Heat Controller HKV084, HKV096, HKV120, HKV150, HKV168 Installation, Operation & Mainenance Manual
...
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
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
TABLE OF CONTENTS
Model Nomenclature .................................................... 2
Tensioning V-Belt Drives............................................. 19
Physical Data................................................................ 3
Dimensional Data ...................................................... 4-5
General Information ...................................................... 6
Vertical Unit Installation ............................................. 7-8
Piping Installation ......................................................... 9
Condensate Installation .............................................. 10
Water-Loop Heat Pump Applications ...........................11
Electrical Data ............................................................ 12
Electrical - Power Wiring ............................................ 13
Electrical - Low Voltage .............................................. 14
CXM Control Operation .............................................. 15
Wiring Schematics ................................................. 16-17
Blower Adjustment ...................................................... 18
Blower Sheave Information ........................................ 20
Blower Performance Tables ................................... 21-34
Unit Commissioning & Operating Conditions ............. 35
Piping System Cleaning & Flushing ........................... 36
Unit & System Checkout........................................ 36-37
Unit Start Up Procedure ........................................ 38-39
Startup Logsheet ........................................................ 40
Unit Operating Conditions .......................................... 41
Preventive Maintenance ............................................. 42
Functional Troubleshooting ................................... 43-44
Troubleshooting Form ................................................ 45
Field Conversion Options ...................................... 46-57
1
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
60- 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” (25mm),
2” (50mm) or 4” (100mm) lter and full lter rack.
2
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
HKV Physical Data
Model 084 096 120 150 168 192 240 300
Compressor Quantity Scroll (1) Scroll (2)
Factory Charge R410a (oz) [kg] per
circuit
Blower Motor
Blower Motor Quantity 1
Standard Motor (hp) [kw] 1 [.75] 1.5 [1.12] 2 [1.49] 3 [2.24] 2 [1.49] 3 [2.24] 5 [3.73] 5 [3.73]
Large Motor (hp) [kw] 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 [5.60]
Blower
No. of Blowers 1 2
Blower Wheel Size D x W (in0 [cm] 15 x 11 [38.1 x 38.1]
Water Connection Size
FPT (in) [mm] 1-1/2" [38.1] 2" [50.8] 2-1/2" [63.5]
Coax Volume
Volume (US Gallons) [liters] 2.19 [8.28] 2.48 [9.37] 3.46 [13.11] 4.83 [18.29] 6.36 [24.08] 7.39 [27.98]
Condensate Connection Size
FPT (in) [mm] 1" [25.4]
Air Coil Data
Air Coil Dimensions H x W (in) [cm] 36 x 48 [91.4 x 121.9] 2 - 36 x 48 [91.4 x 121.9]
Air Coil Total Face Area (ft2) [m2] 12 [1.11] 24 [2.22]
Air Coil Tube Size (in) [cm] 3/8" [0.953]
Air Coil Fin Spacing (fpi) [ns per cm] 14 [5.5] 12 [4.72] 14 [5.5] 12 [4.72]
Air Coil Number of Rows 2 3 4 2 3 4
Miscellaneous Data
Filter Standard - 1" [25.4mm] Throwaway (qty) (in) [cm]
Weight - Operating (lbs) [kg] 650 [294] 696 [316] 700 [318] 1300 [589] 1346 [611] 1404 [637]
Weight - Packaged (lbs) [kg] 665 [301] 711 [322] 715 [324] 1330 [603] 1376 [624] 1434 [650]
140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03] 140 [3.97] 156 [4.42] 224 [6.35] 248 [7.03]
15 x 15 [38.1
x 38.1]
(QTY.4) 18 x 25 [45.74 x 63.5] (QTY.8) 18 x 25 [45.74 x 63.5]
15 x 11 [38.1 x 38.1]
15 x 15 [38.1
x 38.1]
All units have grommet & spring compressor mountings, and 1/2" & 1-3/4" electrical knockouts.
3
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA SHOWN BELOW. (RR/FD)
HKV084-150 Dimensional Data
F
B
7.6
BSP
NRP
C
02
P
01
1
2
3
4
5
LEGEND
Water Inlet (See Note 2)
Water Outlet (See Note 2)
Condensate Drain (See Note 3)
High Voltage Access (See Note 4)
Low Voltage Access (See Note 4)
BSP - Blower Service Panel
CAP - Control Access Panel
CSP - Compressor Access Panel
MSP - Motor Service Panel
NRP - Non Removable Panel
Q
3
CAP+MSP
CSP
RETURN AIR
2
D
AIR OUT
1
Control Box
REAR RETURN TOP DISCHARGE
S
L
HKV084-120
TLV084-120
NRP
R
NRP
3
M
K
A
1-1/2” FPT
1-1/2” FPT
1” FPT
1-3/8” [3.49 CM]
7/8” [2.2 CM]
R
U
N
HKV150
TLV150
2” FPT
2” FPT
4
5
4
3
NRP
NOTES FOR LEGEND:
1. While access to all removable panels is not required, installer
should take care to comply with all building codes and allow
adequate clearance for future field service.
2. Water inlet and water outlet connections are available on either
side (left or right) of the unit. Qty (2x) MPT Plugs are shipped loose
in a plastic bag tied to the water leg in front of the unit. Installer must
plug water inlet/outlet side not being connected to.
3. Condensate drain is available on either side (left or right) of unit.
Drain hose and drain connection will be tied inside the unit. Installer
will untie the drain hose and connect to the condensate drain hole of
installer’s choice.
4. Electrical access is available on either side (left or right) of unit and
is also available (left or right) in the front of the unit.
7.6
NRP
AIR OUT
RETURN AIR
2
Control Box
4
1
CSP+CAP+MSP
FRONT RETURN TOP DISCHARGE
F
BSP
NRP
3
5
4
L
M
K
084
-120
150
Model
Overall Cabinet
A
DepthBWidthCHeightDSupply
in.
34.0
53.1
86.4
34.0
86.4
134.9
53.1
134.9
cm.
in.
cm.
SERVICE ACCESS
3’ (91 CM)
FRONT AND BACK
Discharge Connections
Width
79.0
17.5
200.7
44.5
79.0
21.4
200.7
54.4
1.7
F
D
RETURN AIR
E
BSP
NRP
4
5
4
AIR OUT
3
CAP+MSP
2
CSP
NOTES:
- All dimensions in inches (cm)
- Units require 3’ (9.1 cm) clearance for water connections, CAP, CSP, MSP and BSP service access.
- Overall cabinet height dimension does not include duct flange when in top discharge configuration.
- Overall cabinet width dimensions does not include filter rack and duct flange when on front or back discharge configuration.
- Side service access must be 3 feet (91 cm) on either side that connections are made. If no connections are made on a side
then service access can be 6 inches (1.5 cm) minimum.
Duct Flange
E
Supply
Depth
17.6
44.6
17.6
44.6
BSP
NRP
1
Control Box
REAR RETURN FRONT DISCHARGE
Water Connections Electrical Knockouts
F K
1
Water
Inlet
17.8
31.0
45.1
78.7
17.8
31.0
45.1
78.7
4
4
NRP
5
L
1
Water
Outlet
3.0
7.6
3.0
7.6
3
densate
4
5
4
NRP
SIDE
SERVICE ACCESS
(SEE NOTE)
M
N O1 O2 P Q R S
3
Con-
27.0
25.6
68.6
65.1
27.0
25.6
68.6
65.1
3
BSP
RETURN AIR
Control Box
CSP+CAP+MSP
31.0
78.7
31.0
78.7
AIR OUT
2
4
4
1
FRONT RETURN REAR DISCHARGE
38.0
34.6
96.4
87.7
38.0
34.6
96.4
87.7
F
NRP
3
5
Return Air Connections
Using Return Air Opening
T
U V W
Return
Return
Depth
Height
1.0
3.0
48.0
32.4
44.6
2.7
2.5
1.0
2.5
7.6
3.0
7.6
121.9
48.0
121.9
82.2
32.4
82.2
113.3
44.6
113.3
6.9
2.7
6.9
2.0
5.1
2.0
5.1
4
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA SHOWN BELOW. (RR/FD)
HKV168-300 Dimensional Data
3
(See Note)
7.6
RETURN AIR
3
Control Box
CSP+CAP
RETURN AIR
Control Box
CSP+CAP
AIR OUT
2
1
AIR OUT
2
1
V
7.6
NRP
C
02
BSP
Q
3
P
01
CSP
1. Water inlet (see note 2)
2. Water outlet (see note 2)
3. Condensate drain (see note 3)
4. High voltage access (see note 4)
5. Low voltage access (see note 4)
1.7
F
E
NRP
4
5
4
CSP
Service Access
3’ (91 cm)
Front and Back
(All Configurations)
F
D
AIR OUT
E
2
LEGEND
MSP
1
2
NRP
RETURN
1
NRP
BSP
CAP
CSP
G
AIR
NRP
CAP
NRP
CSP
RETURN AIR
S
MSP
BSP - Blower Service Panel
CAP - Control Access Panel
CSP - Compressor Access Panel
MSP - Motor Service Panel
NRP - Non Removable Panel
BSP
D
AIR OUT
3
NOTES:
- All dimensions in inches (cm)
- Units require 3’ (9.1 cm) clearance for water connections, CAP, CSP, MSP and BSP service access.
- Overall cabinet height dimension does not include duct flange when in top discharge configuration.
- Overall cabinet width dimensions does not include filter rack and duct flange when on front or back discharge configuration.
- Side service access must be 3 feet (91 cm) on either side that connections are made. If no connections are made on a side then
service access can be 6 inches (1.5 cm) minimum.
B
G
D
AIR OUT
E
RETURN AIR
S
Control Box
L
REAR RETURN TOP DISCHARGE
168-240
D
AIR OUT
Control Box
300
2½” FPT
2” FPT
21/2”FPT
21/2”FPT
2½” FPT
2” FPT
1” FPT
1
3/8” (3.49 cm)
7/8” (2.2 cm)
RETURN
AIR
REAR RETURN FRONT DISCHARGE
T
4
5
4
NRP
4
5
NRP
4
U
N
A
NOTES FOR LEGEND:
1. While access to all removable panels is not required, installer should
take care to comply with all building codes and allow adequate
clearance for future field service.
2. Water inlet and water outlet connections are available on either side
(left or right) of the unit. Qty (2x) MPT Plugs are shipped loose in a
plastic bag tied to the water leg in front of the unit. Installer must
plug water inlet/outlet side not being connected to.
3. Condensate drain is available on either side (left or right) of unit.
Drain hose and drain connection will be tied inside the unit. Installer
will untie the drain hose and connect to the condensate drain hole of
installer’s choice.
4. Electrical access is available on either side (left or right) of unit and
is also available (left or right) in the front of the unit.
NRP
4
5
4
3
Side Service Access
R
3
H
K
NRP
AIR OUT
RETURN AIR
NRP
CSP+MSP
FRONT RETURN TOP DISCHARGE
BSP
AIR OUT
RETURN AIR
NRP
CSP+MSP
FRONT RETURN REAR DISCHARGE
BSP
5
4
F
NRP
4
5
3
4
L
H
K
F
NRP
4
3
Discharge Connections
Width
79.0
17.5
200.7
44.5
79.0
21.4
200.7
54.4
Duct Flange
E
Supply
Depth
17.6
17.8
44.6
45.1
17.6
17.8
44.6
45.1
168-
240
300
Model
Overall Cabinet
A
DepthBWidthCHeightDSupply
in.
34.0
106.7
86.4
34.0
86.4
270.9
106.7
270.9
cm.
in.
cm.
F G K
Water
31.3
79.4
23.4
59.4
Water Connections Electrical Knockouts
Inlet
31.0
78.7
31.0
78.7
L
1
1
Water
Outlet
3.0
7.6
3.0
7.6
M
3
Condensate
27.0
68.6
27.0
68.6
N O1 O2 P Q R S
25.6
31.0
78.7
31.0
78.7
38.0
96.4
38.0
96.4
65.1
25.6
65.1
5
34.6
87.8
34.6
87.8
1.0
2.5
1.0
2.5
3.0
7.6
3.0
7.6
Return Air Connections
Using Return Air Opening
T
U V W
Return
Return
Depth
Height
48.0
32.4
82.2
32.4
82.2
44.6
113.3
44.6
113.3
121.9
48.0
121.9
2.7
6.9
2.7
6.9
2.0
5.1
2.0
5.1
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
General Information
Inspection
Upon receipt of the equipment, carefully check the
shipment against the bill of lading. Make sure all units
have been received. Inspect the carton or crating of each
unit, and inspect each unit for damage. Assure the carrier
makes proper notation of any shortages or damage on all
copies of the freight bill and completes a common carrier
inspection report. Concealed damage not discovered
during unloading must be reported to the carrier within
15 days of receipt of shipment. If not led within
15 days, the freight company can deny the claim
without recourse. Note: It is the responsibility of the
purchaser to le all necessary claims with the carrier.
4. Inspect all electrical connections. Connections must
be clean and tight at the terminals.
5. Remove any blower support packaging from mouth
of blower.
6. Loosen compressor bolts on units equipped with
compressor spring vibration isolation until the
compressor rides freely on the springs. Remove
shipping restraints.
7. Locate and verify any hanger, or other accessory kit
located in the compressor section and or the
blower section.
WARNING!
Storage
Equipment should be stored in its shipping carton in a
clean, dry area. Store units in an upright position at all
times. Stack units a maximum of 3 units high.
Unit Protection
Cover units on the job site with either shipping cartons,
vinyl lm, or an equivalent protective covering. Cap
the open ends of pipes stored on the job site. In areas
where painting, plastering, and/or spraying has not
been completed, all due precautions must be taken to
avoid physical damage to the units and contamination
by foreign material. Physical damage and contamination
may prevent proper start-up and may result in costly
equipment clean-up.
Examine all pipes, ttings, and valves before installing
any of the system components. Remove any dirt or trash
found in or on these components.
Pre-Installation
Installation, Operation, and Maintenance instructions
are provided with each unit. HKV units are typically
installed in a oor level closet or in a mechanical room.
The installation site chosen should include adequate
service clearance around the unit. Before unit startup, read all manuals and become familiar with the unit
and its operation. Thoroughly check the system before
operation.
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 shipping carton
until installation is complete and all plastering,
painting, etc. is nished.
3. Verify refrigerant tubing is free of kinks or dents and
that it does not touch other unit components.
DO NOT store or install units in corrosive environments or
in locations subject to temperature or humidity extremes
(e.g., attics, garages, rooftops, etc.) Corrosive conditions
and high temperature or humidity can signicantly reduce
performance, reliability, and service life. Always move units
in an upright position. Tilting units on their sides may cause
equipment damage.
To avoid equipment damage, DO NOT use these units
as a source of heating or cooling during the construction
process. The mechanical components and lters used in
these units will quickly become clogged with construction
dirt and debris which may cause system damage.
To avoid the release of refrigerant into the atmosphere,
the refrigerant circuit of this unit must be serviced only by
technicians who meet local, state, and federal prociency
requirements.
All refrigerant removed 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.
If a compressor is removed from this unit, system refrigerant
circuit oil will remain in the compressor. To avoid leakage of
compressor oil, the refrigerant lines of the compressor must
be sealed after it is removed.
6
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
Installation
Figure 1: Typical Vertical Installation
Rear Return/Top Discharge shown
Refer to Dimensional Data pages for
other arrangements & dimensions
Ductwork not shown.
All components external
of unit are field supplied.
Supply
Water
Return
Water
Unions
Shutoff
Hoses
Optional
Drain
To
Water
Optional
Balancing
Valve
Return Air
In
Return Air
Supply
Supply
Air
Water
Out
Condensate Internally
Trapped. Do not trap externally.
Pitch horizontal runs ¼” per foot.
1
/4”
Air
24 V Remote
Thermostat
Plug water
in and out
connections
Control Box
Disconnect Box
Per NEC and
Local Codes
Vertical Location and Access
HKV units are not designed for outdoor installation.
Locate the unit in an indoor area that allows enough
space for installation and for service personnel to perform
typical maintenance or repairs. HKV units are typically
installed in a oor level closet or in a small mechanical
room. Refer to Figure 1 for an illustration of a typical
installation. Install units with adequate clearance to allow
maintenance and servicing. Conform to the following
guidelines when selecting
unit location:
1. Provide adequate clearance for lter replacement
and drain pan cleaning. DO NOT block lter access
with piping, conduit or other materials. Refer to
submittal drawing for Vertical Unit Dimensions.
2. Provide access for fan and fan motor maintenance
and for servicing of the compressor and coils without
removal of the unit.
3. Provide an unobstructed path to the unit within the
closet or mechanical room to enable removal of the
unit if necessary.
4. Provide access to water valves and ttings, and
screwdriver access to the unit side panels, discharge
collar and all electrical connections
Duct System Design & Installation Guidelines
The following application guidelines must be used when
installing HKV units. Failure to follow these guidelines
could result in unsatisfactory unit performance and/
or premature failure of some unit components. Heat
Controller will not warrant, or accept responsibility for
products which fail, have defects, damage or insufcient
performance as a result of improper application.
• The duct system must be sized to handle the
airow quietly and must not exceed the maximum
allowable External Static Pressure. To maximize
sound attenuation metal supply and return ducts
should include internal insulation or be of duct board
construction for the rst 10 feet or end of rst full-
sized elbow.
• Install a exible connector in all supply and return
air ducts close to the unit to inhibit sound transfer to
the ducts.
• Do not install uninsulated duct in an unconditioned
space. The unit performance will be adversely
affected and damage from condensate can occur.
• On units with multiple fan outlets a “pair of pants”
duct connection must be used for proper air balance
and distribution and to prevent fan oscillation.
7
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
Installation
•
Include at least one 90-degree turn in supply air
ducts to reduce noise transmission.
• Existing ducts must be checked to insure proper
size and conguration prior to installation of any
replacement unit. Also inspect for and repair all air
leaks in existing ducts.
• Units may only be connected to a dedicated duct
system. Consult the factory BEFORE connecting
multiple units to a common duct system.
• Never connect a unit to a duct system with automatic
or modulating dampers, VAV boxes, etc. in the supply
air system. Never allow a situation where the total
unit CFM can drop below the minimum required for
proper unit operation.
•
Never connect a bypass damper from the supply air
duct to the return air duct. Never allow the return air
temperature to drop below the minimum allowable
normal temperature for proper unit operation.
• Do not use HKV units for 100% outdoor air treatment.
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.
• Do not exceed 10% of the total unit CFM with
untreated outdoor air.
8
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
Swivel
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 riser to facilitate system ushing.
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. Select the proper hose length to allow slack between
connection points. Hoses may vary in length by +2%
to -4% under pressure.
5. Refer to Table 1. Do not exceed the minimum bend
radius for the hose selected. Exceeding the minimum
bend radius may cause the hose to collapse which
reduces water ow rate. Install an angle adapter to
avoid sharp bends in the hose when the radius falls
below the required minimum.
CAUTION!
CAUTION! Piping must comply with all applicable codes.
Table 1: Metal Hose Minimum Bend Radii
Hoses in Inches Minimum Bend Radius
1” [25.4mm] 5.5” [140mm]
1.25” [31.8mm] 7.0” [178mm]
1.5” [38.1mm] 8.5” [216mm]
Insulation is not required on loop water piping except
where the piping runs through unheated areas or outside
the building or when the loop water temperature is below
the minimum expected dew point of the pipe ambient.
Insulation is required if loop water temperature drops
below the dew point.
WARNING!
WARNING! Do not bend or kink supply lines or hoses.
Figure 2: Supply/Return Hose Kit
Rib Crimped
Length
(2 ft [0.6m] Length Standard)
Brass
Fitting
Note: When anti-freeze is used in the loop, assure
that it is compatible with Teon tape or pipe joint
compound employed.
Maximum allowable torque for brass ttings is 30 foot-
pounds [41 N-m]. If a torque wrench is not available,
tighten nger-tight plus one quarter turn. Tighten steel
ttings as necessary.
Optional pressure-rated hose assemblies designed
specically for use with Heat Controller units are available.
Similar hoses can be obtained from alternate suppliers.
Supply and return hoses are tted with swivel-joint ttings
at one end to prevent kinking during installation.
Refer to Figure 2 for an illustration of a Supply/Return
Hose Kit. External Pipe Thread (EPT) adapters secure
hose assemblies to the unit and risers. Install hose
assemblies properly and check them regularly to avoid
system failure and reduced service life.
Brass
Fitting
EPT
CAUTION!
Pipe joint compound is not necessary when Teon
threaded tape is pre-applied to hose assemblies or when
ared-end connections are used. If pipe joint compound
is preferred, use compound only in small amounts on the
male pipe threads of the tting adapters. Prevent sealant
from reaching the ared surfaces of the joint.
CAUTION! Corrosive system water requires corrosion
resistant ttings and hoses and possibly water treatment.
9
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
Pipe Connected Connected
Size Tons kW
3/4” [19mm] <4 <14
1” [25mm] <6 <21
1-1/4” [32mm] <30 <105
1-1/2” [38mm] <50 <175
2” [51mm] <150 <527
3” [76mm] <300 <1055
4” [102mm] <500 <1758
* Make sure all connections are secure and
water tight.
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.
Outside of unit, connect 1” EPT tting to plate assembly.
Run line to building drain. Horizontal runs must be pitched
¼” per foot (10 mm per 46 cm) toward drain. Do not trap
externally.
Figure 3 illustrates a typical trap and vent used with HKV
series equipment.
Figure 3: HKV
Each unit must be installed with its own individual line to
the building main condensate drain line or riser. Provide a
means to ush or blow out the condensate line. DO NOT
install units with a common trap and or vent.
Always vent the condensate line when dirt or air can
collect in the line or a long horizontal drain line is
required. Also vent when large units are working against
higher external static pressure than other units connected
to the same condensate main since this may cause
poor drainage for all units on the line. WHEN A VENT
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)
minimum from bottom of unit. (Vent per code)
WARNING!
WARNING! Ensure condensate line is pitched toward
drain 1/4" per foot [10mm per 46cm] of run.
Drain main or riser must be sized for all units connected
to it.
Open
Vent
1” EPT
46” Min
To Bottom
Of Unit
To main
drain, pitch
¼” Per foot
1” IPT
Fitting
2 Screws
All fittings and tubing outside of the unit are field supplied.
Condensate
Pan
After drain is connected to main and all drain connections
are secure and water tight, pour 1 gallon of water into
condensate pan. Water should drain out freely. Repair
any leaks.
10
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
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. In piping
systems expected to utilize water temperatures below
50°F [10°C], 1/2" [13mm] closed cell insulation is required
on all piping surfaces to eliminate condensation. Metal
to plastic threaded joints should never be employed due
to their tendency to leak over time. All non-distributor
class units include a low temperature-soldered bracket-
supported FPT water connection. Teon tape thread
sealant is recommended to minimize internal fouling
of the heat exchanger. Do not overtighten connections
and route piping so as not to interfere with service or
maintenance access. Hose kits are available from Heat
Controller in different congurations as shown in Figure
4 for connection between the HKV Series and the piping
system. The piping system should be ushed to remove
dirt, piping chips, and other foreign material prior to
operation. See Piping System Cleaning and Flushing
Procedures. The ow rate is usually set between 2.25
and 3.5 gpm per ton [2.9 l/m and 4.5 l/m per kW] of
cooling capacity. Heat Controller recommends 2.5 gpm
per ton [3.2 l/m per kW] for most applications of water
loop heat pumps. To insure proper maintenance and
servicing, P/T ports are imperative for temperature and
ow verication, as well as performance checks.
Cooling Tower/Boiler Systems typically utilize a
common loop maintained 60-90°F [16-32°C]. The use
of a closed circuit evaporative cooling tower with a
secondary heat exchanger between the tower and the
water loop is recommended. If an open type cooling
tower is used continuously, chemical treatment and
ltering will be necessary.
Figure 4: Typical Water Loop Application
Supply
Air
Supply
Air
Return Air
Water
Control Valve
Thermostat
Wiring
Unit
Power
Field Supplied
Disconnect Box
TO Drain, See Fig. 4
Ball Valve with
integral P/T plug
Water In
Ball Valve with
integral P/T plug
Water Out
11
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
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.
Use only copper conductors for eld installed electrical
wiring. Unit terminals are not designed to accept other
types of conductors.
CAUTION!
Table 4A: HKV Electrical Data Standard
Model
HKV084
HKV096
HKV120
HKV150
HKV168
HKV192
HKV240
HKV300
HACR circuit breaker in USA only
All fuses Class RK-5 Created: 3/26/09B
Voltage
Code
3 208-3-60 197/254 A, B, C 1 23.2 164.0 4.0 27.2 33.0 50
3 208-3-60 197/254 D, E 1 23.2 164.0 5.0 28.2 34.0 50
4 460-3-60 414/506 A, B, C 1 11.2 75.0 2.0 13.2 16.0 25
4 460-3-60 414/506 D, E 1 11.2 75.0 2.4 13.6 16.4 25
5 575-3-60 518/633 A, B, C 1 7.9 54.0 1.4 9.3 11.3 15
5 575-3-60 518/633 D, E 1 7.9 54.0 1.9 9.8 11.8 15
3 208-3-60 197/254 A, B, C 1 25.0 164.0 5.0 30.0 36.3 60
3 208-3-60 197/254 D, E 1 25.0 164.0 6.2 31.2 37.5 60
4 460-3-60 414/506 A, B, C 1 12.2 100.0 2.4 14.6 17.6 25
4 460-3-60 414/506 D, E 1 12.2 100.0 3.1 15.3 18.4 30
5 575-3-60 518/633 A, B, C 1 9.0 78.0 1.9 10.9 13.1 20
5 575-3-60 518/633 D, E 1 9.0 78.0 2.3 11.3 13.6 20
3 208-3-60 197/254 A, B, C 1 30.1 225.0 6.2 36.3 43.8 70
3 208-3-60 197/254 D, E 1 30.1 225.0 9.2 39.3 46.8 70
4 460-3-60 414/506 A, B, C 1 16.7 114.0 3.1 19.8 24.0 40
4 460-3-60 414/506 D, E 1 16.7 114.0 4.3 21.0 25.2 40
5 575-3-60 518/633 A, B, C 1 12.2 80.0 2.3 14.5 17.5 25
5 575-3-60 518/633 D, E 1 12.2 80.0 3.4 15.6 18.6 30
3 208-3-60 197/254 A, B, C 1 48.1 245.0 9.2 57.3 69.3 110
3 208-3-60 197/254 D, E 1 48.1 245.0 14.1 62.2 74.2 110
4 460-3-60 414/506 A, B, C 1 18.6 125.0 4.3 22.9 27.6 45
4 460-3-60 414/506 D, E 1 18.6 125.0 7.0 25.6 30.3 45
5 575-3-60 518/633 A, B, C 1 14.7 100.0 3.4 18.1 21.8 35
5 575-3-60 518/633 D, E 1 14.7 100.0 5.2 19.9 23.6 35
3 208-3-60 197/254 A, B, C 2 23.2 164.0 6.2 52.6 58.4 80
3 208-3-60 197/254 D, E 2 23.2 164.0 9.2 55.6 61.4 80
4 460-3-60 414/506 A, B, C 2 11.2 75.0 3.1 25.5 28.3 35
4 460-3-60 414/506 D, E 2 11.2 75.0 4.3 26.7 29.5 40
5 575-3-60 518/633 A, B, C 2 7.9 54.0 2.3 18.1 20.1 25
5 575-3-60 518/633 D, E 2 7.9 54.0 3.4 19.2 21.2 25
3 208-3-60 197/254 A, B, C 2 25.0 164.0 9.2 59.2 65.4 90
3 208-3-60 197/254 D, E 2 25.0 164.0 14.1 64.1 70.3 90
4 460-3-60 414/506 A, B, C 2 12.2 100.0 4.3 28.7 31.8 40
4 460-3-60 414/506 D, E 2 12.2 100.0
5 575-3-60 518/633 A, B, C 2 9.0 78.0 3.4 21.4 23.6 30
5 575-3-60 518/633 D, E 2 9.0 78.0 5.2 23.2 25.5 30
3 208-3-60 197/254 A, B, C 2 30.1 225.0 14.1 74.3 81.8 110
3 208-3-60 197/254 E 2 30.1 225.0 21.7 81.9 89.4 110
4 460-3-60 414/506 A, B, C 2 16.7 114.0 7.0 40.4 44.6 60
4 460-3-60 414/506 E 2 16.7 114.0 10.0 43.4 47.6 60
5 575-3-60 518/633 A, B, C 2 12.2 80.0 5.2 29.6 32.6 40
5 575-3-60 518/633 E 2 12.2 80.0 7.7 32.1 35.1 45
3 208-3-60 197/254 A, B, C 2 48.1 245.0 14.1 110.3 122.3 150
3 208-3-60 197/254 D, E 2 48.1 245.0 21.7 117.9 129.9 175
4 460-3-60 414/506 A, B, C 2 18.6 125.0 7.0 44.2 48.9 60
4 460-3-60 414/506 D, E 2 18.6 125.0 10.0 47.2 51.9 70
5 575-3-60 518/633 A, B, C 2 14.7 100.0 5.2 34.6 38.3 50
5 575-3-60 518/633 D, E 2 14.7 100.0 7.7 37.1 40.8 50
Voltage
Min/Max
Voltage
Blower
Option
Compressor Fan
QTY RLA LRA
Motor
FLA
7.0 31.4 34.5 45
Total
Unit
FLA
Min
Circuit
Amp
Max
Fuse/
HACR
12
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
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! Use only copper conductors for eld installed
electrical wiring. Unit terminals are not designed to accept
other types of conductors.
WARNING!
WARNING! Disconnect electrical power source to prevent
injury or death from electrical shock.
General Line Voltage Wiring
Be sure the available power is the same voltage and phase
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.
HKV Power Connection
Line voltage connection is made by connecting the
incoming line voltage wires to the power block as shown in
Figure 6. Consult Table 4a and 4b for correct fuse size.
Thermostat Installation
The thermostat should be located on an interior wall in
a larger room away from supply duct drafts. Do NOT
locate the thermostat in areas subject to sunlight, drafts
or on external walls. The wire access hole behind the
thermostat may in certain cases need to be sealed to
prevent erroneous temperature measurement. Position the
thermostat backplate against the wall so that it appears
level and so the thermostat wires protrude through the
middle of the backplate. Mark the position of the backplate
mounting holes and drill holes with a 3/16" bit. Install
supplied anchors and secure plate to the wall. Thermostat
wire must be 18 AWG wire. Wire the appropriate thermostat
as shown in Figure 10 to the low voltage terminal strip
in the CXMControl as shown in Figure 7 using 18 AWG
thermostat wire of minimum length.
Figure 6: Typical HKV Series Line Voltage
Field Wiring
208 Volt Operation
All 208-230 Volt units are factory wired for 208 Volt. The
transformers may be switched to 230V operation as
illustrated on the wiring diagram by switching the Red
(208V) and the Orange (230V) at the contactor terminal L2.
All eld installed wiring, including electrical ground, must
comply with the National Electrical Code as well as all
applicable local codes.
Refer to the unit wiring diagrams for fuse sizes and a
schematic of the eld connections which must be made by
the installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of the
compressor access panel to ensure proper electrical hookup.
All nal electrical connections must be made with a length of
exible conduit to minimize vibration and sound transmission
to the building.
Figure 7: Low Voltage Field Wiring (CXM
board shown)
13
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
Electrical - Low Voltage
Low Water Temperature Cutout - FP1
The CXM control allows the eld selection of source uid low
temperature cutout points. The factory setting of FP1 is set for
water (30°F [-1.1°C]). In cold temperature applications jumper
JW3 (FP1- antifreeze 10°F [-12.2°C]) should be clipped as
shown in Figure 8 to change the setting to 10°F [-12.2°C], a more
suitable temperature when using antifreezes. It should be noted
that the extended range option should be specied to operate the
HB Series at entering water temperatures below 60°F [15°C].
Figure 8: FP1 Jumper
Figure 9: 24 Volt Accessory Wiring
CXM Terminal Strip
These terminals may be
used to power 24 volt
water valves on units
size 084-150. Refer to
Figure 9a for water valve
wiring to dual compressor units.
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
water will ow before 45 seconds) and it activates the
compressor only after the valve is completely opened (by
closing its end switch). Only relay or triac based electronic
thermostats should be used with the AVM valve. When
wired as shown, the valve will operate properly with the
following notations:
1-The valve will remain open during a unit lockout.
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.
Accessory Connections
A terminal paralleling the compressor contactor coil has been
provided on the CXM control board. “A” has been provided to
control accessory devices, such as water valves, electronic
air cleaners, humidiers, etc. Note: This terminal must be
used only with 24 Volt signals and not line voltage signals. This signal operates with the compressor contactor. See
Figure 9 or the wiring schematic for details.
Water Solenoid Valves
When using external solenoid valves on ground water
installations, a slow closing valve may be desired. Figure 9
illustrates a typical slow closing water control valve wiring
which will limit wasted water during a lockout condition. A slow
Figure 10: Well Water AVM Valve Wiring
CXM/DXM #1
C
1
2
Heater Switch
C
Y1
Thermostat
Y1
3
HKV Unit
AVM
Taco Valve
CAUTION!
CAUTION! For units with manual or electric water shut-off
valve. DAMAGE WILL OCCUR if shut-off valve is closed
during unit operation. A high pressure switch must be installed
on the heat pump side of any eld provided shut-off valves
and connected to the heat pump controls in series with the
built-in refrigerant circuit high pressure switch to disable
compressor operation if water pressure exceeds pressure
switch setting. The eld installed high pressure switch shall
have a cut-out pressure of 300 psig and a cut-in pressure of
250 psig.
14
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
CXM Control Operation
Note: See CXM operation manual for detailed information pertaining to controller 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/
2 cool thermostat wiring with HKV unit & CXM
15
Heat Controller, Inc. HKV LArge CommerCiAL IOM Instructions
HKV084-150 with CXM Schematic
HKV084-150 with CXM
16
IOM Instructions HKV LArge CommerCiAL Heat Controller, Inc.
HKV168-300 with CXM Schematic
17
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