual INSTALLATION R090303 Installation Operation Maintenance Manual is subject to change without notice Page 7 ...
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Page 10: Wiring
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 areas on the exterior of the building. The normal loop operating temperature range is 85°F (29°C) to 120°F (49°C). WIRING 1. Wire room temperature sensor to electrical panel as indicated on the wiring diagram. 2. Connect power. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 8 ... -
Page 11: Operation
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 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 as controlled by the unit thermostat or by a direct digital controller. The CGC Group hybrid heat pump provides cooling with a water‐cooled refrigeration circuit, and provides heating using a hydronic 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 appropriate temperature. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 9 ... - Page 12 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION The unit circuit board incorporates six relay outputs with the following functions: • 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 circuit board incorporates digital inputs that are opto‐coupled to a 24V AC source. These have amber LED indicators located near the input locations which are lit when the input is closed. The inputs include: •...
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Page 13: Fan
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION FAN 1. 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. 2. A call on “W” for heat on the thermostat terminal strip will also cause the fan to operate on low speed. If the heating call is still present after a 10 minute period, the multi speed units will switch the fan to high speed through Relay K6. 3. A call on “Y” for cooling on the thermostat terminal strip will cause the fan on multi‐ speed units to immediately step up to high speed through Relay K6. 4. Fan operation will terminate whenever all calls are dropped. 5. When the fan is operating at high speed, both relays are energized along with their associated LED indicators. HEATING OPERATION 1. A call on “W” for heat will activate the fan at low speed. It will also simultaneously energize the heat relay K2 and its associated 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 from coming on line at the same time when 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 allows the refrigeration cycle to achieve pressure equalization so that the compressor is ... -
Page 14: Cool Operation
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION during start‐up. If the switch does not remake with the 5 minute ignore period, the compressor will immediately be 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 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 the DIAGNOSTICS section. COOL OPERATION 1. 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, the switch will open and the control board will terminate the compressor operation within 10 seconds. At this time a flash code of 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 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 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 15 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, and the green power light goes out. 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. 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 ...
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Page 16: Operational Algorithm
alarm will be triggered. This fault signal will automatically reset once the condensate level goes below the sensor. 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 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 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. ... - Page 18 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual OPERATION is 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 a period in excess of 15 minutes. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 16 ...
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Page 19: Commission & Start Up
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’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 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. SAFETY NOTE: In the following part of the procedure it will be necessary to access the areas around the electrical wiring and the circuit board. Do not adjust or remove any board connections or wiring connections to other components without first powering down the unit. On older SKH 008 to 018, the disconnect will be a power plug at a receptacle. On model sizes 20 and post Oct 7/2005 SKH 008 to 018 up there will be a switch disconnect. Disconnects are usually within reach of the unit. Exercise caution at all times. Verify Fan Rotation & Compressor Operation (3‐Phase): With the power OFF, remove the front panel and the electrical panel cover. Remove any thermostat block and turn power ON to the unit with the electrical disconnect. Ensure that the correct standby protocol is in place ‐ the following board lights will come on in standby: Power, HP, LP, and Alarm. Inspect the fan section to ensure that it is clear of any debris and that the fan rotates freely. CGC’s Horizontal Spacekeeper units come equipped with a 3‐phase fan and compressor that are matched to each other as well as the other internal components. Although internal connections to the fan and compressor are made at the factory, variances in power supply in the field will require that both components be tested for correct operation. The procedure is outlined below: • Using a screwdriver with an insulated handle, push and hold in the manual plastic button of the fan contactor for a few seconds, making sure not to touch any of the metal parts. This will cause the fan to rotate. • The correct rotation will have the fan vanes rotating towards the housing exit. • If the rotation is incorrect, power OFF the unit and switch two of the three wires at the bottom of the contactor that feed the fan. Power ON the unit and again using the screwdriver, press the contactor for a few seconds to activate the fan. The rotation should now be reversed. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 18 ...
- Page 21 Hybrid Horizontal Spackeeper – Installation Operation Maintenance Manual COMMISSION & START UP At this stage, the rotation of the scroll compressor will need to be verified as follows: • Using a screwdriver with an insulated handle, push and hold in the manual plastic button of the compressor contactor, making sure not to touch any of the metal parts. This will cause the compressor to start and the following checks will verify correct operation: The discharge from the compressor (top most line) will become hot almost immediately. There will be a cloudy Freon surge visible in the sight glass. The compressor noise will have a distinctive whirring sound and not be overly loud. There will be no run‐on, or idling‐on of the compressor motor when you release the manual button of the contactor. • If the above signs are not present, then power OFF the unit using the disconnect and switch around two of the three wires at the contactor that feed the compressor (typically black wires at the lower edge of the contactor). Power ON the unit and perform the check again. If the operation is correct, power OFF the unit and replace the thermostat block, the electrical panel cover, and the front panel of the unit. NOTE: This equipment is designed for indoor installation ONLY. R090303 Installation Operation Maintenance Manual is subject to change without notice Page 19 ...
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Page 22: Maintenance
Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM 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 required. A vacuum can be used to clean filters, as well as the surface of coil components. 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 into place. Check Fan motors annually: All CGC Hybrid Heat Pumps are permanently lubricated when shipped from the factory. Do not oil fan motors. Visual Inspection: Visually inspect units and give 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 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 continuing use of the unit. ... - Page 23 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 21 ...
- Page 24 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM R090303 Installation Operation Maintenance Manual is subject to change without notice Page 22 ...
- Page 25 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual MAINTENANCE – STANDARD WIRING DIAGRAM APPENDIX A R090303 Installation Operation Maintenance Manual is subject to change without notice Page 23 ...
- Page 26 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 24 ...
- Page 27 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 25 ...
- Page 28 Hybrid Horizontal Spacekeeper – Installation Operation Maintenance Manual DETAILS R090303 Installation Operation Maintenance Manual is subject to change without notice Page 26 ...
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