Heat Controller HKV Installation, Operation & Mainenance Manual
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Heat Controller HKV Installation, Operation & Mainenance Manual

Heat Controller HKV Installation, Operation & Mainenance Manual

Commercial vertical packaged heat pump: hkv large commercial
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Installation, Operation
& Mainenance Manual
Commercial Vertical
Packaged Heat Pump:
HKV Large Commercial
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

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  • Page 1 Installation, Operation & Mainenance Manual Commercial Vertical Packaged Heat Pump: HKV Large Commercial Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com...

  • Page 2: Table Of Contents

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. TABLE OF CONTENTS Model Nomenclature ............ 2 Tensioning V-Belt Drives..........19 Physical Data..............3 Blower Sheave Information ........20 Dimensional Data ............4-5 Blower Performance Tables ........21-34 General Information ............6 Unit Commissioning &...

  • Page 3: Model Nomenclature

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions 6 0 - 9 0 ° F ( 1 5 . 5 - 3 5 ° C ) • Cabinetry - Galvanized steel construction - blower access panel - control box access panel - compressor access panel - FPT water connections, FPT condensate connections, hi and low voltage knockouts - 1”...

  • Page 4: Physical Data

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. HKV Physical Data Model Compressor Quantity Scroll (1) Scroll (2) Factory Charge R410a (oz) [kg] per 140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03] 140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03]...

  • Page 5: Dimensional Data

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions HKV084-150 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA SHOWN BELOW. (RR/FD) AIR OUT AIR OUT RETURN AIR RETURN AIR Control Box CAP+MSP Control Box CSP+CAP+MSP FRONT RETURN TOP DISCHARGE REAR RETURN TOP DISCHARGE NOTES FOR LEGEND: 1.

  • Page 6: Dimensional Data

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. HKV168-300 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA SHOWN BELOW. (RR/FD) AIR OUT AIR OUT AIR OUT AIR OUT RETURN AIR RETURN AIR RETURN AIR RETURN AIR Control Box Control Box...

  • Page 7: General Information

    Installation, Operation, and Maintenance instructions compressor oil, the refrigerant lines of the compressor must are provided with each unit. HKV units are typically be sealed after it is removed. installed in a floor level closet or in a mechanical room.

  • Page 8: Vertical Unit Installation

    Valve Vertical Location and Access Duct System Design & Installation Guidelines HKV units are not designed for outdoor installation. The following application guidelines must be used when Locate the unit in an indoor area that allows enough installing HKV units. Failure to follow these guidelines...
  • Page 9 • replacement unit. Also inspect for and repair all air Do not use HKV units for 100% outdoor air treatment. leaks in existing ducts. Do not add hot-gas-bypass to “convert” a unit for •...

  • Page 10: Piping Installation

    Tighten steel fittings as necessary. Table 1: Metal Hose Minimum Bend Radii Optional pressure-rated hose assemblies designed specifically for use with Heat Controller units are available. Hoses in Inches Minimum Bend Radius Similar hoses can be obtained from alternate suppliers.

  • Page 11: Condensate Installation

    IS INSTALLED IN THE DRAIN LINE, IT MUST BE LOCATED AFTER THE TRAP IN THE DIRECTION OF THE CONDENSATE FLOW and opening 46” (117 cm) Figure 3 illustrates a typical trap and vent used with HKV minimum from bottom of unit. (Vent per code) series equipment.

  • Page 12: Water-Loop Heat Pump Applications

    Hose kits are available from Heat Controller in different configurations as shown in Figure 4 for connection between the HKV Series and the piping system. The piping system should be flushed to remove dirt, piping chips, and other foreign material prior to operation.

  • Page 13: Electrical Data

    To avoid possible injury or death due to electrical shock, wiring. Unit terminals are not designed to accept other open the power supply disconnect switch and secure it in an types of conductors. open position during installation. Table 4A: HKV Electrical Data Standard Compressor Total Voltage Min/Max...

  • Page 14: Electrical - Power Wiring

    General Line Voltage Wiring Figure 6: Typical HKV Series Line Voltage Be sure the available power is the same voltage and phase Field Wiring as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

  • Page 15: Electrical - Low Voltage

    Figure 8: FP1 Jumper closing valve may be required to prevent water hammer. When using an AVM -Taco Slow Closing valve on HKV Series equipment Figure 10 wiring should be utilized. The valve takes approximately 60 seconds to open (very little...

  • Page 16: Cxm Control Operation

    Electrical - Thermostat Typical Thermostat Selection and Wiring Practically any multi-stage contact type thermostat will work with the HKV Series. Figure 11 shows typical thermostat wiring. Thermostats with Triac outputs are not compatible with CXM boards. Figure 11: Typical Manual Changeover 2 heat/...

  • Page 17: Wiring Schematics

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions HKV084-150 with CXM Schematic...
  • Page 18 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. HKV168-300 with CXM Schematic...

  • Page 19: Blower Adjustment

    (1.33 l/s). Sheave setting for ARI is Selection Adjustment 3.5 turns open. The HKV Series is available with standard, low, and high Note 2: All HKV096 ratings @ 3200CFM (1510 l/s) static options. These options will substitute a different w/24GPM (1.51 l/s).

  • Page 20: Tensioning V-Belt Drives

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Tensioning V-Belt Drives General rules of tensioning 1. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions. 2. Check tension frequently during the first 24-48 hours of operation.

  • Page 21: Blower Sheave Information

    7.5HP Belt BX80 BX80 BX78 BX80 BX78 Note 1: D-drive is not available because standard sheave is not available in 1-3/8”. HKV Series Wet Coil to Dry Coil Conversion Table Required Required Air Coil Face Velocity (fpm) Multiplier Multiplier 1.00 1.00...

  • Page 22: Blower Performance Tables

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 084 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 23 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 096 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 24 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 096 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60...
  • Page 25 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 120 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 26 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 120 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60...
  • Page 27 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 150 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 28 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 150 Blower Performance Table Continued from Previous Page All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60...
  • Page 29 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 168 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 30 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 192 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 31 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 192 Blower Performance Table Continued from Previous Page All Data is Wet Coil 7600 1.68 1.78 1.88 2.08 2.26 2.38 2.48 2.68 2.86 2.98 3.08 3.28 3.46 3.58 3.68 3.88...
  • Page 32 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 240 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 33 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 240 Blower Performance Table Continued from Previous Page All Data is Wet Coil 9000 2.98 3.08 3.28 3.48 3.68 3.88 4.08 4.18 4.28 4.48 4.68 4.88 5.08 5.28 5.48 5.68...
  • Page 34 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Blower Performance HKV 300 Blower Performance All Data is Wet Coil Airflow (cfm) at External Static Pressure (in. wg) Airflow (SCFM) 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10...
  • Page 35 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Blower Performance HKV 300 Blower Performance Table Continued from Previous Page All Data is Wet Coil 10600 3.68 3.88 4.08 4.28 4.48 4.68 4.88 5.08 5.28 5.48 5.68 5.88 6.18 6.38 6.58 6.78...

  • Page 36: Unit Commissioning & Operating Conditions

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Unit Commissioning & Operating Conditions Environment – This unit is designed for indoor The commissioning table indicates air and water installation only. Do not install in an area subject to temperatures which are suitable for initial unit...

  • Page 37: Piping System Cleaning & Flushing

    CXM is properly set. and repair appropriately. Unit Fan: Manually rotate fans to assure free 4. Verify all strainers are in place. (Heat Controller recom- rotation and ensure blower wheel is secured to mends a strainer with a #20 stainless steel wire mesh.) motor shaft.

  • Page 38: Unit & System Checkout

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Unit & System Checkout be cleaned using a 10% solution of dish washing Standby Pumps: Verify the standby pump is detergent. properly installed and in operating condition. Unit Controls: Verify CXM field selection options System Controls: Verify system controls function are proper and complete.

  • Page 39: Unit Start Up Procedure

    20°F [11°C] and 30°F [17°C]. Heat 5. Two factors determine the operating limits of a Heat of extraction can be calculated and compared to Controller HKV System– (a) return air temperature, and specification catalog. (b) water temperature. When any one of these factors is at f.

  • Page 40: Unit Start Up Procedure

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Unit Start Up Procedure Table 7: Coax Water Pressure Drop CXM Safety Control Reset Lockout - In Lockout mode, the Status LED will begin fast flashing. The compressor relay is turned off immediately.

  • Page 41: Startup Logsheet

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions 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.

  • Page 42: Unit Operating Conditions

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Unit Operating Conditions Table 8: Typical Unit Operating Pressures and Temperatures Cooling Heating Entering Water Water Voltage Suction Discharge Water Suction Discharge Super- Sub- Temp Super- Sub- Temp Temp Pressure Pressure Temp...

  • Page 43: Preventive Maintenance

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Preventive Maintenance Water Coil Maintenance – Generally water coil maintenance is not needed however, Compressor if the installation is located in a system with a known Conduct annual amperage checks to ensure amp draw...

  • Page 44: Functional Troubleshooting

    IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Functional Troubleshooting Fault Htg Clg Possible Cause Solution Main power Problems Green Status LED Off Check Line Voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor...

  • Page 45: Functional Troubleshooting

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Functional Troubleshooting Check G wiring at heat pump. Jumper G and R for fan Only Compressor Runs Thermostat wiring operation. Jumper G and R for fan operation. Check for Line voltage Check G wiring at heat pump. Jumper G and R for fan...

  • Page 46: Troubleshooting Form

    Model Number: ________________________ Serial Number: ________________________ IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Date: ________________________ Packaged Unit Refrigeration Schematic Location: ________________________ Troubleshooting Form Customer: _____________________________________ Antifreeze: ________________________ Model Number: ________________________ Model#: ________________________ Serial#: ________________ Loop type: _______________ Serial Number: ________________________...

  • Page 47: Field Conversion Options

    Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Follow All Warnings and Cautions in Field Conversion Options This Manual Before Attempting Conversion. Top Discharge to Straight Discharge Convertible Follow all warnings and cautions in this manual No More Ordering New Panels From the Vendor before attempting conversion.
  • Page 48 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Step 2: Remove Blockoff Air Handler as shown. Loosen belt and remove. Blockoff Air Handler Step 3: Remove bolts (4x) off blower panel. Remove bolts (4x) (2x ea. side) from blower sides.
  • Page 49 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Step 4: Remove bolts (4x) and take blower glides out. Blower Glides (2x) Step 5: Attach Blower Glides to Blower BTM Load Brackets as shown. Use bottom set of holes (.203 Dia.) on Blower BTM Load Brackets.
  • Page 50 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Step 6: Stand in front and pull Blower ASM on to the ridge of the Blower Glides. Step 7: Rotate Blower ASM using Blower Glides as a guiding track. Step 8: When the Blower ASM is parallel to the floor, push the Blower ASM...
  • Page 51 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Step 9: Attach Blower ASM with bolts (4x) as shown. Step 10: Remove Bower Glides (2x) and re-attach back in compressor section. Step 10...
  • Page 52 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Important! Step 11: Re-bolt Blower ASM to Blower BTM load brackets 4 ¼-20 UNC bolts, (2x) each side Re-attach belt and tighten.
  • Page 53 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Step 12: Re-attach Blockoff Air Handler as shown. Blockoff Air Handler Blower Filler Panel C-Box/Motor Access Panel Compressor Panel Access Step 13: Put (3x) panels back on. Reverse steps to change a Straight Discharge to a Top Discharge.
  • Page 54 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Front Control Box/ Motor Access to Back Access Convertible • No More Dumping Charge/ Adding Charge • No More Unbrazing/ Brazing Copper • No More Heavy Lifting (Blower/ Motor ASM) • No More Flipping Coil Over What may have taken a day can now be a 15-minute job Step 1: Remove the three panels as shown.
  • Page 55 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions Step 3: Remove screws from Control Box (Qty 4x) and A) flip down, B) slide across and C) flip up as shown using the guide rails inside as a guide. Re-attach control box with screws.
  • Page 56 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Step 6: Move Bolt-Belt Adjustment ASM to opposite side and re-attach. Step 6 Step 7: Put Belt back on and tighten. Step 8: Place panels back on unit. Put Control Box Cover and Reverse steps to go from Motor Cover on return side.
  • Page 57 Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions • Water In-Out Available on Either Side • Hi-Low Voltage Access on Any Side • Full Filter Frame - Bottom Access - 1”, 2”, or 4” • Filters - 1” or 2” Fiberglass and 4” Merv 8...
  • Page 58 IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc. Condensate Drain Can Connect to Either Side of Unit TLV Units come with flex hose and 1” FPT condensate connection tied inside (shown above) Installer will untie flex hose and make an internal trap on either the left side (shown above) or on the right side.
  • Page 59 11/2010 04/2009...

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