Installation, operation and maintenance manual HydroBank MS ® Compact, Single Stage Water Source Heat Pumps ½ to 6 Tons – Horizontal and Vertical MAMM-WSHP-IOM-1MSA (October 2014) - PN 7144926
Contents Introduction............................................................................................................................3 Nomenclature........................................................................................................................4 General Information...............................................................................................................6 Horizontal Unit Installation....................................................................
Introduction Introduction This manual provides guidelines for installation, startup, operation and maintenance of Mammoth HydroBank vertical and horizontal water source heat pumps. Installation, startup and operation of this unit must follow accepted industry practices as described in the ASHRAE Handbook, the National Electric Code, and other applicable standards. Operate this equipment in accordance with regulations of authorities having jurisdiction and all applicable codes.
Nomenclature Nomenclature 1 2 3 4 5 6 7 8 9 M S H 1 0 1 9 D L Digits 1-2: Model Type MS = Standard Efficiency 11 E 12 S 13 A 14 C 15 Y 16 1 17 18 0 1 01 = Standard Galvanized XX = Special Digit 16: Filtration Digit 4: Design Series 1 = A Design Digits 5-7: Nominal Capacity 036 = 36,000 006 = 6,000 040 = 40,000 (Vertical Only) 009 = 9,000 042 = 42,000 012 = 12,000 048 = 48,000 015 = 15,000 060 = 60,000 019 = 19,000 070 = 70,000 024 = 24,000 030 = 30,000 Digit 9: Return Air L = Left
Nomenclature 19 20 21 23 23 Y Y Y Y Y 24 25 26 Y M V 27 Y 28 29 0 1 30 31 32 33 34 35 36 37 38 39 40 41 H G B W S E C M R Y Y Y 42 S 43 44 1 B Digit 44: Build Type Digits 19-21: Heating Option YYY = None (standard) XXX = Special A = Stock finish good B = Configured to order C = Special build Digits 22-23: Reserved - Future Digit 43: Warranty YY = None (standard) 1 = 1 Yr Delayed Startup Ext Warranty 2 = 2nd Yr Refrig Circuit Parts 3 = 2nd Yr Complete Unit Parts 4 = 2-5 Yr Compress
General Information General Information Receiving Inspection Unit Protection When receiving equipment, check the Bill of Lading to verify that all crates and cartons have been received. Compare shipped-loose items received against the list provided. Check for damage. Claims for loss or damage must be made with the carrier. Keep units covered during construction to protect components from dust and other harmful material. Cap the ends of all open pipes.
Horizontal Unit Installation Horizontal Unit Installation Unit Location Do not locate units above noise-sensitive areas such as offices, meeting rooms, and classrooms. If possible, avoid locations above areas where there is considerable traffic as service time may be limited during occupied hours. Placing units above hallways is a typical location in schools to avoid potential noise problems, with supply and return air ducted to adjacent classrooms.
Horizontal Unit Installation Repositioning Mounting Brackets Horizontal unit mounting brackets can be repositioned from the end to the side of the unit as needed to accommodate installation requirements, as follows. 14. Rotate the assembly 180 degrees and turn it 90 degrees, as shown in Figure 4. 1. Raise and support the corner of the unit to provide access to the mounting bracket. 2. Carefully pry the rubber isolator out of the bracket. 3.
Horizontal Unit Installation No heat pump should be connected to the supply and return piping until the water system has been cleaned and flushed completely. See”Cleaning and Flushing the Water System” on page 23. Check for proper water balance by measuring the differential temperature reading across the water connections. To ensure proper water flow, it should be between 10°F and 14°F for heat pumps in the cooling mode.
Vertical Unit Installation Vertical Unit Installation Figure 7: Suggested Vertical Unit Clearances Location Vertical units are typically installed in a small mechanical room or closet, with discharge ductwork routed overhead into the conditioned space. See Figure 8. Return air may be ducted or non-ducted. If non-ducted, provision must be made for return air to freely enter the mechanical room. This is often accomplished by using a louvered door at the entrance.
Vertical Unit Installation The piping may be steel, copper, or PVC. Avoid dissimilar metal fittings as they may corrode. If the use of dissimilar metals is unavoidable, use dielectric isolation at that connection point. Supply and return run-outs usually join the heat pump via short lengths of high-pressure flexible hose which are sound attenuators for both heat pump operating noise and hydraulic pumping noise. One end of the hose should have a swivel fitting to facilitate removal for service.
Discharge Duct Sizing Considerations The return air may be ducted or non-ducted. If it is nonducted, provisions must be made for return air to freely enter the space, through a louvered door for example. A sound baffle may be needed on the door to attentuate noise from the unit. For non-ducted applications, a clearance in front of the unit of at least 12” is suggested to provide even air distribution across the air coil.
Ventilation Air Considerations Ventilation Air Considerations Outside air may be required for ventilation. Refer to local codes. The temperature of the ventilation air must be controlled so that the mixture of outside air and return air entering the unit is within application limits. It is recommended that the ventilation air inlet be closed during unoccupied periods (i.e. night setback). The ventilation air system is typically a separate building subsystem with its own distribution ductwork.
Optional Water Side Economizer Piping and Control Optional Water Side Economizer Piping and Control The waterside economizer option (WSE) allows precooling of the entering air to take advantage of cool loop fluid and to reduce compressor operation during cool weather. Water lines and condensate drain lines are attached to the unit as shown in Figure 16. All water lines and valves should be insulated to prevent condensation.
Hot Gas Bypass Option Hot Gas Bypass Option Hot gas bypass prevents frosting of the evaporator coil during low-load conditions by keeping the compressor more fully-loaded. Hot, high-pressure refrigerant gas is diverted to the low-pressure suction side to help stabilize the system balance point. This option includes a hot gas bypass valve.
Motorized Shutoff Valve Option Motorized Shutoff Valve Option The motorized valve option is typically used in systems that employ VFDs on the condenser water pumps. When the space temperature set point is satisfied, the unit shuts down and the valve closes. Pump power is thus greatly reduced at reduced flows, resulting in significant energy savings. The motorized valve shuts off the water flow through the unit when the compressor is off.
HP-5 Microprocessor Control RANDOM START: A 5 to 35 second time delay of fan, reversing valve and compressor operation will occur each time the unit comes off shutdown mode, unoccupied mode and low/high voltage mode. The random start time varies each time it is activated; for example, the time delay may be 5 seconds, then 12, then 30, then 17, then 32, then 6, etc. Note: The following descriptions assume Initial Powerup and Random Start functions have occurred.
HP-5 Microprocessor Control call for mechanical heating or cooling. Intelligent reset automatically terminates the lockout mode 5 minutes after a lockout condition occurs. The purpose of intelligent reset is to allow the unit to attempt to reset itself if the condition that caused the original lockout corrects itself. After 3 attempts in a 6000 second (100 minute) period after the first lockout, the intelligent reset feature is terminated and the unit stays in lockout until the unit is manually reset.
Thermostat Wiring Thermostat Wiring The HP-5 microprocessor control is designed to operate with wall thermostats sold by Mammoth. It can be used with other heat pump thermostats but some features may not be available. Wiring from the thermostat is routed through an electrical knockout in the front of the unit. See Figure 12 and Figure 13 on page 13. A removable terminal block simplifies hookup. See Figure 20. To remove it, gently pull it straight out from the control board.
Thermostat Wiring Figure 22: Thermostat Wiring With Override and Night Setback Figure 23: Thermostat Wiring - Emergency Shutdown Mode With Override 20 HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014)
Thermostat Wiring Figure 24: Thermostat Wiring - Emergency Shutdown Mode Without Override HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014) 21
EPiC™ DDC Controls EPiC™ DDC Controls As an option, Mammoth offers factory-programmed and unit-mounted EPiC DDC controllers for precise unit operation. They are factory programmed per the application, and have a 16-bit processor with 1MB Flash RAM and 4MB of battery-backed RAM. The control programs, hand-held human-machine interface (HMI) files and editable set-points are stored on Flash RAM at the time of download or upon manual archive initiation.
Cleaning and Flushing the Water System Cleaning and Flushing the Water System Before water is connected to any units, the water system must be flushed clean of particulate contaminants. Supply and return hoses to each unit should be connected together during this process to ensure the entire system is properly flushed. Follow the procedures described in this section. IMPORTANT: Performance of WSHP units relies upon a loop water supply filtered of any particulate and chemical contaminants.
Startup Startup Prior to Startup Before unit startup, please check the following. Switch off the main power to the unit before beginning. 6. In the heating mode, measure the temperature difference between entering and leaving air and entering and leaving water. WARNING! Electric shock and moving equipment hazard. Can cause severe injury or death. Lock and tag out all electric power before carrying out this procedure. More than one disconnect may be required to deenergize the unit.
General Maintenance General Maintenance Normal maintenance on any HydroBank MS unit includes but may not be limited to the following. an alarm status and the unit will shut down. The alarm must be cleared before the switch will reset. Air filter changes Condensate drain Air filters must be replaced a minimum of two times per year. A good standard to follow is at the beginning of the cooling season and the beginning of the heating season.
Troubleshooting Troubleshooting Charts in this section provide general guidelines for troubleshooting problems with your unit. For additional help, contact your local Mammoth representative. For assistance locating your Mammoth representative, visit www.mammoth-inc.com.
Physical Data and Operating Limits Physical Data and Operating Limits Table 6: Physical Data: Horizontal Units Unit Size 006 009 Compressor Type (Qty 1) 012 015 019 024 030 Rotary 036 042 048 060 Reciprocating Max Water Working Pressure 070 Scroll 400 PSIG (2758 kPa) Blower Motor Type/Speeds PSC/3 PSC Motor HP PSC/3 or ECM/5 Consult Factory ECM Motor HP 1/5 1/5 1/3 1/3 1/2 1/2 1/2 3/4 3/4 NA 1/3 1/3 1/3 1/2 1/2 1/2 3/4 1 1 Consult Factory 9x6 9x6 9x7 10 x 7 1
Operating Pressures and Temperatures Operating Pressures and Temperatures MS Unit Operating Pressures and Temperatures (Horizontal Models) Table 9: Operating Pressures and Temperatures - Horizontal Unit Sizes 015, 019, 024 Full Load Cooling Horizontal 015 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 2.8 30 Out of Range 4.0 4.8 2.
Operating Pressures and Temperatures Table 10: Operating Pressures and Temperatures - Horizontal Unit Sizes 030, 036, 042 Full Load Cooling Horizontal 030 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 4.9 30 Out of Range 7.0 8.4 4.
Operating Pressures and Temperatures Table 11: Operating Pressures and Temperatures - Horizontal Unit Sizes 048, 060, 070 Full Load Cooling Horizontal 048 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 8.4 30 Out of Range 12.0 14.4 8.
Operating Pressures and Temperatures MS Unit Operating Pressures and Temperatures (Vertical Models) Table 12: Operating Pressures and Temperatures - Vertical Unit Sizes 015, 019, 024 Full Load Cooling Vertical 015 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 2.8 30 Out of Range 4.0 4.8 2.
Operating Pressures and Temperatures Table 13: Operating Pressures and Temperatures - Vertical Unit Sizes 030, 036, 042 Full Load Cooling Vertical 030 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 4.9 30 Out of Range 7.0 8.4 4.
Operating Pressures and Temperatures Table 14: Operating Pressures and Temperatures - Vertical Unit Sizes 048, 060, 070 Full Load Cooling Vertical 048 Entering Water Water Temp Flow GPM °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating Water Temp Air DB Drop Rise °F °F 8.4 30 Out of Range 12.0 14.4 8.
Electrical Data Electrical Data Figure 28: Electrical - Horizontal Units, StandardPSC PSCBlower Blower Motor Electrical Data - Data Horizontal Units, Standard Motor Unit Size 006 009 012 015 019 024 030 036 042 048 060 070 34 Voltage Code Rated Voltage A 115-1-60 D 208/230-1-60 E 265/277-1-60 A 115-1-60 D 208/230-1-60 E 265/277-1-60 A 115-1-60 D 208/230-1-60 E 265/277-1-60 Compressor RLA LRA Blower Motor FLA Blower Motor HP Total Unit Min Circuit FLA Amps Min.
Electrical Data Figure 29: Electrical - Horizontal Units, ConstantTorque Torque ECM Motor Electrical Data - Data Horizontal Units, Constant ECMBlower Blower Motor Unit Size 015 019 024 030 036 042 048 060 070 Voltage Code Rated Voltage Compressor RLA LRA Blower Motor FLA Blower Motor HP Total Unit Min Circuit FLA Amps Min. Fuse Max. Fuse D 208/230-1-60 5.4 29 3.5 1/2 8.9 10.3 15 20 E 265/277-1-60 5.0 28 3.2 1/2 8.2 9.5 15 20 D 208/230-1-60 7.3 43 3.5 1/2 10.8 12.
Electrical Data Figure 30: Electrical - Vertical Units, Standard PSCBlower Blower Motor Electrical Data - Data Vertical Units, Standard PSC Motor Unit Size 006 009 012 015 019 024 030 036 040 042 048 060 070 36 Voltage Code Rated Voltage A 115-1-60 D 208/230-1-60 E 265/277-1-60 A 115-1-60 D 208/230-1-60 E 265/277-1-60 A 115-1-60 D 208/230-1-60 E 265/277-1-60 Compressor RLA LRA Blower Motor FLA Blower Motor HP Total Unit Min Circuit FLA Amps Min. Fuse Max.
Electrical Data Figure 31: Electrical - Vertical Units, ConstantTorque Torque ECM ECM Blower Motor Electrical Data - Data Vertical Units, Constant Blower Motor Unit Size 015 019 024 030 036 040 042 048 060 070 Voltage Code Rated Voltage Compressor RLA LRA Blower Motor FLA Blower Motor HP Total Unit Min Circuit FLA Amps Min. Fuse Max. Fuse D 208/230-1-60 5.4 29 3.5 1/2 8.9 10.3 15 20 E 265/277-1-60 5.0 28 3.2 1/2 8.2 9.5 15 20 D 208/230-1-60 7.3 43 3.5 1/2 10.
Blower Performance Tables Blower Performance Tables Figure 32: Blower Performance, Standard PSC PSC Blower Motor Blower Performance - Standard Blower Motor Unit Size Fan Speed Rated Airflow Airflow (cfm) at Listed External Static Pressure (inches of water column) 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.
Blower Performance Tables Blower - Constant-Torque ECM Motor Figure 33: Performance Blower Performance Data, Constant Torque ECMBlower Blower Motor Unit Rated Tap # Size Airflow 015 019 024 030 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.
Typical Wiring Diagrams Typical Wiring Diagrams Wiring Diagram - PSC Motor, Single-Phase 208-230 or 277V/1PH/60H 40 HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014)
Typical Wiring Diagrams Wiring Diagram - PSC Motor , Three-Phase 208-230 or 460V/3PH/60H HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014) 41
Typical Wiring Diagrams Wiring Diagram - Constant-Torque ECM Motor, Single-Phase 208-230V/1PH/60H 42 HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014)
Typical Wiring Diagrams Wiring Diagram - Constant-Torque ECM Motor, Single-Phase 277V/1PH/60H HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014) 43
Typical Wiring Diagrams Wiring Diagram - Constant-Torque ECM Motor, Three-Phase 208-230V/1PH/60H 44 HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014)
Typical Wiring Diagrams Wiring Diagram - Constant-Torque ECM Motor, Three-Phase 460V/1PH/60H HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014) 45
Typical Wiring Diagrams Wiring Wiring Diagram - EPiC DDC 560 Controller 46 HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014)
Typical Wiring Diagrams Diagram - EPiC DDC 583 Controller with Analog Outputs HydroBank MS Installation and Operation Manual MAMM-WSHP-IOM-1MSA (October 2014) 47
Unit Checkout Sheet Unit Checkout Sheet WSHP UNIT CHECK-OUT SHEET Customer Data Customer Name ____________________________ Date _____________________________________________ Address _____________________________________________________________________________________ Phone ____________________________________ Unit Number ________________________________________ Unit Nameplate Data Make _________________ Model Number ________________ Serial Number ____________________________ Compressor: RLA _________
CES Group has a policy of continuous product improvement and reserves the right to change design and specifications without notice. CES Group is a leader in innovative custom and engineered HVAC solutions for commercial, industrial and critical environments through our brands Eaton-Williams, Governair, Huntair, Mammoth, Temtrol, Venmar CES and Ventrol. CES Group, LLC is a subsidiary of Nortek, Inc.
