Geothermal Installation Manual. Geothermal Installation. Manual

Transcription

1 Geothermal Installation Geothermal Installation Manual Manual Water To Water Water To Water January 2013 January Document 2012 Revision 1 Document Revision 1

2 January 2013 ii Spectrum Manufacturing LLC

3 Table of Contents Table of Contents iii Getting Started with the Unit 1 Safety Considerations 3 Electrical 5 January 2013 iii Spectrum Manufacturing LLC

4 Table Of Contents Condensate Drain Setup 16 Duct Work 17 System Piping 21 Importance of Water Quality 26 Desuperheater Installation 28 Smart Relay Features and Functions 30 January 2013 iv Spectrum Manufacturing LLC

5 Table Of Contents Safety Guidelines and Functions 34 Maintenance Requirements 38 Troubleshooting Tips 39 Unit Components 44 January 2013 v Spectrum Manufacturing LLC

6 Table Of Contents Unit Checkout Sheet 50 Strip Heat 51 Heating and Cooling Refrigeration 56 January 2013 vi Spectrum Manufacturing LLC

7 Getting Started with the Unit Initial Inspection Moving and Storage January Spectrum Manufacturing LLC

8 Getting Started With The Unit Model Configuration Nomenclature Tag Type Tag Capacity Tag Configuration WA Water to Air Ton U Up-flow WW Water to Water Ton D Down-flow HFC Hydronic Fan Coil Ton H Horizontal DXFC DX Fan Coil Ton S Split Ton D Domestic HWG Tag Return Air Tag Voltage Tag Desuperheater L Left 1 Single Phase 1 Yes R Right 3 Three Phase 0 No Tag Heat Exchanger Tag Backup Heat Element Tag Warranty C Copper 0 None Year N CuproNickel 1 5 KW 5 5 Year CD Copper Double Wall 2 10 KW ND CuproNickel Double Wall 3 15 KW 4 20 KW January Spectrum Manufacturing LLC

9 Safety Considerations Pre-Installation Location January Spectrum Manufacturing LLC

10 Safety Considerations Equipment Installation January Spectrum Manufacturing LLC

11 Electrical Loop Pumping Flow Centers Electrical Model Voltage Compressor DHW Pump FLA External Loop Pump Total Unit FLA Min Circuit Ampacity (MCA) Max Fuse Min AWG RLA LRA QTY FLA Total WW-024 WW-036 WW-048 WW-060 WW /1 Ø 240/1 Ø 240/1 Ø 240/1 Ø 240/1 Ø Water to Water Electrical Data January Spectrum Manufacturing LLC

12 Electrical Model Voltage Fan Blower Total Unit FLA Min. Circuit Ampacity (MCA) Min. Breaker Size Min AWG FLA HP HFC-024 HFC-036 HFC-048 HFC-060 HFC /1 Ø 240/1 Ø 240/1 Ø 240/1 Ø 240/1 Ø 2.3 1/ / / / Hydronic Fan Coil Electrical Data January Spectrum Manufacturing LLC

13 Electrical Legend WW HFCH HFCV Water to Water Hydronic Fan Coil Horizontal Hydronic Fan Coil Vertical Model Weight (lbs.) Shipping Weight Shipping Dimensions Refrigerant Charge WW 024 WW 036 WW048 WW 060 WW Lbs 6 Oz HFCH 024 HFCH 036 HFCH 048 HFCH 060 HFCH 072 HFCV 024 HFCV 036 HFCV 048 HFCV 060 HFCV 072 Unit Weights/Refrigerant Charge January Spectrum Manufacturing LLC

14 Electrical Wiring Diagram Ladder January Spectrum Manufacturing LLC

15 Electrical Wiring Diagram Pictorial January Spectrum Manufacturing LLC

16 Electrical Wiring Diagram Ladder Air Handler January Spectrum Manufacturing LLC

17 Electrical Wiring Diagram Pictorial Air Handler January Spectrum Manufacturing LLC

18 Electrical SelecTech Motor Connections January Spectrum Manufacturing LLC

19 Electrical Control Connections Wall Stat Connections 24V G Y1 Y2 O AUX Com L Function 24 Volt Fan Circulate Speed Fan Med-High Speed Fan High Speed Reversing Valve (default is energized in Cooling) Auxiliary Heat Common Fault Light Wall Thermostat Connections Aqua Stat Connections 24V Y1 Y2 C NC NO Aqua Stat Connections Function 24 Volt Compressor Operation Compressor Second Stage Common Normally Closed-Energized in Heating Normally Open- Energized in Cooling Note: The Normally Open And Normally Closed terminals are to be used with a Heating and Cooling Aqua Stats or Controller, to avoid Overheating or Freezing the Tank. January Spectrum Manufacturing LLC

20 Electrical Air Handler Connections 240 Volt Fan Breaker Motor Opt. Load Pump GND Air Handler Connections From 24Volt Pan Aux EMH Fan 1 Fan 2 Fan 3 COM GND Air Handler Connections Function Line Voltage From Building Panel Fan Blower Motor Optional Pump Output For Pumping Water To the Air Handler Ground Function Condensate Pan Level Switch Auxiliary Heat Emergency Heat Fan Speed Low Fan Speed Med/High (or where the installer prefers) Fan Speed High (or where the installer prefers Common Ground January Spectrum Manufacturing LLC

21 Electrical January Spectrum Manufacturing LLC

22 Condensate Drain Setup January Spectrum Manufacturing LLC

23 Duct Work Design Requirements Flex Duct Building Cavities and Ducts Static Losses January Spectrum Manufacturing LLC

24 Duct Work Maximum Velocities Location Main Ducts Branch Ducts Supply Outlet Face Velocity Return Grill Face Velocity Filter Grill Face Velocity Supply 900 FPM 600 FPM 700 FPM 500 FPM 300 FPM Maximum Air Velocities Duct Connections Zonal Pressure Relief January Spectrum Manufacturing LLC

25 Duct Work Duct Installation Insulation Air Tightness January Spectrum Manufacturing LLC

26 Duct Work System Air Flow January Spectrum Manufacturing LLC

27 System Piping Open Loop Systems (Ground Water) January Spectrum Manufacturing LLC

28 System Piping January Spectrum Manufacturing LLC

29 System Piping Closed Loop Systems (Ground Loop) January Spectrum Manufacturing LLC

30 System Piping Pressurized Flow Center Installation Non-Pressurized Flow Center Installation January Spectrum Manufacturing LLC

31 System Piping January Spectrum Manufacturing LLC

32 Importance of Water Quality Antifreeze Overview January Spectrum Manufacturing LLC

33 Importance of Water Quality Antifreeze Characteristics Antifreeze Charging January Spectrum Manufacturing LLC

34 Desuperheater Installation Desuperheater Package January Spectrum Manufacturing LLC

35 Desuperheater Installation Desuperheater Piping January Spectrum Manufacturing LLC

36 Smart Relay Features and Functions Sequence of Operations January Spectrum Manufacturing LLC

37 Smart Relay Features and Functions January Spectrum Manufacturing LLC

38 Smart Relay Features and Functions Unit Checkout Sheet Short Cycle Protection January Spectrum Manufacturing LLC

39 Smart Relay Features and Functions Component Delays Manual (24 Volt Disconnect Switch Inside Panel) Electronic Condensate Overflow Protection January Spectrum Manufacturing LLC

40 Safety Guidelines and Functions High Pressure Low Pressure January Spectrum Manufacturing LLC

41 Safety Guidelines and Functions Flow Switch Condensate Overflow Fault Retry Mode Soft Reset January Spectrum Manufacturing LLC

42 Safety Guidelines and Functions Hard Lockout System Checkout Unit Startup January Spectrum Manufacturing LLC

43 Safety Guidelines and Functions January Spectrum Manufacturing LLC

44 Maintenance Requirements Annual Maintenance Lockouts January Spectrum Manufacturing LLC

45 Troubleshooting Tips Troubleshooting Problem/Issue Possible Cause Actions and Corrections Entire unit will not run. Power supply is off Circuit breaker Apply power and close disconnect. reset circuit breaker. Voltage supply low If voltage is below minimum voltage specified on unit data plate, contact local power company. Thermostat/Aquastat Set the fan to On. The fan should run. Set thermostat to Cool and lowest temperature setting, the unit should run in the cooling mode. Set unit to Heat and the highest temperature setting, the unit should run in the heating mode. If neither the blower nor compressor run in all three cases, the thermostat or Aquastat could be wired incorrectly or faulty. To ensure correct wiring or faulty Aquastat, verify 24 volts is available on the low voltage terminal strip in the compressor section between "R" and "C", "Y" and "C", and, if in cooling mode, "O" and "C". When utilizing an air handler, and the blower does not operate, verify 24 volts between terminals "G" and "C". Replace the thermostat if defective. January Spectrum Manufacturing LLC

46 Troubleshooting Tips Problem/Issue Possible Cause Actions and Corrections Compressor does not run. Wiring Check for loose or broken wires at compressor, capacitor, or contactor. PLC reads High Pressure Check Unit Or HARD LOCKOUT HI PRESSURE Safety controls Capacitor Compressor overload open Compressor motor grounded Compressor windings open Discharge pressure too high Check Smart Relay screen for faults. Check capacitor and replace if defective. If the compressor has cooled down and the overload will not reset, replace compressor. Internal winding grounded to the compressor shell. Replace compressor. If compressor burnout has occurred, install suction filter dryer. After compressor has cooled, check continuity of the compressor windings. If the windings are open, replace the compressor. In Cooling mode, check: Lack of or inadequate water flow Entering water temperature too warm Scaled or plugged condenser In Heating mode check: Lack of or inadequate air flow Blower is inoperative, clogged filter or restrictions in ductwork Refrigerant charge High pressure The unit is overcharged with refrigerant. Reclaim refrigerant, evacuate and recharge with factory recommended charge. Check for defective or improperly calibrated high pressure switch. January Spectrum Manufacturing LLC

47 Troubleshooting Tips Problem/Issue Possible Cause Actions and Corrections PLC reads: Low Pressure Check Unit, or HARD LOCKOUT LOW PSI. Suction pressure too low In Cooling mode, check: Lack of or inadequate air flow Entering water temperature too cold Blower is inoperative, clogged filter or restrictions in ductwork In Heating mode check: Lack of or inadequate water flow Entering water temperature too cold Scaled or plugged condenser Check refrigerant charge. Always charge to nameplate. Refrigerant charge Low pressure switch TXV Bulb may be defective/severed, TXV valve stuck shut, or moisture in the refrigerant system The unit is low on refrigerant. Check for refrigerant leaks. Repair, evacuate and recharge with factory recommended charge. Check for defective low pressure switch. TXV bulb and TXV control diaphragm can be replaced after removing the charge, replacing the control device and bulb, and properly recharging the unit to nameplate value. Unit Short Cycles Unit oversized Adjust deadband on aquastats Wiring and controls Loose connections in the wiring or a defective compressor contactor. Insufficient cooling Unit undersized Recalculate heating and or cooling loads. January Spectrum Manufacturing LLC

48 Troubleshooting Tips Problem/Issue Possible Cause Actions and Corrections Insufficient heating Loss of conditioned air by leaks Check for leaks in duct work or look for entering ambient air through doors or windows. Airflow Refrigerant charge Compressor Reversing valve Operating pressures TXV Moisture, noncondensables Lack of adequate air flow or improper distribution of air. Replace dirty filter. Low on refrigerant charge causing poor operation. Check for defective compressor. If discharge is too low and suction pressure is too high, compressor is not pumping properly. Replace compressor. Defective reversing valve creates a bypass of refrigerant from discharge to suction side of compressor. Replace reversing valve. Compare unit operating pressures to a pressure/ temperature chart for the refrigerant used. Check TXV for restriction or defect. Replace if necessary. The refrigerant system may be contaminated with moisture or noncondensables. Reclaim refrigerant, evacuate and recharge with factory recommended charge. NOTE: A liquid line dryer may be required. PLC Reads: HARD LOCKOUT FLOW SWITCH PLC Reads: HARD LOCKOUT PAN LEVEL PLC Reads: HARD LOCKOUT CURRENT SENS Troubleshooting Tips Loss of conditioned air by leaks Inadequate or no water flow Pan level switch Current sensor Check for leaks in duct work or entering ambient air through doors or windows. Check for water flow. Check flow switch by temporarily bypassing it. Make sure all air is purged from lines. Make sure flow center is purged and functional. Check for proper flow direction. Check condensate drain for blockage. Make sure condensate drain is properly installed. Check Pan level switch by temporarily bypassing it. Make sure unit is on a level surface. Refer to compressor does not run. Check current sensor by temporarily bypassing it. January Spectrum Manufacturing LLC

49 Troubleshooting Tips January Spectrum Manufacturing LLC

50 Unit Components Compressor (Copeland) Flow Switch High Pressure Switch Low Pressure Switch Low Voltage Breaker High Voltage Breakers January Spectrum Manufacturing LLC

51 Unit Components Master Contactor Reversing Valve Smart Relay Terminals Transformer Remote Fan Coil Components Pump Relay January Spectrum Manufacturing LLC

52 Unit Components High Voltage Breaker Blower Motor (Selectech) Electric Heater Terminals January Spectrum Manufacturing LLC

53 Unit Components Unit Dimensions January Spectrum Manufacturing LLC

54 Unit Components January Spectrum Manufacturing LLC

55 Unit Components January Spectrum Manufacturing LLC

56 Unit Checkout Sheet Customer Data Name: Address: Date: Phone: Make: Model: Serial #: Refrigerant Charge (OZ): Compressor RLA: Compressor LRA: Blower FLA/HP: Maximum Fuse Size (A): Maximum Circuit Ampacity (A): Operating Conditions Cooling Mode Heating Mode EAT/LAT / / EWT/LWT / / January Spectrum Manufacturing LLC

57 Strip Heat Model KW Amps Min. CFM KS KS SCCR 10 KA 250V MAX. 10KA 250V MAX. Min. Supply Ampacity Max Overcurrent Protection Multi-Feed Single Feed 30 N/A 30 A 50 N/A 50 A KS KA 250V MAX. 80 #1 30 A #2 50 A 80 A KS KA 250V MAX. 100 #1 30 A #2 50 A 100 A 240 Volts Single Phase Note: When using multi-feed, metal jumpers in the screw connection terminals must be removed January Spectrum Manufacturing LLC

58 Strip Heat January Spectrum Manufacturing LLC

59 Strip Heat January Spectrum Manufacturing LLC

60 Strip Heat January Spectrum Manufacturing LLC

61 Strip Heat January Spectrum Manufacturing LLC

62 Heating and Cooling Refrigeration When the Compressor (1) is energized, it starts to pump refrigerant through the system. Because of the compressor increasing the pressure of the refrigerant, it therefore increases the temperature and has compressed it into a high pressure HOT vapor, (Superheated Gas) Then, in systems equipped with a Desuperheater (2), (hot water generator) the high pressure vapor will go through and release some of its superheat into the home's Potable Water. The hot vapor then goes to the Reversing valve (3). In the Heating Cycle, the reversing valve will direct the hot vapor to a Water to Refrigerant Heat Exchanger (4) (Condenser), where it will be condensed to a liquid. This Heat Exchanger is typically connected to an insulated storage tank inside the home. As it travels through the Heat Exchanger, the hot vapor will release its stored heat into the Water from the storage tank. This is considered condensing, (the action of changing a vapor or gas, to a liquid). At the end point of the Water to Refrigerant Heat Exchanger (Condenser), the refrigerant is a high pressure sub-cooled liquid. Sub-cooling is the cooling of liquid refrigerant below its condensing temperature. The high pressure liquid then enters the Expansion Valve (5). This device reduces the pressure from the high side to the low side in a refrigeration system. This is accomplished by metering the liquid refrigerant into the evaporator coil. This rapid decrease in pressure lowers the temperature of the refrigerant considerably. In the Heating Cycle of a, the Evaporator (6) is also a water to refrigerant heat exchanger. This Heat Exchanger is typically connected to a ground loop. The refrigerant at the start point of the evaporator is in a low pressure, cold, vapor and liquid mixture. As it travels through the evaporator (water to refrigerant heat exchanger) it begins to collect heat from the ground water that is also traveling through the coil. As the refrigerant absorbs heat, it will start to vaporize (changing from a liquid to a gaseous state). When it has left the evaporator, the refrigerant is a 100% saturated vapor. At this point, it will enter the compressor to begin the cycle again. January Spectrum Manufacturing LLC

63 Heating and Cooling Refrigeration When the Compressor (1) is energized, it starts to pump refrigerant through the system. Because of the compressor increasing the pressure of the refrigerant, it therefore increases the temperature and has compressed it into a high pressure HOT vapor, (Superheated Gas). Then, in systems equipped with a Desuperheater (2), (hot water generator) the high pressure vapor will go through and release some of its superheat into the home's Potable Water. The hot vapor then goes to the Reversing Valve (3). In the Cooling Cycle, the reversing valve directs the hot vapor to the Water to Refrigerant Heat Exchanger (4) (Condenser) that is connected to the ground water, where it will be condensed to a liquid. As it travels through the Heat Exchanger, the hot vapor will release its stored heat into the Water from the ground. This is considered condensing, (the action of changing a vapor or gas, to a liquid). At the end point of the Water To Refrigerant Heat Exchanger (Condenser) the refrigerant is a high pressure sub-cooled liquid. Sub-cooling is the cooling of liquid refrigerant below its condensing temperature. The high pressure liquid then enters the Expansion Valve (5). This device reduces the pressure from the high side to the low side in a refrigeration system, by metering the liquid refrigerant into the evaporator coil. This rapid decrease in pressure lowers the temperature of the refrigerant considerably. In the Cooling Cycle of a, the Evaporator (6) is also a Water To Refrigerant Heat Exchanger. Because we have directed the HOT vapor to the Ground Water Heat Exchanger for the condensing cycle, the storage tank in the home is now connected to the Evaporator Coil (also a Water to Refrigerant Heat Exchanger). The refrigerant at the start point of the evaporator is in a low pressure, cold, vapor and liquid mixture. As it travels through the evaporator (water to refrigerant heat exchanger) it begins to collect heat from the water that has come from storage tank. As the refrigerant absorbs heat it will start to vaporize (changing from a liquid to a gaseous state). When it has left the evaporator, the refrigerant is a 100% saturated vapor. At this point it will enter the compressor to begin the cycle again. January Spectrum Manufacturing LLC

64 Heating and Cooling Refrigeration January Spectrum Manufacturing LLC