INSTALLATION, OPERATION & MAINTENANCE MANUAL Large Commercial Vertical Packaged Heat Pump with R-410A HKV Series Heat Controller, LLC • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.
Installation, Operation & Maintenance HKV SERIES Table of Contents Model Nomenclature .................................................................................................. 2 General Information ................................................................................................. 3-4 Physical Data.............................................................................................................. 5 Dimensional Data ..........................................................
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Model Nomenclature Z03 1 2 3 4 5 6 7 8 9 10 11 12 13 14 HK V 084 A 3 C 3 A C BF MODEL TYPE AIR FLOW OPTIONS HK = HEAT CONTROLLER LARGE COMMERCIAL LS = LEFT RETURN / STRAIGHT SUPPLY ( HKH ONLY ) BF = BACK RETURN / FRONT SUPPLY ( HKV084-360 ) BT = BACK RETURN /TOP SUPPLY ( HKV084 - 360 ) FB = FRONT RETURN / BACK SUPPLY ( HKV084-360 ) FT = FRONT RETURN / TOP SUPPLY ( HKV084 - 360 ) VS = LEFT RETURN / STRAIGHT SUPP
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC General Information Safety ! Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment. WARNING! All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION. Technicians must follow industry accepted guidelines and all local, state, and federal statutes for the recovery and disposal of refrigerants.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC General Information Prepare units for installation as follows: ! 1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped. 2. Keep the cabinet covered with the original packaging until installation is complete and all plastering, painting, etc. is ¿QLVKHG 3.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC HKV Physical Data Model 084 096 Compressor Quantity Factory Charge R410a (oz) [kg] per circuit 120 150 168 192 Scroll (1) 240 300 Scroll (2) 140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03] 140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03] 1 [.75] 1.5 [1.12] 2 [1.49] 3 [2.24] 2 [1.49] 3 [2.24] 5 [3.73] 5 [3.73] 1.5 [1.12] 2 [1.49] 3 [2.24] 5 [3.73] 3 [2.24] 5 [3.73] 7.5 [5.60] 7.5 [5.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC HKV084-150 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA DESCRIBED IN NOTES 7, 8, 9, AND 10. 7.6 F D B 7.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC HKV168-300 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA DESCRIBED IN NOTES 7, 8, 9, AND 10. V 7.6 F D 7.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Installation Figure 2b: Typical Vertical Installation Rear Return/Top Discharge shown 5HWXUQ $LU Refer to Dimensional Data pages for other arrangements & dimensions 5HWXUQ $LU Ductwork not shown. All components external of unit are field supplied.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Installation 1HYHU FRQQHFW D E\SDVV GDPSHU IURP WKH VXSSO\ DLU GXFW to the return air duct. Never allow the return air temperature to drop below the minimum allowable normal temperature for proper unit operation. 'R QRW XVH +.9 XQLWV IRU RXWGRRU DLU WUHDWPHQW Do not add hot-gas-bypass to “convert” a unit for outdoor air treatment. Always use a dedicated outdoor air unit for outdoor air treatment.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Piping Installation Installation of Supply and Return Piping Follow these piping guidelines. 1. Install a drain valve at the base of each supply and return ULVHU WR IDFLOLWDWH V\VWHP ÀXVKLQJ 2. Install shut-off / balancing valves and unions at each unit to permit unit removal for servicing. 3. Place strainers at the inlet of each system circulating pump. 4.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Condensate Installation Condensate Piping - HKV Remove knockout on side that drain will be connected. Remove access panels. Inside of unit, untie and uncoil drain hose. Form trap in hose, make sure hose is not kinked or deformed. Connect plate assembly to side frame with 2 screws. 2XWVLGH RI XQLW FRQQHFW ´ (37 ¿WWLQJ WR SODWH DVVHPEO\ 5XQ line to building drain.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Water-Loop Heat Pump Applications Commercial systems typically include a number of units plumbed to a common piping system. Any unit plumbing maintenance work can introduce air into the piping system, therefore air elimination equipment is a major portion of the mechanical room plumbing.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Ground-Loop Heat Pump Applications ! CAUTION! ! Piping Installation CAUTION! The following instructions represent industry accepted installation practices for Closed Loop Earth Coupled Heat Pump Systems. They are provided to assist the contractor in installing trouble free ground loops. These instructions are recommended only. State and Local Codes MUST be followed and installation MUST conform to ALL applicable Codes.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Ground-Loop Heat Pump Applications Antifreeze In areas where minimum entering loop temperatures drop below 40°F (5°C) or where piping will be routed through areas subject to freezing, anti-freeze is needed. Alcohols and glycols DUH FRPPRQO\ XVHG DV DQWLIUHH]HV KRZHYHU D VSHFL¿F W\SH RI antifreeze may be better suited for your area .
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Ground-Water Heat Pump Applications Table 3: Water Quality Standards >H[LY 8\HSP[` 7HYHTL[LY /? 4H[LYPHS *SVZLK 9LJPYJ\SH[PUN 6WLU 3VVW HUK 9LJPYJ\SH[PUN >LSS :JHSPUN 7V[LU[PHS 7YPTHY` 4LHZ\YLTLU[ (IV]L [OL NP]LU SPTP[Z ZJHSPUN PZ SPRLS` [V VJJ\Y :JHSPUN PUKL_LZ ZOV\SK IL JHSJ\SH[LK \ZPUN [OL SPTP[Z ILSV^ W/ *HSJP\T /HYKULZZ 4L[OVK (SS W/ # HUK *H /HYKULZZ # WWT 0UKL_ 3PTP[Z MVY 7YVIHISL :JHSPUN :P[\H[PVUZ 6WLYH
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Electrical Data ! WARNING! ! ! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. CAUTION! ! 8VH RQO\ FRSSHU FRQGXFWRUV IRU ¿HOG LQVWDOOHG HOHFWULFDO ZLUing. Unit terminals are not designed to accept other types of conductors.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Electrical - Power Wiring ! WARNING! ! WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. ! CAUTION! ! CAUTION! 8VH RQO\ FRSSHU FRQGXFWRUV IRU ¿HOG LQVWDOOHG electrical wiring. Unit terminals are not designed to accept other types of conductors.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Electrical - Low Voltage 2-The valve will draw approximately 25-35 VA through the “Y” signal of the thermostat. Note: This can overheat the anticipators of electromechanical thermostats. Therefore only relay or triac based thermostats should be used. Figure 12: Well Water AVM Valve Wiring TL Unit CXM < 7KH &;0 FRQWURO DOORZV WKH ¿HOG VHOHFWLRQ RI VRXUFH ÀXLG ORZ temperature cutout points.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC CXM Control Operation Note: See CXM Operation Manual included with any unit utilizing the CXM controller. Electrical - Thermostat Typical Thermostat Selection and Wiring Practically any multi-stage contact type thermostat will work with the HKV Series. Figure 13 shows typical thermostat wiring. Thermostats with Triac outputs are not compatible with CXM boards.
Installation, Operation & Maintenance HKV SERIES Typical Wiring Diagram Three Phase HKV084-150 With CXM Controller 20 Heat Controller, LLC
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC CXM Controls CXM Control On = EH2 Normal. Off = DDC Output at EH2. NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1. Jumper not clipped = EH2 Normal. Jumper clipped = DDC Output at EH2. DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Safety Features Safety Features – CXM Control one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC %ORZHU $GMXVWPHQW ! Special Note for AHRI Testing CAUTION! ! Note 1: All HKV084 ratings @ 2800CFM (1321 l/s) w/21GPM (1.33 l/s). Sheave setting for AHRI is 3.5 turns open. Note 2: All HKV096 ratings @ 3200CFM (1510 l/s) w/24GPM (1.51 l/s). Sheave setting for AHRI is 3.0 turns open. Note 3: All HKV120 ratings @ 4000CFM (1888 l/s) w/30GPM (1.89 l/s). Sheave setting for AHRI is 2.5 turns open. Note 4: Cooling capacities based upon 80.
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HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Sheave Information Table 4a: HKV Blower Sheave and Belt Information Model &RQ¿JXUDWLRQ Return/Supply Drive Package Component A B C D E 084 Blower Sheave Motor Sheave Motor Belt BK95 X 1” 1VP40 X 7/8” 1HP BX79 BK110 X 1” 1VP34 X 7/8” 1HP BX81 BK95 X 1” 1VP50 X 7/8” 1HP BX81 BK95 X 1” 1VP40 X 7/8” 1.5HP BX79 BK95 X 1” 1VP50 X 7/8” 1.5HP BX81 096 Blower Sheave Motor Sheave Motor Belt BK95 X 1” 1VP40 X 7/8” 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 084 Blower Performance All Data is Wet Coil Airflow (SCFM) Airflow (cfm) at External Static Pressure (in. wg) ESP 0.00 2100 BHP 2100 Sheave/Mtr 2100 RPM 2100 Turns Open 2200 BHP 2200 Sheave/Mtr 2200 RPM 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.24 0.29 0.34 0.37 0.41 0.44 0.49 0.54 0.59 0.64 0.69 0.74 0.79 0.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 096 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) ESP 0.00 2400 BHP 2400 Sheave/Mtr 2400 RPM 2400 Turns Open 2500 BHP 2500 Sheave/Mtr 2500 RPM 2500 Turns Open 2600 BHP 2600 Sheave/Mtr 2600 RPM 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.29 0.34 0.39 0.44 0.49 0.54 0.59 0.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 096 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (SCFM) ESP 3800 BHP 3800 Sheave/Mtr 3800 RPM 3800 Turns Open 3900 BHP 3900 Sheave/Mtr 3900 RPM 3900 Turns Open 4000 BHP Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.84 0.89 0.94 1.04 1.13 1.19 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 120 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP 3000 BHP 3000 Sheave/Mtr 3000 RPM 3000 Turns Open 3100 BHP 3100 Sheave/Mtr 3100 RPM Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.54 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.54 0.59 0.64 0.69 0.74 0.84 0.89 0.94 1.04 1.09 1.14 1.19 1.24 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 120 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (SCFM) 4500 4500 4500 4500 4600 4600 4600 4600 4700 4700 4700 ESP BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.49 A 653 5 1.59 A 668 4.5 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 150 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.04 1.14 1.24 1.29 1.34 1.44 1.54 1.64 1.74 1.84 1.94 Sheave/Mtr B B B A A A A A A A A 3800 3800 RPM Turns Open 659 5.5 688 4.5 718 3.5 746 6 774 5 802 4.5 829 4 855 3 879 2.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 150 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 168 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.58 0.68 0.74 0.82 0.88 0.98 1.08 1.18 1.28 1.38 1.48 1.58 1.68 4200 BHP 4200 Sheave/Mtr B B B B A A A A A A A A C 4200 4200 RPM Turns Open 457 6 499 5 537 3.5 577 2.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 192 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.68 0.78 0.88 0.98 1.08 1.18 1.28 1.38 1.48 1.58 1.68 1.78 1.88 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 192 Blower Performance Table Continued from Previous Page All Data is Wet Coil 7600 7600 7600 7600 7800 7800 7800 7800 8000 8000 8000 8000 BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open 1.68 B 515 4 1.78 B 525 4 1.88 B 539 3 1.78 B 549 3 1.88 B 556 2.5 2.08 B 569 2.5 1.88 B 580 2 2.08 B 586 2 2.18 B 601 1.5 2.08 A 611 6 2.18 A 617 5.5 2.28 A 629 5.5 2.26 A 640 5.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 240 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.18 1.28 1.38 1.48 1.68 1.78 1.88 2.08 2.18 2.28 2.38 2.48 2.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 240 Blower Performance Table Continued from Previous Page All Data is Wet Coil 9000 9000 9000 9000 9200 9200 9200 9200 9400 9400 9400 9400 9600 9600 9600 9600 9800 9800 9800 9800 10000 10000 10000 10000 BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open 2.98 A 653 6 3.18 A 668 5.5 3.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 300 Blower Performance All Data is Wet Coil Airflow (SCFM) ESP Airflow (cfm) at External Static Pressure (in. wg) 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 2.08 2.28 2.48 2.58 2.68 2.88 3.08 3.28 3.48 3.68 3.88 Sheave/Mtr B B B B A A A A A A A 7600 7600 RPM Turns Open 659 5.5 688 4.5 718 3.5 746 3 774 6 802 5 829 4.5 855 3.5 879 3 905 2 931 1.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance HKV 300 Blower Performance Table Continued from Previous Page All Data is Wet Coil 10600 10600 10600 10600 10800 10800 10800 10800 11000 11000 11000 11000 11200 11200 11200 11200 11400 11400 11400 11400 11600 11600 11600 11600 11800 11800 11800 11800 12000 BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/Mtr RPM Turns Open BHP Sheave/M
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Unit Commissioning & Operating Conditions Environment – This unit is designed for indoor installation only. Do not install in an area subject to freezing or where humidity levels can cause cabinet condensation. Power Supply ± $ YROWDJH YDULDWLRQ RI RI QDPHSODWH utilization voltage is acceptable.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Piping System Cleaning & Flushing ! 8. When the cleaning process is complete, remove the short-circuited hoses. Reconnect the hoses to the proper supply, and return the connections to each of the units. 5H¿OO WKH V\VWHP DQG EOHHG RII DOO DLU 9. Test the system pH with litmus paper. The system water should be slightly alkaline (pH 7.5-8.5). Add chemicals, as appropriate, to maintain acidity levels.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Unit & System Checkout slag, and strong chemical cleaning agents. Verify all air is purged from the system. Air in the system can cause poor operation or system corrosion. Cooling Tower/Boiler: Check equipment for proper setpoints and operation. Standby Pumps: Verify the standby pump is properly installed and in operating condition. System Controls: Verify system controls function and operate in the proper sequence.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Unit Start Up Procedure ! WARNING! ! WARNING! When the disconnect switch is closed, high voltage is present in some areas of the electrical panel. Exercise caution when working with energized equipment. ! CAUTION! ! INSTALLER CAUTION! After making water connections on units equipped with ClimaDry, ensure the three union nuts on the internal three-way water valve are tight. 1. Turn thermostat fan position to “ON”.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Unit Start Up Procedure Table 7: Coax Water Pressure Drop Model GPM HKV084 CXM Safety Control Reset /RFNRXW ,Q /RFNRXW PRGH WKH 6WDWXV /(' ZLOO EHJLQ IDVW ÀDVKing. The compressor relay is turned off immediately. Lockout mode can be soft reset via the thermostat “Y” input or can be hard reset via the disconnect. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Start-up Sheet Log 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.
HKV SERIES Installation, Operation & Maintenance Heat Controller, LLC Unit Operating Conditions Table 8: Typical Unit Operating Pressures and Temperatures Cooling Entering Water Temp F 30 50 70 90 110 Heating Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop F Air Temp Rise F DB 1.5 60-69 297-321 9-15 6-14 7-10 18-23 2.3 63-72 301-325 9-15 6-14 5-8 19-23 3.
Installation, Operation & Maintenance HKV SERIES Heat Controller, LLC Preventive Maintenance Water Coil Maintenance – Condensate Drain (Direct Ground Water Applications Only) In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically with an algaecide every three months or so to minimize the problem. The condensate pan may also need to be cleaned periodically to assure indoor air quality.
HKV SERIES Installation, Operation & Maintenance Functional Troubleshooting Fault Main power Problems Htg Clg Possible Cause X HP Fault-Code 2 High pressure Solution X Green Status LED Off 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 X Reduced or no water f
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Revision History Date Page # 17 Dec. 13 6, 7 Description Contents Updated Design, material, performance data and components subject to change without notice.
