PATH HDJ, freewatt HDJ Installation, Operation & Maintenance Manual

Download

Page 1

Hydronic

freewatt Plus

Model

HDJ

INSTALLATION,

OPERATION &

MAINTENANCE

MANUAL

System,

Information and speciﬁ cations in the manual were in effect at time of printing of this manual. ECR International reserves the right to discontinue, change speciﬁ cations or system design at any time without notice and without incurring any obligation, whatsoever.

Check our website frequently for updates:

www.freewatt.com

P/N # 240008214, Rev. C [01/2011]

www.ecrinternational.com

Page 2

TABLE OF CONTENTS

1 - Safety Information........................................ 3

2 - Introduction ................................................. 4

3 - Components, Controls and Accessories ...........12

4 - APC Universal Transfer Switch .......................14

5 - Compatible Room Thermostats .....................17

6 - freewatt Transfer Switch Model FTS-1.8 ........18

7 - Before installing the system ..........................19

8 - Placing the system .......................................22

9 - Exhaust Gas Leak Sensor .............................29

10 - Combustion Air and Vent Pipe ......................31

11 - Gas Supply Piping ......................................33

12 - Electrical Wiring & Connections ....................34

13 - Commissioning and Startup .........................40

14 - Maintenance and Cleaning...........................41

15 - Detailed Sequence of Operation ...................43

16 - Troubleshooting .........................................47

17 - Piping and Wiring Schematics ......................53

Safety Symbols

Manual contains important safety information. Read all freewatt

and warnings

PLUS

System manuals for safety information

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

Energy Star partner, ECR International has determined the boiler included as part of

freewatt

guidelines for energy efﬁ ciency .

PLUS

System meets Energy Star

Honda MCHP Intertek-ETL Listed, “Utility Interactive, Cogeneration, Stationary Engine-Generator Assembly, Control # 3163904 (US).”

Boiler and HI Module assembly design certiﬁ ed in US and Canada by Canadian Standards Association.

Page 3

1 - SAFETY INFORMATION

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

WARNING

Do not install this system in mobile home! Boiler is not approved for installation in mobile home. Doing so could cause ﬁ re, personal injury or loss of life.

Instructions intended as aid to qualiﬁ ed, service personnel for proper installation, adjustment and operation of this system. Read instructions before attempting installation or operation. F ailure to follow instructions could cause malfunction of system and result in death, serious bodily injury. Consult qualiﬁ ed installer, service agency or gas supplier for assistance or additional information.

WARNING

Do not store or use gasoline or other ﬂ ammable vapors and liquids, or other combustible materials in vicinity of this or any other appliance.

Natural gas and propane are normally odorized by fuel supplier. Odorant may not be perceivable. Installation of UL and CUL recognized fuel gas detectors installed in accordance with manufacturer’s instructions is recommended as additional safety.

Exhaust gases from boiler contain chemicals which may include carbon monoxide (CO). Carbon monoxide is odorless, tasteless, clear colorless gas, which is highly toxic. Even low concentrations are suspected of causing birth defects and other reproductive harm.

NOTICE

UL and ULC recognized CO detectors are required for all buildings equipped with ECR freewatt PLUS System. All CO detectors should be installed in accordance with manufacturer’s instructions and applicable local building codes.

1.1 Safety Information

Check all applicable state, local building codes and • utility company requirements before installation. Installation shall conform to these requirements in their entirety. In absence of these codes, use NFPA, National Gas and National Electric installation codes and authority having jurisdiction.

Use only with gas approved for system components. • Refer to boiler and MCHP unit rating plates.

Provide adequate combustion and ventilation air to • system space as speciﬁ ed in Section 10, “Combustion Air and Vent Pipe.”

Combustion products shall be discharged outdoors. • Connect system components (boiler and MCHP unit) to approved vent system only, speciﬁ ed in Section 10, “Combustion Air and Vent Pipe’.

Allow system to cool before servicing. • Shut off electricity and gas supply connected to system •

before servicing. Never test for gas leaks with open ﬂ ame. Use •

commercially available soap solution speciﬁ cally made for detection of leaks to check all connections. See Section 11, ‘Gas Supply Piping’.

Verify natural gas input rate is correct. Over ﬁ ring • may result in early failure of the boiler’s components. Under ﬁ ring may result in too much air for combustion process causing poor or loss of combustion.

Install boiler to operate within its intended temperature • range. See boiler ‘Installation Operation & Maintenance’ manual.

Follow regular service and maintenance schedule for • efﬁ cient and safe operation.

Keep system area clean of debris and free from • combustible and ﬂ ammable materials.

System is not intended for temporary heating of • buildings under construction.

System is not do-it-yourself project. Install and servic• by qualiﬁ ed professionals only.

NOTICE

Installation Requirements Speciﬁ c To The State Of Massachusetts, boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to: Installation by licensed plumber or gas ﬁ tter.

Page 4

2- INTRODUCTION

2.1 Hydronic

combined heat and power (micro-CHP) system suitable for residential and light commercial space and water heating applications up to 200,000 Btu/hr.

freewatt PLUS

• System consists of these main components:

•

freewatt

• high efﬁ ciency boiler Model FW95M certiﬁ ed as Category IV direct vent central heating boiler with combustion air supplied directly from outdoors through special air intake system. Combustion products of

freewatt

direct vent system. Hydronic hybrid integration (HI) module and control •

module integrate unit into hydronic heating circuit of building.

HONDA MCHP unit, Model MCHP1.2 D & DP, is • manufactured by HONDA Corporation for use with

freewatt PLUS

For additional details on system components refer to section 3.

freewatt PLUS

high efﬁ ciency (condensing) boiler• control module • hydronic hybrid integration (HI) module • HONDA MCHP unit•

freewatt • transfer switch

electrical load distribution and management panel

zone control relays heat rejection system

Boiler are exhausted to outdoors through

freewatt

System.

Produces electrical power while also generating heat • in response to building’s nor mal thermostatic heat demand. The

Produces 240VAC power delivered to main circuit • panel through 240VAC dedicated circuit.

Certiﬁ ed under UL 2200 - Stationary Generators • and UL 1741 - Inverters, Converters, Controllers and Interconnection Sys tem Equipment for Use With Distributed Energy Resources.

HONDA MCHP unit utilizes indoor air for combustion • and vents combustion products to outdoors with PVC pipe. Honda MCHP unit is non-direct vent appliance.

system is gas-ﬁ red micro-

Boiler and HONDA MCHP

2.2

Application Notes

Maximum design water temperature of 160°F. Heat • emitters sized for heat output using maximum design water temperature of 160°F. Heat loss calculations based on approved industry methods and outdoor temperature corresponding to design water

temperature appropriate for local area’s weather. Hydronic•

normal variety of heating loads served by conventional, multi-zone hydronic heating systems.

freewatt PLUS

base-board radiation, • radiant ﬂ oor heating, • domestic hot water via indirect storage tank, • powered convective heaters, • hydro-air handlers*•

System may be applied to

NOTE: *Application limited to speciﬁ c air handler models.

Hydronic • or valves for individual zone temperature control. Conﬁ guration of hydronic distribution system must be in form shown in this manual with respect to overall arrangement of with respect to zone loads.

See speciﬁ c piping schematics provided for systems • zoned with circulators and valves and for systems using

air handlers.

freewatt

• Control Module is common to all applications of hydronic pump/valve relay controls required for use with pump and valve-zoned systems and hydro-air systems.

Do not use anti-freeze solution in • hydronic ﬂ ow loop. Use only good quality water. Install heat exchanger to isolate anti-freeze solution from main hydronic system, if particular zone requires anti-freeze

protection. Priority domestic hot water heating is available and must be •

properly selected in setup of Control Module and ECR zone controls.

freewatt PLUS

Appropriate pump/valve relay control from ECR • family of zone controls must be used as supplied with

freewatt PLUS

See speciﬁ c electrical wiring diagrams provide for • circulator zoned systems, valve zone systems, and

systems with air handlers.

Indirect water heater aquastat setting must be between • 120 to 125°F.

Mixing valve must be used on domestic water supply • outlet of any indirect water heating tank applied with

freewatt PLUS

Systems use circulators

Boiler and MCHP unit

System. Different ECR zone

System.

freewatt PLUS

. Do not use set back.

System

Page 5

2- INTRODUCTION

WARNING

Burn and scald hazard. Failure to install mixing valve will result in hot water scalding hazard. Install mixing valve per manufacturer instructions.

Hydronic system is supplied with • thermostat. Utilize thermostat on single “Smart Zone” only. Select “Smart Zone” as zone with largest heating demand (not domestic hot water zone) typically the largest space heating zone on ﬁ rst ﬂ oor of two story home.

PLUS

beneﬁ t if Smart Zone represents at least 25% of total home heating load. Consider combining zones to achieve desired heat load for Smart Zone if there is no single large zone in

existing distribution system, but many small zones.

freewatt

• communicating thermostat is directly wired to

freewatt

zones, with compatible conventional heating thermostats (new or existing) may be connected directly to Control Module circuit board. If more than compatible six zones (including priority domestic hot water and Smart Zone) are needed expanded to include additional heating zones. Additional

ECR zone controls may be required. Hydronic•

phased. Install in required piping conﬁ guration as shown in leaving installation, commissioning, and operation of MCHP to later date (cap off piping connections to MCHP), if need to supply heat to building quickly as possible.

PLUS

normal loads if MCHP unit is not available for operation. MCHP unit will provide signiﬁ cant portion of annual •

heating energy needed in home, MCHP unit alone cannot be expected to meet all desired comfort and/or freeze protection needs. Maintaining operation status of

freewatt

essential to meeting all comfort and/or freeze protection needs.

“CHP MODE” switch OFF position conveniently • separates and maintains boiler heating function while disabling operation of MCHP unit and generation of

electric power. This is Bypass Mode of operation.

System will produce best electric power generation

Control Module circuit board. Additional ﬁ ve

freewatt PLUS

boiler will provide sufﬁ cient heating capacity to meet

Boiler as part of

freewatt

System can be

System installation may be

Boiler and Control Module

freewatt PLUS

communicating

freewatt

Section 17

freewatt

System is

Installation of UL and ULC recognized CO detectors with • audible alarms (not supplied with system) are required part of Exhaust Gas Detection System included part of

PLUS

tion of building inhabitants from potentially dangerous high levels of carbon monoxide. Install both Exhaust Gas Detection System and separate, independent UL recognized CO Detectors.

Installation of two different outdoor temperature sensors is • required for proper operation of hydronic System, both are supplied. One (Honeywell) connects directly to boiler and other (Tekmar) to

Module. hydronic •

electric power during power outage if installed and commissioned per Installation, Operation, and Maintenance Manual.

Heating system must be connected to APC UTS. Installation, setup, commissioning and maintenance of •

freewatt PLUS PLUS

ning Windows XP or Vista with working serial connection. Call •

watt PLUS

additional information. Heat rejection kit (sold separately) required for instal-•

lation.

Zone Valves with their own 24 VAC power supply may • be used on zones 3-6. Refer to Electrical Wiring and Connections section for detailed information on use of steering relays in

freewatt PLUS

System does not provide audible alarm for protec-

freewatt PLUS

System requires use of

MINT software tool loaded on laptop computer run-

freewatt PLUS

System installations above 3,300 feet and for

Water cooled heat rejection kit used when there • is uninterruptable supply of water during power outage. Kit ties into main water supply line and discharges water to appropriate drain.

Air cooled heat rejection kit used when there is • not uninterruptable supply of water during outage (houses with well pumps). Air cooled heat rejection system is vertically arranged side discharge fan-coil unit with closed coolant loop designed for outdoor installation.

installation.

System will generate heat &

Technical Support Line for

freewatt control module.

freewatt PLUS

freewatt

freewatt PLUS

freewatt

Control

free-

Full heating operation of hydronic • is not dependent on maintaining working connection to Internet. Lack of internet connection will prevent remote communication with system by homeowner or service

provider.

freewatt PLUS

System

Page 6

2- INTRODUCTION

2.3 Save These Instructions

Read this manual carefully and keep for future reference by service technician. Manual is considered permanent part of your Hydronic freewatt with system.

Manufacturer is not responsible for any ﬁ eld installation changes made to system installation that are not described or acknowledged in this manual.

Product must be installed by licensed plumber or gas ﬁ tter when installed within Commonwealth of Massachusetts.

Appliance has been equipped for residential installations. If used for commercial applications, all code requirements must be adhered to for installation. May require additional

controls or system components.

2.4 Read All Documents

Hydronic • Information Manual.

freewatt PLUS

PLUS

System and should remain

(Model HDJ) User’s

freewatt

• FW95M-200 Boiler Installation, Installation, Operation and Maintenance Manual, Parameter Guide, Control Manual & Troubleshooting Guide.

HONDA MCHP, Model1.2D and MCHP1.2DP, Type UCFJ, • Installation Manual and Owner’s Manual.

HAI Thermostat Installation Instructions and Owner’s • Manual

Applicable ECR Zone Control Manual•

freewatt

• Indirect Water Heater Set-up, Operating & Maintenance Instruction Manual

freewatt

• Transfer Switch Installation, Operation and Maintenance Manual.

APC Universal Transfer Switch Site Preparation and • Installation Guide.

Hydronic • Installation, Operation and Maintenance Manual.

freewatt

(model HDJ) Control Module

Page 7

2- INTRODUCTION

Figure 2-1 - freewatt PLUS System Components ( Zoned with Circulators)

freewatt® PLUS System Components

Heating Zone Returns

freewatt System Control Module

Zone Controls

Honda MCHP Exhaust Gas Sensor

Programmable & Communicating HAI Thermosat

freewatt Outdoor Temperature Sensor

Boiler Outdoor Temperature Sensor

HI Module

Honda MCHP

From DHW

To HI Module

From HI Module

To Boiler

From Boiler

Heating Zone Circulators

APC UTS6H

DHW Circulator

freewatt Transfer

Switch W/Load

Balancing Transformer

freewatt Indirect Hot Water Heater

Figure 2 -2

freewatt PLUS

freewatt Boiler

95% AFUE

Boiler

Page 8

Table 2-1 System Rating and Sizing

2- INTRODUCTION

Unit

MCHP Mode

Input

(MBH)

Heating

Capacity

(MBH)

18.4 12.3 12.3 1.2 180

Overall

Efﬁ ciency

(%)

Nominal

Power (kWe)

Weight

(lbs)

Honda

MCHP Unit

Backup Mode

18.5 - 26 12 - 17 12 - 17 0 - 1.8 180

(0 - 3,300’)

Boost Mode

Boiler

Boiler Module (0 - 2,000’)

Ratings are for sea level applications. Boiler: Consult boiler Installation, Operation and Maintenance Manual for high altitude conversion and derating

instructions. Honda MCHP: Consult with ECR International Technical Support for high altitude conversion and derating instructions

Boiler manual has I=B=R Net Rating (MBH) data for system design. Proper application of Hydronic

Relatively lower heat output of MCHP unit, priority heating device, and automatic modulation of ﬁ ring rate of condensing boiler allows Hydronic performance depends signiﬁ cantly on sizing of heat distribution system relative to actual space heating demands. Under-radiated distribution systems that require high system water temperatures (above 180°F during design (coldest) day outdoor temperature conditions) will signiﬁ cantly compromise electric generation performance of System. Recommend hydronic heating system be designed for 160°F or lower water temperature to produce greatest annual electrical power generation and highest energy efﬁ ciency. 160°F design water temperature may require installation of new radiation or re-conﬁ guration of existing radiation to acceptably heat zones.

freewatt PLUS

System to be applied to wide range of loads without efﬁ ciency penalty. System

26 17 17 1.8 180

80-200 76-190 95% - 284

System requires assessment of heat loss and applied building needs.

freewatt PLUS

Hydronic and boiler delivering high heat. hours will maximize system’s electrical power production. Boiler will ﬁ re to provide heat if additional heat is needed or anticipated.

Boiler will automatically modulate in range of 80,000 to 200,000 BTU/hour, and MCHP unit will continue to run to provide needed level of heat supply in high heat mode. Hydronic programmable outdoor temperature reset of hydronic system water temperature to provide uniform heating.

freewatt PLUS

System operates with two levels of heat: HONDA MCHP’s thermal output delivering low heat

freewatt PLUS

uses proprietary heating algorithm to ensure long MCHP operating

freewatt PLUS

System operates with automatic and

Page 9

2- INTRODUCTION

Figure 2-3 MCHP & Hydronic Hybrid Integration Module

Figure 2-4b Hydronic Hybrid Integration Module

Figure 2-4a Hydronic Hybrid Integration Module

Figure 2-5 Typical freewatt PLUS Control Module Conﬁ guration

Page 10

2- INTRODUCTION

Figure 2-6 freewatt PLUS Control Module Details

Figure 2-7 MCHP Dimensions

Dimensions Boiler Honda MCHP Top 1" ( 8" for service) 14" Sides 1" (24" for service) 0.4" (12" for service) Base See Note 1 See Note 2 Front 0" (24" for service) 0.4" (20" for service) Rear 6" 0.4" (2" for service) Intake/Vent Piping 0" 0" Near Boiler HW Piping 1" 0"

System Clearances to Combustibles

NOTE: 1. Combustible ﬂ oor approved, but not carpet.

2. MCHP attached to base anchored to concrete ﬂ oor .

Page 11

2- INTRODUCTION

Figure 2-8 MCHP Electrical Connection Details

Figure 2-9 MCHP Front Interface Details

Page 12

3 - COMPONENTS, CONTROLS AND ACCESSORIES

Section provides brief description of components, controls, and accessories of hydronic freewatt PLUS

System.

3.4 HONDA MCHP Unit

3.1 Boiler

Refer to separate freewatt boiler documentation for detailed information on the freewatt boiler.

3.2 freewatt Control Module

freewatt • control module monitors and controls

operation of Hydronic freewatt PLUS System. Sensing inside and outside temperature as well as other system temperatures and settings, proprietary heating algorithm controls operation of Honda MCHP optimizing power production and low level heat delivery.

freewatt • control module includes relay/interconnect

board, DC power supply, and advanced singleboard computer board incorporating powerful microprocessor, RS-232/RS-485 serial ports, and

10/100 Base-T Ethernet port.

3.5 Smart Zone Communicating Thermostat

3.3 freewatt PLUS Hydronic Hybrid Integration (HI) Module

freewatt PLUS • Hydronic HI Module location is

where heat in MCHP coolant is transferred into hydronic water.

freewatt PLUS • Hydronic HI module consists of

brazed plate heat exchanger, mixing valve, coolant reservoir and coolant pump.

Hydronic water is pumped through secondary circuit, • MCHP coolant is pumped through primary circuit.

Mixing valve is ﬁ eld adjusted to deliver minimum • 152°F coolant to pump, which returns coolant to Honda MCHP unit.

Coolant reservoir holds spare coolant and is • instrumental in proper commissioning of system.

Hydronic HI Module designed to mount on • adjacent wall or on side of boiler. Module’s brazed plate heat exchanger has two ¾” NPT hydronic water connections and two ¾” NPT coolant loop connections connected to HI module

Hydronic water circulator for HI module is mounted • external to HI module as part of hydronic system piping.

freewatt • control module operates both HI module

coolant pump and hydronic circulator suppling hydronic water ﬂ ow to HI module. Coolant pump operates on 24VDC supplied directly by freewatt control module. Associated 120VDC hydronic circulator is powered through ECR AR822-II relay

control.

3.6 Outdoor Temperature Sensor

3.7 Internet Connection

Connecting control module to high-speed internet service allows freewatt PLUS service provider to monitor system’s operating characteristics. freewatt control module will notify service provider of abnormality, if system has operating characteristics outside normal operating range and remote monitoring

system is enabled and active.

Honda MCHP Unit is custom-engineered micro-• combined heat and power module integrated into Hydronic freewatt PLUS System. MCHP unit designed to start and stop by means of digital signal from control module when control module senses there is heat demand in dwelling.

MCHP unit is ETL certiﬁ ed for grid interconnection • if your utility allows, unit can deliver electrical power back into electric grid. Unit provides system operating data and diagnostic data to control

module.

Smart zone communicating HAI thermostat • communicates directly with control module. Allows freewatt control module to download thermostat settings and maximize system’s electrical power generation, providing higher level of comfort to dwelling.

Zone which thermostat is applied is referred to as • “Smart Zone”. Supplied communicating thermostat must be used on one space heating zone of hydronic system. freewatt PLUS System will not work with any other thermostat installed in “Smart Zone”. Compatible conventional thermostats, may be used

in other zones.

Hydronic • freewatt PLUS System uses two outdoor temperature sensors to anticipate heat demand within dwelling by tracking outdoor temperature. Control module will determine optimum temperature to activate Honda MCHP unit and provide thermal comfort, maximizing generation of electrical power as outdoor temperature falls.

Honeywell temperature sensor is connected directly • to freewatt PLUS Boiler and Tekmar temperature sensor is connected directly to freewatt Control Module.

Both sensors are required for proper operation. • Route in separate cables at least on foot apart to

ensure signal quality.

Page 13

3 - COMPONENTS, CONTROLS AND ACCESSORIES

3.8 Website

freewatt control module web site address is assigned

to system at time of installation allowing homeowner and service provider to monitor or control system’s

operation.

3.9 External Condensate Pump

Float activated condensate pump with integral • sump is required for installation where there is no ﬂ oor drain or other appropriate drainage receptacle available to receive condensate from system (boiler and MCHP unit).

Condensate pump can be piped to remote point to • sanitary sewer system (Please follow all state or local regulations regarding disposal of condensate). Install system so proper pitch can be placed on piping to

deliver condensate safely to external condensate sump.

3.10 Exhaust Gas Leak Sensor

Exhaust Gas Leak Sensor (EGLS) monitors integrity of • Honda MCHP unit combustion system and shuts down MCHP unit if certain potentially unsafe conditions are detected.

Monitors carbon monoxide level in air space near MCHP • unit.

Exhaust Gas Leak Sensor is independent and separate • from audible CO alarming system installed with

freewatt PLUS

practices for all fuel-ﬁ red central heating equipment. Proper installation of the EGLS is required to •

commission Hydronic

System in compliance with best

freewatt PLUS

System.

3.11 Concentric Vent/Air Intake Termination (Optional)

Optional concentric vent/air intake termination utilizes • single opening for boiler through wall or roof of structure.

MCHP unit requires use of exhaust vent.•

3.12 Heat Rejection System

Heat rejection kit (sold separately) is required for backup mode operation during times when no space heating or

water heating is required.

A water cooled heat rejection system is available • for installations where there is uninterrupted supply of water during power outage (city water). Kit ties into main water supply line and discharges water to appropriate drain. Drain must be suitable for 0.35 GPM at 180° F. Kit contains ball valve, pressure reducer, electronic ball valve, and ﬂ ow reducer. Installer must supply piping to tie into main water line, and deliver water to appropriate drain.

Installations without uninterrupted supply of water • during power outage (most houses with well pumps) air cooled heat rejection system is available. Contains vertically arranged side discharge fan-coil unit installed outside, and is connected to HI Module through closed coolant loop. Dimensions of unit are 24” Length, 15” Width, and 36” Height.

Air cooled heat rejection system installer must • supply secure mounting pad or foundation, power wiring, low voltage wiring (18 AWG minimum), and closed Propylene Glycol coolant loop from HI Module to unit (3/4” piping, circulator, air separator, pressure relief valve, expansion tank, ﬂ ow check, and purge valve). See FWHRJ Air cooled heat rejection system Installation, Operation, Maintenance manual for speciﬁ c installation

instructions.

3.13 Display/User Interface

Homeowner can scroll through control settings and change operating settings to customize freewatt PLUS

System operation using PC.

3.14 Internet Connection & Commissioning

freewatt • System control module connects to

customer’s home network in same way any computer or other network appliance does connecting via Ethernet connection available on most routers. freewatt PLUS connection uses 10/100 Mbit/s wired Ethernet connection, wireless bridges may be used when wired connection isn’t possible.

freewatt • control module is assigned static address

outside of DHCP range available from router. IP address, netmask, gateway and DNS addresses •

are programmed into control module using freewatt PLUS service tool. Common conﬁ guration (with router at address 192.168.1.1) would have freewatt address set to 192.168.1.200, netmask set to 255.255.255.0, gateway set to 192.168.1.1 and DNS entries set to 208.67.222.222 and

208.67.220.220 (addresses for Open DNS). Router conﬁ gured to allow incoming trafﬁ c for •

diagnostics and (if requested by customer) access to user web page. Routers refer to these settings as ‘port forwarding’, ‘applications’’, or ‘virtual servers’. Refer to router manufacturer’s documentation.

Remote diagnostics require port 4500 be directed • to freewatt control module. Port for customer web pages is conﬁ gurable - usually set to 8082 because many ISPs (Internet Service Provider) block use of standard port 80.

Number of wireless bridge or gaming bridges • have been tested to work with control module if wireless conﬁ guration is required. Conﬁ gure using manufacturer’s instructions.

Page 14

4 -APC UNIVERSAL TRANSFER SWITCH CONFIGURATION

NOTICE

APC universal transfer switch is provided for use with freewatt Plus system and is not intended for emergency backup power applications. Manufacturer is not responsible for the use of this switch in any manner not outlined in this manual or APC UTS6H Installation Guide.

4.1 APC Universal Transfer Switch

freewatt•

Transfer Switch as load panel in Back-Up Power Mode. UTS6H requires customized conﬁ guration in order •

to operate effectively with freewatt Following section will explain conﬁ guration process for this component.

Set-up for APC Universal Transfer Switch (UTS6H) • involves following System Conﬁ guration and Setup section in UTS’s Installation Guide.

Important notes about this product:•

Improper conﬁ guration may result in improper operation of freewatt PLUS System in Backup Power Mode. Failure to follow these instructions could cause malfunction of system and result in death, or serious bodily injury. Read and follow these instructions before attempting installation, commissioning or operation.

PLUS

System incorporates APC Universal

WARNING

PLUS

System.

Circuit 5 & 6

Although all UTS circuits do not need to be used, • Circuits 5 & 6 must be connected to main circuit panel and must receive power for UTS to function. Circuits 5 & 6 must also be connected to circuits that are in opposite phases, so 240V is present across two circuits. Allows UTS6H to monitor Utility power supply.

4.2 Uninterruptible Power Supply (UPS)

If using UPS to power “uninterruptable” loads, plug UPS • power input cord into convenience outlet to charge UPS batteries when MCHP Backup Power is available. Note, UPS batteries will also be charged from convenience outlet when grid power is available.

Follow UPS and UTS6H instructions for sizing UPS for • loads conﬁ gured to be powered by UPS in Backup Mode. Typically, low power circuits, such as computers or security systems, are conﬁ gured for use with UPS.

4.3 Non-Delayable & Delayable Circuits

Circuit assigned to • freewatt boiler shown in examples on Circuit 3 must be conﬁ gured as “Delayable-No” to ensure freewatt when in Backup Mode, otherwise system may not operate correctly.

All other circuits must be conﬁ gured as “Delayable-• Yes” except in case of example where UPS is used and circuit source is conﬁ gured as “UPS” or “Un- interruptable”.

PLUS

System always has power

NOTICE

Use only outlet mounted AFCI and GFCI circuit interrupters with the UTS. Do not connect the UTS to circuits utilizing AFCI or GFCI circuit breakers in the main electrical panel.

Circuit 1

Circuit 1 includes Load attached to Circuit-labeled “1” • and convenience outlet on front of UTS6H, together must consume less than 15 amps when system is operating in Backup Mode. If not using Uninterruptable Power Supply (UPS), it is recommended to use circuit 1 to power freewatt condensate pump.

Circuit 1 is only powered by MCHP when in Backup • Power Mode. It will not be powered from UPS if UTS6H is equipped and conﬁ gured to use UPS. It is recommended that UPS be plugged into front convenience outlet and therefore is powered by Circuit

PLUS

System’s low power

4.4 Hardwire Kit

UTS6H is supplied with Hardwire Kit used to connect • freewatt Parts, Kits & Optional Accessories for kit part number. Hard-wire kit is installed in UTS6H and accepts cable delivering Honda generator’s backup power output. Follow electrical schematics in this manual and instructions in Hard-wire Kit for installation.

PLUS

Transfer Switch to UTS6H. See

NOTICE

Circuits 5 & 6 must be connected to circuits in opposite phases to ensure 240VAC is present across two circuits, to allow UTS6H to monitor utility power supply and sense power outage.

NOTICE

Mark all breakers in Electric Panel as moved to UTS6H for future reference.

Page 15

4 - APC UNIVERSAL TRANSFER SWITCH CONFIGURATION

Table 4-1 Typical UTS6H Circuit Setup without UPS

Typical UTS Circuit Setup without UPS

PARAMETER

CIRCUIT

Other (con-

Load Type

densate

pump) Source GEN GEN GEN GEN GEN GEN Delayable Yes Yes (1) No Yes Yes Yes Max time off (min) 30 1 30 5 60 30 Min time on (min) 30 2 30 5 60 15 Security Mode Off Off Off Off Off Off Amp Rating(A) 15 15 15 15 15 15

Note (1) Delayable - Yes:

or sump pump from losing power when in Backup Mode. If sump pump and boiler may operate at same time (power outages during heating season and heavy rain events), possible solutions include:

Battery-backed sump pumpA. UPS and conﬁ gure sump pump power source as “Either” UPS or Generator.B.

Setting is required for Warm Air freewatt

CIRCUIT2CIRCUIT3CIRCUIT4CIRCUIT5CIRCUIT

Sump

pump

Boiler Computer

PLUS

System boiler to prevent freewatt

Security

System

Refrigerator

PLUS

System

Table 4-2 Typical UTS6H System Setup without UPS

Typical UTS6H System Setup without UPS

Bypass mode No Load shedding? On Voltage sensitivity Medium Time Management On Reset Energy Meter No System Test No Backup1 Source Type Generator GEN power rating 1700 (1) GEN SRGE Overload Time 0 seconds GEN Start Mode manual Backup2 Source Type none GEN power rating 1800 GEN SRGE Overload Time 0 seconds Reset to default no

NOTE: (1) Available generator power is set to 1,700 watts to account for 100 watt power consumption of load balancing

transformer.

Page 16

4 - APC UNIVERSAL TRANSFER SWITCH CONFIGURATION

Table 4-3 Typical UTS6H Circuit Setup with UPS

Typical UTS Circuit Setup with UPS

PARAMETER

Load Type

Source GEN EITHER GEN EITHER EITHER GEN Delayable Yes Yes No Yes Yes Yes Max time off (min) 30 1 30 5 60 30 Min time on (min) 30 2 30 5 60 15 Security Mode Off Off Off Off Off Off Amp Rating(A) 15 15 15 15 15 15

Note: UPS power output cord shall be attached to “UPS” inlet port of the UTS6H.

CIRCUITICIRCUIT2CIRCUIT3CIRCUIT4CIRCUIT5CIRCUIT

Other (con-

densate

pump)

Sump pump

Boiler Computer

Security

System

Refrigerator

Table 4-4 - Typical UTS6H System Setup with UPS

Typical UTS6H System Setup with UPS

Bypass mode No Load shedding? On Voltage sensitivity Medium Time Management On Reset Energy Meter No System Test No Backup1 Source Type Generator (1) GEN power rating 1700 (2) GEN SRGE Overload Time 0 seconds GEN Start Mode manual Backup2 Source Type UPS (3) GEN power rating 2100 (4) GEN SRGE Overload Time 0 seconds Reset to default no

Notes:

Generator:1. Corresponds to 240VAC GEN port on UTS6H. GEN Power Rating (Backup1)2. : Set to 1,700 watts to account for 100 watt power consumption of load

balancing transformer.

UPS:3. Corresponds to UPS inlet port on UTS6H. GEN Power Rating (Backup2):4. Corresponds to 1,700 watts of MCHP power PLUS UPS power rating (in this

case 400 watts).

Page 17

5 - COMPATIBLE ROOM THERMOSTATS

5.1 freewatt Hydronic Zone Thermostat Requirements

Select heat or heat/cool thermostat with following properties, except Zone-2. Zone 2 must use HAI Smart

Zone Thermostat.

Use isolated relay contacts to switch W call for heat • signal. to thermostat’s “R” terminal to pass directly thru thermostat’s W relay to drive “W” signal back with minimal loss of signal voltage when calling for heat.

Thermostat’s W relay must present high-impedance • (ie. no current ﬂ ow) when open, not calling for heat.

Thermostat must not add resistive elements to W • signal path (resistors, voltage divider networks, MOSFET(s), transistors, etc.) when not calling for heat. Open circuit impedance of W signal path must be greater than 100,000 ohms, and preferably higher

(ie 1 Megohms or more).

5.2

Known Problematic Thermostats:

Honeywell T87N, T87K

•

freewatt

expects 24VAC “HOT” connected

Voltage must be greater than 20 Volts AC, when • thermostat calls for heat. Thermostat is not suitable for use with

less than 20 Volts AC.

5.5 Communication Registers On RC-1000 Smart Zone Thermostat:

Apply factory reset to restore communications on RC-• 1000-WH-ECR.

Select “Setup”. • Select “Installation Settings”. • Notice warning for installers. Press “Continue”.• Select “Factory Reset” (last item in list). • Press “Back” as required to return to normal operation. •

All settings, including setback programming have been cleared.

freewatt PLUS

ress (“click”) on scroll wheel to start.

System if voltage is

5.3

Known

HAI Omnistat1, Onmistat2• LUX 1500•

Braeburn Model 3000•

Compatible thermostats:

5.4 Tests For Thermostat Compatibility:

Resistance test: •

Thermostat calling for heat, W relay closed: • Thermostat relay impedance must be less than 40 ohms when measured across thermostat R and W terminals. Impedance greater that 40 ohms is unacceptable and will not work reliably with

freewatt PLUS

Thermostat not calling for heat, W relay open: • Thermostat relay impedance should be greater than

1 Megohm (1 million ohms).

Voltage test:•

AC voltage measured between 24V common • terminal on circuit board J02 connector (labeled 24VAC - bottom of board) and circuit board J02 W1, W3 or W4 terminals (top of board) must be less than 1.5 Volts AC when no call for heat, attached to

freewatt PLUS

volts AC from not suitable for use with voltage is greater than 1.5 Volts AC.

System.

System and powered by 24 to 28

freewatt

Control Module. Thermostat

freewatt PLUS

System if

Page 18

6 - freewatt TRANSFER SWITCH MODEL FTS-1.8

6.1 freewatt Transfer Switch Model FTS-1.8

freewatt• Transfer Switch is speciﬁ cally designed for

use with freewatt power (micro-CHP) system.

freewatt• of electric load from utility power source to MCHP unit. No manual adjustments or switching are required by

homeowner under normal operation. freewatt• System Control Module and freewatt

Transfer Switch monitor utility power source for failure. Monitor HONDA MCHP power source for electrical power •

output and proper operating conditions.

Transfer Switch provides automatic transfer

PLUS

micro-combined heat and

Figure 6-1 freewatt Transfer Switch

freewatt• Transfer Switch provides freewatt

product line with reliable means of providing backpower to critical loads while preventing electrical feedback to utility from MCHP.

PLUS

freewatt•

and is limited in type, wattage, and number of loads supported.

freewatt• freewatt PLUS

Consult • freewatt Transfer Switch Installation, Operation, and Maintenance manual for installation, operating and troubleshooting information.

System by qualiﬁ ed installer.

provides backup power up to 1.8 kW

Transfer Switch certiﬁ ed for use as part of

PLUS

System. Only install with freewatt

PLUS

Page 19

7 - BEFORE INSTALLING THE SYSTEM

7.1 Codes

See boiler manual for information pertaining to installation in State of Massachusetts.

System incorporates gas-ﬁ red, direct vent, condensing appliances and must be installed in accordance with the

following:

Fuel Gas:

United States: Installation shall conform to National • Fuel Gas Code (NFPA-54/ANSI Z223.1).

Canada: Installation shall be in accordance with CSA-• B149.1 and B149.2 installation codes.

Authority having jurisdiction•

Electrical:

United States: National Electrical Code (ANSI/NFPA-•

70). Canada: CAN/CSA-C22.1 Canadian Electrical Code.•

Authority having jurisdiction•

Condensate Disposal:

Authority having jurisdiction•

7.2 System Sizing And Application

Select system with proper capacity before continuing • installation. Firing rate of system should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by system. See Section 2 for system ratings.

Base heat loss calculations on approved industry • methods.

Conﬁ gure hydronic • 2 operated by Smart Zone HAI thermostat supplied with

freewatt PLUS

must have sufﬁ cient thermal load to provide proper operation of MCHP unit. Too small of heat load in Smart Zone will result in frequent MCHP cycling and poor electrical power savings. The “Smart Zone” should be selected as zone with largest heating demand (but not domestic hot water zone). Normally, this would be largest space heating zone on ﬁ rst ﬂ oor of two story home. best electric power generation beneﬁ t if Smart Zone represents about 25% of total home heating load. Consider combining zones to achieve desired heat load for Smart Zone if there is no single large zone in

existing distribution system but many small zones.

freewatt PLUS

System. Zone 2, Smart Zone,

freewatt PLUS

System with Zone

System will produce

Installers:

Authority having jurisdiction• Follow recommended maintenance outlined in this •

manual.

Grid Interconnection:

Authority having jurisdiction with respect to • interconnecting to grid.

freewatt PLUS

• System must be applied with hydronic heating systems having ample heat delivery capacity relative to maximum or design heat load. This is requirement for efﬁ ciency hydronic systems to achieve maximum energy efﬁ ciency. “Under-radiated” system requiring high supply water temperature (above 180°F) during outdoor low-temperature design conditions will result in reduced contribution of MCHP to total heat delivery, reducing electrical power production beneﬁ t. Preferred design operating temperature is 160°F. Consider adding additional heat radiation to existing underradiated distribution systems for proper application of

freewatt PLUS

Power generation performance of • System may be adversely affected if there is any zone resulting in constant active call for heat during heating season (i.e., highly under-radiated zone). Verify all zones have enough radiation, even during very cold weather, so no zone thermostat will produce continuous

call for heat (i.e., cannot be satisﬁ ed).

freewatt PLUS

• requires different ECR zone relay controls depending on type of zoning utilized: zoned by circulators, valves, or air handlers. Verify you have correct ECR zone relay control before beginning

installation.

freewatt PLUS

and all high-

freewatt PLUS

Page 20

7 -BEFORE INSTALLING THE SYSTEM

7.3 Considerations for System Location

Before selecting location for system, following should be considered. Each system component considered for

installation must be:

Supplied with correct type of gas.• Connected to separate (two) combustion gas vent •

pipes discharging to outdoors: one for Boiler unit and one for MCHP unit. Each vent must meet minimum and maximum vent lengths for each unit. (See Section 10).

Connected to suitable combustion air intake piping • system to supply fresh (outdoor) air for combustion (3” for

freewatt PLUS

(See Section 10) Connected to suitable forced hot water distribution •

system. Supplied with suitable 120VAC electrical supply for •

all system motors and controls and separate 240VAC supply for MCHP unit.

Connected to properly located thermostat or operating • control ( Smart Zone thermostat supplied with system and must

be installed and connected to “Zone 2”). Placed on level surface (must NOT be installed on •

carpeting). Condensate drain line must be pitched down to ﬂ oor •

drain or external condensate pump with reservoir at ¼” per foot (wood frame or concrete blocks may be used to raise boiler). MCHP unit must be bolted to concrete

ﬂ oor as speciﬁ ed.

freewatt PLUS

Boiler) (not required for MCHP)

requires communicating

freewatt PLUS

7.4 Locating the System

Select level location central to distribution system and • close to vent and air intake terminals.

Use accessibility clearances for system installation, if • more stringent (i.e. larger clearances) than required ﬁ re protection clearances.

Must install MCHP unit on solid, concrete ﬂ oor with • adequate make-up air available for 18,500 Btu/hr net input heating appliance. System shall not be installed on carpeting. Shimming should be done between base and MCHP, not between base and ﬂ oor.

Advise owner to keep venting and combustion air • intake passageways free of obstructions. Both venting and combustion air intake piping systems connected to outdoors must permit ﬂ ow through piping systems without restrictions for system to operate.

Install control module and switching components to • protect from water (dripping, spraying, rain, etc.) during operation and service (pump replacement, MCHP maintenance, etc.).

Locate system where ambient room temperatures • (minimum possible temperatures where system is installed assuming system is not in operation and therefore contributes no heat to space) are at or above

32°F to prevent freezing of liquid condensate.

7.5 Combustion Air and Vent Pipe Requirements

System requires dedicated direct vent system for boiler • and separate vent for HONDA MCHP to discharge all combustion products to outside atmosphere.

Boiler requires combustion air intake to complete its • sealed combustion direct-vent system and provide air from outdoors. HONDA MCHP requires make-up air from installation space.

CAUTION

Keep system area clean of debris and free of ﬂ ammable and combustible materials, vapors and liquids.

Combustion air supply and boiler vent pipes must • terminate together in same atmospheric pressure zone, through roof or sidewall (roof termination preferred). Boiler and MCHP vent terminations may be at different locations, feature may assist in locating appropriate

venting locations. Consult boiler and HONDA MCHP Installation Manuals for speciﬁ c guidelines for required

clearances and installation instructions. Refer to boiler Installation, Operation and Maintenance •

Manual for guidelines regarding concentric vent termination installation and guidelines.

Install equipment in location facilitating operation of • venting and combustion air intake piping systems described in this manual (Section 10).

Page 21

7 -BEFORE INSTALLING THE SYSTEM

7.6 Condensate Drain Requirements

Install condensate drain lines with pitch down to ﬂ oor • at minimum of ¼” per foot.

External condensate pump (not furnished) may be used • if ﬂ oor drain is not available. One condensate pump can be used for both boiler and MCHP.

Use condensate pump designed for ﬂ ue gas condensate • application.

Consult boiler and Honda MCHP Installation Manuals for • guidelines for condensate drain installation.

NOTICE

It is recommended no additional electrical connections be made within

System for line power. Separate junction box and receptacle should be provided if line power is required for condensate pump,.

7.7 Foundation Requirements

Place system on level concrete surface. DO NOT install • on carpeting.

freewatt PLUS

7.9 Requirements for Hydro-air Applications:

Application of • Air Handler as Smart Zone requires Smart Zone Air Handler be of type powered with ECM blower motor.

VHBXB Air Handlers manufactured by First Co. having • ECM blower motor are known to work with

PLUS

Consult factory for additional information before • application of other air handlers with Smart Zone of

freewatt PLUS

System.

freewatt PLUS

System.

with Hydro-Air System

freewatt

System:• Level System will allow the condensate drain lines to function properly. Shims should be used between boiler, ﬂ oor, MCHP and base to make up for minor surface irregularities or tilt.

HI Module: The HI Module will be mounted on boiler or • nearby wall.

Honda MCHP: Honda MCHP is supplied with a base to • raise unit above ﬂ oor and secure to concrete ﬂ oor.

7.8 Removal of Existing Furnace from Common Vent System

Existing common venting system is likely to be too large for proper venting of appliances remaining connected to it. Refer to decommissioning procedure outlined in boiler

Installation, Operation and Maintenance manual.

Page 22

8 - PLACING THE SYSTEM

8.1 Place system to provide direct connections to:

combustion air/vent piping system, • natural gas piping, • return and supply duct-work, • condensate removal system,•

electrical connections.•

8.2 Instructions for preparation and placement of Hydronic freewatt

Determine location for boiler, MCHP and indirect hot • water tank (if used), identify location for hydronic HI module, relay switches and circulators. Typical conﬁ guration for Hydronic shown in Figure 2-1.

Place crated boiler and HONDA MCHP unit as close to • selected location as possible and un-crate units.

Follow instructions outlined in • Installation, Operation and Maintenance Manual for placing boiler. See Figure 2-2 for boiler details.

System conﬁ guration and ﬁ nal placement should allow • for future servicing of equipment.

See Figure 8-2 for typical piping schematic to assist • in determining layout of components.

Reference HONDA MCHP Installation Manual for • instructions regarding placement.

Install MCHP unit base as speciﬁ ed in HONDA MCHP, • Model YM2Z, Installation Manual and Owner’s Manual as summarized below and Figure 8-1.

Place base on concrete ﬂ oor and level.• Mark anchor bolt locations on concrete ﬂ oor.•

PLUS

System:

freewatt PLUS

System is

Boiler

system

CAUTION

Penetration or modiﬁ cations of MCHP cabinet will result in potential electrical or ﬁ re hazard. Do not attach controls, wire, piping, conduit or other hardware to MCHP unit.

Place HONDA MCHP on base and secure MCHP unit to • base with supplied hardware after base installed. See Figure 8-1.

Determine location of Hydronic HI Module enclosure. • Mount enclosure on solid wall or partition. Recommend enclosure be located close to HONDA MCHP. HI module may be mounted up to 10 feet away from HONDA MCHP unit. Locate enclosure with installation and service accessibility in mind.

Hydronic HI Module bottom should be installed at • height of 32” to 42” above ﬂ oor elevation where base of HONDA MCHP is installed.

Ensure top of Hydronic Hybrid Integration (HI) • module is mounted above Honda MCHP’s top cover. HI Module bottom should not be above MCHP top.

Hydronic piping between HI module and primary • hydronic loop manifold should not exceed 40 feet. Piping and circulator should be designed for water ﬂ ow rate of 4gpm. HI module heat exchanger pressure drop is approximately 1 psi.

Position enclosure, check for level, mark mounting • holes.

Start screws (#10 ,4 each, ﬁ eld source) for keyhole • type mounting holes in upper corner(s). Tighten screws down to about 1/8” (3mm) from surface.

Hang enclosure on screws, position enclosure and • start bottom screws.

Tighten all screws.•

Drill hole diameters in concrete for anchor bolts • per manufacturer’s installation instructions. If obstruction is hit, move base and re-drill.

Attach base to anchor bolts with supplied hardware.• Locate washers between MCHP and base if unit •

needs to be shimmed level. Orientation of bolt & nut is important. Bolt must be •

installed from top with nut on bottom. Use nuts and bolts supplied in installation kit. Do not use shipping bolts which attach MCHP to shipping pallet.

Do not make penetrations or drill holes in MCHP unit • cabinet.

Figure 5-1 MCHP Base Installation

Page 23

8 - PLACING THE SYSTEM

8.3 freewatt PLUS

Place equipment in proper locations. • Conﬁ gure system piping to connect boiler and HONDA •

MCHP to distribution piping. Hydronic •

modiﬁ ed primary-secondary, allowing heat from MHCP unit be injected into return piping upstream from

freewatt PLUS

return water be delivered to MCHP unit’s hydronic hybrid integration (HI) module.

freewatt PLUS

Figure 8-2 Hydronic

System Piping

piping conﬁ guration is

boiler. Conﬁ guration ensures coldest

Freewatt PLUS

System Distribution Piping Schematic with Zone Valves and

Priority DHW Pump

Figure 8-2 shows • schematic for system zoned with zone valves for heating zones and priority pump for indirect water heater zone. Conﬁ guration of heating zones, boiler and MCHP heat sources shown is mandatory for proper operation of

See piping schematics in Section 17 for circulator zoned • systems, valve zoned systems and systems with air handlers.

freewatt PLUS

distribution piping

System.

Page 24

8 - PLACING THE SYSTEM

8.4 Design Tips

Install bottom of Hydronic HI Module at height of • 32” to 42” above ﬂ oor elevation where HONDA MCHP installed.

Maximum 10ft. length of ½” Onix coolant tubing • connecting Hydronic HI module and MCHP.

Install mixing valve if indirect hot water tank is • installed. Mixing valve will provide anti-scalding protection and allow for summer operation of MCHP unit. Review installation requirements supplied with

Indirect Water Tank.

8.5 Near Boiler Piping

Do not install Copper piping directly into aluminum • boiler casting due to galvanic corrosion between dissimilar metals. Two (2) dielectric isolation unions shipped loose in boiler parts bag. Install dielectric isolation unions at boiler supply and return line. Use of dielectric unions is required. furnished with iron piping where necessary for supply and return connections.

Conﬁ gure near boiler piping in accordance with •

freewatt PLUS

Maintenance Manual. Overall conﬁ guration with MCHP unit and heated zones must be in conformance with Figure 8-2.

Boiler’s Installation, Operation and

freewatt PLUS

boiler

NOTICE

Use only long life coolant supplied with

PLUS

System. Use of any other coolant will void

warranty. System will not operate properly and permanent

damage to Hydronic HI Module or HONDA MCHP may occur if followings steps are not followed.

Following steps are required to install long life coolant (LLC) tubing between Hydronic HI module and HONDA MCHP.

Figure 8-3 MCHP Coolant Loop Drain Tee (LLCLong Life Coolant Supplied with System)

freewatt

freewatt PLUS

• Boiler provided with 1 ¼” NPT return and supply piping connections shown in Figure 2-2.

freewatt PLUS

• Boiler Installation, Operation and Maintenance Manual includes directions on distribution system requirements, including expansion tank, makeup water, air separator, air vent and condensate drain piping (pump).

Install 1 ¼” ball valves on supply and return legs of • boiler connection to allow for servicing of boiler or

circulators.

8.6 Honda MCHP & Hydronic HI Module

Install MCHP near piping in accordance with HONDA • MCHP installation manual and instructions found in this section.

Typical piping conﬁ guration is shown in Figure 2-1, • shows MCHP connecting to hydronic HI Module. Hydronic HI Module connects to hydronic water distribution system.

Place hydronic HI module in location allowing MCHP to • connect with maximum 10 feet of ½” Onix tubing, while also located vertically above MCHP unit (32” to 42” above MCHP’s base level).

Onix tubing used to isolate vibrations from Honda • MCHP unit and is provided with installation kit.

8.7 HI Module coolant tubing:

Prepare rear connections (LLC In and LLC Out) of • MCHP unit with pipe thread sealant. Install ½” NPT brass street elbow onto drain ﬁ tting before installing 1/2” NPT street elbow onto MCHP unit’s 1/2” MNPT LLC Out ﬁ tting. Install other 1/2” NPT brass elbow onto MCHP unit’s LLC In ﬁ tting. Install 1/2” NPT x 1/2” barb

ﬁ ttings into drain ﬁ tting and 1/2” NPT elbow. Point ﬁ ttings in direction of front of hydronic HI Module.

Figures 8-3, 8-4 and 8-5. Long Life Coolant • Out Tubing Installation [MCHP to

BPHX; Figure 8-5]:

Attach supplied 1/2” brass Tee to threaded heat • exchanger ﬁ tting located on bottom of HI Module as shown. (Apply pipe thread compound)

Attach supplied 1/2” NPT x barb ﬁ ttings to remaining • threads on brass Tee. (Apply pipe thread compound)

Attach supplied 12.5” length of tubing to front of • brass tee. Route cable through sheet metal as shown. Attach stackable hose barb ﬁ tting and insert into HOT side of mixing valve. Secure ﬁ ttings using tubing clamps.

Install Onix™ tubing from top rear LLC connection • on MCHP, to hose barb on bottom of tee. Secure

Page 25

8 - PLACING THE SYSTEM

Figure 8-4 MCHP Coolant Line Installation Instructions

Figure 8-5 LLC Out Connection to HHI Module (BPHX)

Figure 8-6 LLC In Connection to Pump

Figure 8-8 Female Swivel Fitting (NPT by IPS)

using tubing clamp.

Long Life Coolant • In Tubing Installation: [Pump to MCHP; Figure 8-6]

Cut section of Onix Tubing to extend from MCHP • unit’s lower Coolant connection to coolant pump in HI Module.

Install barbed end of elbow (barb x IPS) ﬁ tting into • open tube end of tubing and secure with SelfTite clamp. Figures 8-7 and 8-8

Route tubing through hole in bottom of Hydronic HI • Module.

Insert IPS end of same elbow (barb x IPS) ﬁ tting • into female IPS swivel ﬁ tting (Figure 8-7 and 8-8) on coolant pump and secure with collet clip supplied with female swivel ﬁ tting.

Figure 8-7 - Hose Barb by IPS Elbow Fitting

Route tubing to rear of MCHP (if necessary through • open channel in front of MCHP base) and cut to length.

Install tubing onto lower brass hose barb ﬁ tting (LLC • In) and secure SelfTite clamp onto tubing.

Use only Watts Radiant brass barb ﬁ ttings with Onix tubing supplied with ﬁ ttings are made to different dimensions and tolerances,

which may result in leaks.

freewatt PLUS

System. Off-the-shelf brass

Page 26

8- PLACING THE SYSTEM

8.8 HHI Module to Distribution Manifold

Follow industry standards when installing distribution • manifold.

Install MCHP hydronic pump below manifold to prevent • circulator from air locking.

Size tubing or piping connecting Hybrid HI module • with distribution manifold ½” NPT or larger to provide adequate ﬂ ow for transfer of heat from MCHP’s coolant into hydronic water.

Pump shall provide ﬂ ow of at least 4 gpm to brazed • plate heat exchanger (~1 psi Pressure Drop) in Hydronic HI Module. Grundfos SuperBrute Pump (UPS1558FC) is suggested.

See Figure 8-9 design example of piping.• Installation•

Attach two supplied 1/2” NPT X barb ﬁ ttings to A. threads on bottom of heat exchanger per Figure 8-11. Apply pipe thread compound.

Attach Onix tubing to barbs securing with Selftite B. clamps.

8.9 HHI Module Heat Rejection System Connections

Figure 8-9 HI Module to Distribution Manifold Piping

Figure 8-10 Condensate Lines

NOTICE

Follow these steps to ensure proper system operation and prevent permanent damage to Hydronic HI Module or Honda MCHP.

NOTICE

Follow detailed instructions provided with heat rejection accessory kit to construct heat rejection piping loop.

Following steps are required to connect heat rejection system to Hydronic HI Module for Heat Rejection cooling.

Install pipe or tubing from supplied heat rejection loop • to BPHX. Ensure counter ﬂ ow between heat rejection ﬂ uid and MCHP Coolant. See Figure 8-12.

Install pipe or tubing from outlet of BPHX to heat rejec-• tion loop.

Figure 8-11 Hydronic freewatt® PLUS HI Module

8.10 Condensate Drain Piping

NOTICE

Boiler and MCHP’s drain trap assembly must be ﬁ lled with water before operating system. Dry trap may cause pressure switches to behave erratically, preventing boiler from operating normally, or cause exhaust products to enter building space.

From Hydronic Loop

To Hydronic Loop

Page 27

8 - PLACING THE SYSTEM

Figure 8-12 Heat Rejection Connections to HHI Module (BPHX)

Heat Rejection

OUT

Heat Rejection IN

freewatt PLUS

• boiler and MCHP unit will produce condensate at rates up to 2 ½ US quarts per hour. Make provisions to drain condensate away from both boiler and MCHP to ensure proper operation. Boiler is supplied with factory-installed drain trap assembly

with ½” dia. Sch. 40 PVC connection.

Install MCHP condensate line directly into condensate •

pump, located directly behind MCHP unit, if ﬂ oor drain is not available. Condensate line should have “Y connector” to ensure tubing is open to atmosphere, removing chance for air lock in line. Figure 8-10. Route boiler’s condensate line behind MCHP unit and install directly into condensate pump.

Supplied boiler condensate vent drain T must be used.• Do not make any additional electrical connections •

freewatt PLUS

within Separate junction box and receptacle should be provided if 120 VAC power is required for condensate

pump.

Review installation instructions for boiler and HONDA •

MCHP to ensure a proper installation.

System for 120 VAC power.

8.11 Onix Clamps

Do not use screw gun or wrench to tighten TorqueTite •

clamps.

Safety glasses must be worn when installing SelfTite •

Clamps.

Minimum bending radius of ½” Onix tubing is 4”.• Onix requires special Torque-Tite or Self-Tite •

mechanical clamps, designed for higher temperature and burst pressure ratings.

Self-Tite clamps are supplied with •

System.

TorqueTite clamps are heavy-duty screw-type, • wide-band, stainless steel clamps. In. per lb. torque wrench is required to install. Tightened each clamp according to proper torque setting for size of clamp used. Torque settings are listed on instruction

sheet supplied with clamps. Do not over tighten TorqueTite clamp. •

Overtightening may cause long-term damage to Onix tubing and/or to clamp itself.

SelfTite Clamps are chrome-vanadium, constant •

tension clamps. Watts Radiant recommends using SqueezeTite pliers to properly open and install clamps.

freewatt PLUS

Do not allow clamp to ﬂ atten while being held open. • Flattened clamps will not ﬁ t properly over Onix and barb assembly.

Page 28

8 - PLACING THE SYSTEM

All Onix and brass ﬁ tting surfaces must be clean and • dry before making connection.

Avoid making connections or splices in inaccessible • locations.

Repairing Onix having been in service in •

PLUS

System requires special attention. Any residual amounts of Onix tube must be removed. Use an alcohol swab or pad to remove residue(s), allow tube to dry prior to connection.

freewatt PLUS

long life coolant inside

freewatt

NOTICE

Do not solder near, or overheat, any Onix connections. Extreme temperatures associated with soldering may seriously damage Onix and will void warranty.

8.12 Conﬁ guration of Heating Zones and Controls

Hydronic • variety of heating loads served by conventional, multizone hydronic heating systems. Including base-board radiation, radiant ﬂ oor heating, domestic hot water via indirect storage tank, powered convective heaters, hydro coils, and others.

freewatt PLUS

System may be applied to

Expand ECR control using appropriate ECR • expansion relay controls if additional zones are

needed.

Two air handlers with circulators can be accommodated • through use ECR ARH-3 control.

One air handler must be “Zone 2 - Smart Zone”. • If additional zones are needed, expand ECR control •

using appropriate ECR expansion relay controls.

Select “Smart Zone” as zone with largest heating • demand (but not domestic hot water zone). This would normally be largest space in heating zone on ﬁ rst ﬂ oor of two story home. produce best electric power generation beneﬁ t if Smart Zone represents 25% of total home heating load. If there is no single large zone in existing distribution system, but many small zones, consider combining

zones to achieve desired heat load for the Smart Zone.

Installations of Hydronic use of AR-822-II for operation of circulator that provides hydronic water ﬂ ow to HI Module.

freewatt PLUS

System will

System require

Use correct ECR zone control accessory kit, ordered • separately, for type of zoning to be applied with hydronic freewatt smart zone communicating thermostat, AR822-II pump relay for MCHP hydronic loop pump,

and appropriate zone control relay as follows:

Thermostats for up to six zones, must be wired through •

freewatt PLUS

Required ECR heating zone relay controls for use with • pumped zoned systems (ARM-6P) and valve zone systems (AZ-6CP) can accommodate total of 6 zones.

freewatt PLUS

Use Zone Pump Zone Control Accessory Kit which • includes ARM-6P for pump zoned systems,

Use Zone Valve Zone Control Accessory Kit which • includes AZ-6CP for valve zoned systems,

Use Hydro-Air Zone Control Accessory Kit which • includes ARH-3 for distribution systems with air

handlers.

One zone of six zones must designated “Zone 2 - • Smart Zone”.

Zone 1 is used to accommodate indirect water • heater having its own dedicated circulation pump.

Control Module.

System. Kit includes

Page 29

9 - EXHAUST GAS LEAK SENSOR

9.1 EGLS Introduction

Exhaust Gas Leak Sensor System in addition to • separate, independently installed and operating UL approved Carbon Monoxide Detector having audible alarm.

Install both Exhaust Gas Leak Sensor (supplied with •

freewatt PLUS

Monoxide Detector (not supplied with

PLUS

freewatt PLUS

• System and Gas Leak Sensor do not provide audible alarms for protection of building inhabitants from potential high CO hazards.

Function of • System is to automatically stop operation of MCHP unit in event it detects potentially hazardous level of carbon monoxide in vicinity of MCHP unit.

freewatt PLUS

• System Exhaust Gas Leak Sensor System uses Macurco CO Detector con nected directly to Honda MCHP Unit. Read following installation

instructions:

Read and understand installation and operation • manual for Macurco CO Detector part of Exhaust Gas Leak Sensor System.

Install Macurco CO Detector per manufacturer’s • instructions in close proximity of HONDA MCHP unit.

) and audible UL approved Carbon

freewatt

freewatt PLUS

Exhaust Gas Leak Sensor

Exhaust

Figure 9-1 shows connections to Exhaust Gas Leak • Sensor. Exhaust Gas Sensor will automatically stop operation of MCHP unit upon detection of potentially dangerous levels of carbon monoxide gas regardless of

source of carbon monoxide gas.

9.2 Preparation

Following items must be installed before Exhaust Gas Leak Sensor can be installed:

Boiler, Control Module & Hydronic HI Module• Honda MCHP Unit•

Thermostat•

WARNING

Exhaust Gas Leak Sensor does not fulﬁ ll independent CO detector and audible alarm requirement of freewatt PLUS System.

freewatt PLUS System requires separate CO

alarm for protection of building inhabitants. Separate freewatt PLUS System installation requirement is fulﬁ lled by complying with State of Massachusetts’s CO detector and alarm requirements. Your state or local jurisdiction may have additional requirements regarding carbon monoxide detectors and alarms.

Install four-wire cable from HONDA MCHP to • Macurco CO Detector.

Verify cable properly secured (Maximum interval: • every 3 ft.)

Exhaust Gas Leak Sensor (EGLS) monitors integrity of • MCHP unit’s combustion system shutting down MCHP

unit if potentially unsafe conditions are detected.

Monitors carbon monoxide level in air space • near MCHP unit. EGLS is independent of, and separate from, audible CO alarming system that must be installed with compliance with best practices for all fuel-ﬁ red

central heating equipment.

WARNING

freewatt PLUS Exhaust Leak Gas Sensor does

freewatt PLUS

System in

not fulﬁ ll State of Massachusetts’s CO detector and alarm requirement. Exhaust Gas Leak Sensor does not provide an audible alarm for potentially hazardous CO levels.

Exhaust Gas Leak Sensor is supplied with Hydronic •

freewatt PLUS

in close proximity of HONDA MCHP unit.

System and is intended for installation

9.3 Installation

Exhaust Gas Leak Sensor is connected to HONDA MCHP unit using four conductor stranded insulated cable supplied by Honda. Follow installation instructions below to ensure

proper operation of Exhaust Gas Leak Sensor: Honda MCHP Connection

4-pin cable connector to the HONDA MCHP for the • Exhaust Gas Leak Sensor is factory-supplied and ﬁ eld installed. The HONDA MCHP installation kit includes an electrical schematic for the wiring details.

See HONDA MCHP Installation manual for the • connections to the HONDA MCHP and for any servicing

or troubleshooting.

Exhaust Gas Leak Sensor Connections

Field install cable connection to Exhaust Gas Leak • Sensor after installation of sensor. Figure 9-1 shows ﬁ eld connections of supplied cable to Exhaust Gas Leak Sensor.

See MCHP Installation manual for connections to • HONDA MCHP for servicing or troubleshooting.

Field install jumper wire between second terminal (F) • and fourth terminal (N.C.). May need to install another Jumper between COM and B terminals instead of using

crimp.

Page 30

9 - EXHAUST GAS LEAK SENSOR

NOTICE

Exhaust Gas Sensor’s cable connections must be installed properly or Hydronic System will not initialize and not operate (ERROR – 14 or 15 Flashes).

For more instructions on connecting Exhaust Gas Leak Sensor SEE MCHP IOM.

9.4 Test Procedure

Test Exhaust Gas Leak Sensor to ensure proper operation before commissioning system. Use Exhaust Gas Leak Sensor test button in accordance with procedure below. Procedure will stop MCHP unit. See “

Section 16

Disconnect

1. freewatt PLUS

Temporarily disconnect LAN (local area network) cable from side of LAN cable where it plugs into home’s network.

Power is supplied to Exhaust Gas Leak Sensor by

MCHP. MCHP must be operating during testing of Exhaust Gas Leak Sensor. Turn thermostat up until MCHP operates, if MCHP is not operating.

Wait for LED on Macurco CO Detector to begin glowing

green. Press button on Exhaust Gas Leak Sensor labeled “Push Here to Test or Reset” for 6 seconds, when LED on Macurco CO Detector is glowing green continuously. This should cause

System error condition.

if MCHP unit does not stop,.

freewatt

Control module or disconnect

freewatt PLUS

Troubleshooting”

System from Internet.

freewatt PLUS

NOTICE

LED indicator on Exhaust Gas Sensor must be solid green. Sensor is initializing if it is ﬂ ashing red and green. Wait 3 minutes until LED is solid green before proceeding.

Conﬁ rm HONDA MCHP unit has stopped operating,

and red “Service Required” LED on System’s front panel is blinking error code “16”, and yellow “Bypass” LED is on.

Clear error condition. Turn OFF 120 VAC

5. freewatt

PLUS

MCHP Service Switch. Reconnect LAN cable to

6. freewatt PLUS

Turn power ON to HONDA MCHP 240 VAC Service

Switch, turn ON Service Switch, to return system to normal operation.

Exhaust Gas Sensor must be replaced every 5 years with identical unit, installed by qualiﬁ ed and properly trained service personnel.

freewatt PLUS

required LED will indicate fault by ﬂ ashing 16 times if you push test button on Sensor.

Fault message will be transmitted to service center if your system is connected to internet. Clear fault condition to restore MCHP operation. Shut off electrical power to power to reset system using power switch on

Control module to clear fault.

System Service Switch and 240 VAC Honda

freewatt PLUS

generator will stop and red service

freewatt PLUS

System.

System 120 VAC

Exhaust Gas Leak

freewatt PLUS

System and restore

freewatt

Figure 9-1 Exhaust Gas Leak Sensor Connections

Page 31

10 - COMBUSTION AIR AND VENT PIPE

WARNING

Read, understand and follow all instructions. Failure to properly vent or supply combustion air to boiler can cause carbon monoxide poisoning, or an explosion or ﬁ re, personal injury or loss of life.

10.1 General Considerations

Perform tasks outlined in Section 5 of • boiler Installation, Operation and Maintenance Manual, section “Removal of Existing Boiler from Common Vent System” if system will be replacing Category I type

boiler connected to chimney serving other appliances. Vent installations shall be in accordance with ANSI •

Z223.1/NFPA 54, CSA-B149.1 and B149.2, or authority having jurisdiction.

Provisions for combustion and ventilation air shall be • in accordance ANSI Z223.1/NFPA 54, CSA-B149.1 and B149.2, or authority having jurisdiction.

Hydronic • components requiring combustion air and discharge of combustion products.

freewatt PLUS

Boiler component requires dedicated direct vent • system. All air for boiler’s combustion is taken directly from outdoors through combustion air intake pipe. All combustion products are discharged to outdoors through vent pipe.

Honda MCHP takes combustion air from interior • open space and all combustion products are

discharged to outdoors through vent pipe.

System has two separate

freewatt PLUS

Combustion air pipe and vent connections on boiler are • 2” pipe size. Installed combustion air pipe and vents for boiler must be 3” size and, 2” to 3” pipe coupling must be used at boiler connections. MCHP vent connection size is 2”. 2” or 1-1/2” vent size is permitted. Refer to

freewatt PLUS

Maintenance Manual and MCHP IOM for speciﬁ c venting instructions.

Exhaust transition from 2” pipe to 3” pipe must • be made in vertical run. Transition pieces are not included. (See boiler installation manual for more

details.)

Boiler Installation, Operation and

10.2 Combustion and Vent Piping Length

Refer to direct vent and non-direct combustion air and vent sections outlined in installation guides for boiler and Honda

MCHP for speciﬁ c installation procedures and speciﬁ cations.

10.3 Installation

Refer to direct vent and non-direct combustion air and • vent sections outlined in installation guides for boiler and HONDA MCHP for speciﬁ c installation procedures and speciﬁ cations. General guidelines for air intake and vent piping are found in

Installation, Operation and Maintenance Manual.

Use of periscopes on air intake and venting are allowed. • Insulate periscopes with proper weather-resistant pipe

insulation if extend over 24” in length, straight length.

FW95M-200 Boiler

See installation instructions in boiler and HONDA MCHP • manuals for combustion air and vent pipe roof and sidewall termination (Roof termination is preferred). Combustion air and vent pipes for Boiler must terminate together in same atmospheric pressure zone as shown. Boiler and MCHP exhaust vents need not be in same general location on exterior of building. Construction through which vent and air intake pipes may be installed is maximum 24 inches,

minimum ¼” thickness. Combustion air and vent pipe ﬁ ttings must conform •

to American National Standards Institute (ANSI) and American Society for Testing and Materials (ASTM) D1784 (schedule 40 CPVC), D1785 (schedule 40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), or F628 (schedule 40 ABS). Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS). In Canada construct all combustion air and vent pipes for system of CSA or ULC certiﬁ ed schedule-40 CPVC, schedule-40 PVC, PVC- DWV or ABS-DWV pipe and pipe cement. SDR pipe is

not approved in CANADA.

freewatt PLUS

10.4 freewatt PLUS and Venting

Combustion air and venting installation procedures and speciﬁ cations are based on installation speciﬁ cations of boiler and MCHP. Installers are required to follow speciﬁ c installation requirements found in boiler and MCHP installation manuals, following guidelines are taken from

these manuals.

10.5 United States Direct Vent System Requirements

Boiler direct vent exhaust shall be installed in United States in accordance with following requirements. Allowable direct vent intake and exhaust piping lengths for boiler are found in FW95M-200 Boiler Installation, Operation and

Maintenance Manual.

System Combustion Air

Page 32

10 - COMBUSTION AIR AND VENT PIPE

NOTICE

Install boiler per Direct Venting requirements. Install MCHP per Non-Direct Venting Requirements. Distinction is noted to ensure proper location of vent terminations.

Clearance from bottom of termination to grade shall • be 12” or increased to maintain 12” above anticipated accumulated snow level.

Vent shall not terminate over public walkways or over • area where condensate or vapor could create nuisance or hazard.

Vent termination shall be installed at least 1 foot from • any opening through which ﬂ ue gases could enter building.

Vent termination shall have minimum horizontal • clearance of 4 feet from electric meters, gas meters, regulators and relief equipment.

Locate vent terminal 3 feet horizontally from vent • of any side wall vented fuel gas appliance or clothes dryer, except in case of hydronic System where boiler and MCHP vents may be located

with respect to each other per Figures 10-1 or 10-2.

freewatt PLUS

Figure 10-1

Min. Separation

MCHP Vent

12”

3” Max Separation

8”

7”

Boiler Vent

Boiler Air

Intake

3” Min.

Figure 10-2

10.6 United States Non-Direct Vent System Requirements

Non-direct vent exhaust for MCHP shall be installed in United States accordance with following requirements; nondirect vent exhaust piping lengths for MCHP are found in

Honda MCHP Installation Manual:

Clearance from bottom of termination to grade shall • be 12” or increased to maintain 12” above anticipated accumulated snow level.

Vent shall not terminate over public walkways or over • area where condensate or vapor could create nuisance or hazard.

Vent termination shall be installed at least 4 feet below, • 4 feet horizontally from, or 1 foot above any door, window, sofﬁ t, under eave vent or gravity air inlet to the building.

Vent termination shall have minimum horizontal • clearance of 4 feet from electric meters, gas meters, regulators and relief equipment.

Locate vent terminal 3 feet horizontally from vent • of any side wall vented fuel gas appliance or clothes dryer, except in case of hydronic system

where boiler and MCHP vents may be located

with respect to each other per ﬁ gures 10-1 or 10-2.

freewatt Plus

Page 33

11 - GAS SUPPLY PIPING

CAUTION

Units cannot operate properly or safely using fuels outside normal commercial standards. Connect boiler and HONDA MCHP units only to gas supplied by commercial utility or supplier. Private gas wells do not generally provide gas with consistent, uniform and predictable heating values and densities. Many non-commercial wells contain impurities such as sulphur, which may damage furnace or HONDA MCHP.

11.1 Check Gas Supply

Gas pipe to boiler must be correct size for length of run • and for total BTU per hour input of all gas utilization equipment connected to piping. See Tables in boiler and HONDA MCHP installation manuals for proper size. Verify gas line complies with authority having jurisdiction.

freewatt PLUS

• Boiler and MCHP units’ individual shutoff valves must be disconnected from gas supply piping system during any pressure testing of system at test pressures in excess of ½ psig (3.5 kPa).

Table 11-1 Gas Supply Pressures

Gas tyoe

Natural 4” 7” 10”

Propane 10” 12” 14”

Consult boiler and HONDA MCHP installation procedures for leak testing and purging gas lines.

Minimum (in. w.c.)

11.2 Gas Piping

Consult boiler and HONDA MCHP installation procedures for speciﬁ c instructions regarding gas piping.

Nominal

(in. w.c.)

Maximum

(in. w.c.)

freewatt PLUS

• Boiler and MCHP unit system must be isolated from gas supply piping system by closing respective individual manual shutoff valves during any pressure testing of gas supply piping system at test pressures less than or equal to ½ psig (3.5 kPa).

Recommend line pressure be within minimum and • maximum values in Table 11-1 for proper operation of

system.

Page 34

12 - ELECTRICAL WIRING & CONNECTIONS

WARNING

Electric shock hazard. For your safety, turn off electrical power supply at service panel before making any electrical connections. Failure to do so can cause severe personal injury or death.

12.1 Codes

Installation must comply with National Electrical Code, authority having jurisdiction, and in Canada, with CSA C22.1 Canadian

Electrical Code and authority having jurisdiction.

NOTICE

Wiring shall be N.E.C Class 1. Use only type 105°C wire or equivalent if original boiler wiring must be replaced. System shall be electrically grounded as required by National Electric Code ANSI/NFPA 70.

12.2 Line Voltage Connections

System installation must include :

120 VAC dedicated circuit (15 amp) to Boiler, control • module, circulator pumps and relay switches.

120 VAC dedicated circuit will extend up to • Transfer Switch.

240 VAC dedicated circuit (2 pole; 15 amp) to HONDA MCHP • unit.

240 VAC dedicated circuit shall have serviceman’s

•

switch ﬁ eld installed near Honda MCHP on circuit between main service panel and freewatt Transfer

Switch.

freewatt

Figure 12-1 Typical freewatt PLUS Control Module Conﬁ guration

Mounting 2 ft. wide x 4 ft. high sheet of plywood provides • mounting surface for control module, relay switches and HHI module. Unit may be mounted up to 20 feet away. Locate

enclosure with installation and service accessibility in mind.

Position control module enclosure above ECR relay • switches, place enclosure on relay switch modules with four ½” off set nipples, level, and mark mounting holes.

Start screws, #10, 4 each (ﬁ eld sourced) for keyhole type • mounting holes in upper corner(s). Tighten screws down to 1/8” (3mm) from surface.

Hang enclosure on screws, level enclosure and tighten • screws.

Install four nuts on ½” offset nipples to secure enclosure • to relay switch modules. Figure 12-1 .

9.3 Line Voltage Wiring Speciﬁ cations

240 VAC Wiring: All wiring must conform to National • Electric Code and authority having jurisdiction. Wiring must be N.E.C. Class 1. In Canada, C.S.A. C22.1 Cana dian Electrical Code Part 1 and authority having jurisdiction. Wiring must be C.S.A. C22.1 C.E.C. Part 1.

120 VAC Wiring: All wiring must conform to National • Electric Code and authority having jurisdiction. Wiring must be N.E.C. Class 1. In Canada, C.S.A. C22.1 Canadian Electrical Code Part 1 authority having jurisdiction must be followed. Wiring must be C.S.A.

C22.1 C.E.C. Part 1.

12.4 freewatt Control Module Installation

Mount module’s enclosure on solid wall or partition after • determining location of enclosure be located close to Honda MCHP and HI Module, within reach of supplied, preterminated cable.

freewatt

module. Recommend

freewatt PLUS

Boiler,

WARNING

Electric shock hazard. Do not route un-switched line-powered cables or wires through freewatt PLUS System. F ailure to do so can cause sev ere personal injury or death.

Recommend no additional electrical connections be made within power is required for condensate pump, separate junction box and receptacle should be provided.

120 VAC dedicated circuit shall conform to NEC and use as minimum 3-conductor, 14 Ga. Cable.

freewatt

Control module for line power. If line

12.5 Wiring Instructions

Provide and install non-fused disconnect or 120VAC • service switch ( 15 amp recommended) as required by authority having jurisdiction.

Route 120 VAC power wiring from service switch to boiler’s • line voltage terminal strip on boiler control panel as outlined in

freewatt PLUS

Maintenance Manual. See Location 8 in Figure 12-2.

Boiler Installation, Operation and

Page 35

12 - ELECTRICAL WIRING & CONNECTIONS

Route 120 VAC power wiring from service switch to ECR • AR822-II and attach to 120 VAC power terminals.

Route 120 VAC power wiring from junction / switch • box to ECR ARM-6P (or AZ-6CP or ARH-3). Wiring can be routed through ½” offset nipple connector and into control module enclosure. Connect 120 VAC power wiring to 12 VDC power supply’s pig tail in control module using wire nuts, attach ground wire to control module enclosure grounding screw located inside bottom of enclosure. Figure 12-3.

Wire control module to zone relay control and AR822-II • following appropriate and line voltage electrical schematics.

Wire circulators and MCHP’s hydronic pump to zone relay • control and AR822-II following instructions found in their installation manuals and schematics.

Connect MCHP Coolant Pump’s 24VDC power cable to system • controller.

Connect 24 VAC circuits between boiler control and •

freewatt

schematic. Conﬁ gure jumper on control module circuit board (Figure •

12-4) for set-up of hydronic system water heating and space heating zones. Install jumper on DHW pins if zone 1 is connected to aquastat in indirect water tank. Install jumper on HEAT pins If zone 1 is connected to thermostat for space heating. Zone 1 input on the control module must be used for indirect water heater if indirect water heater is used with

freewatt PLUS

Connect Coolant Pump in HI Module to Control Module J04 • connector using furnished coolant pump cable.

Control Module per applicable electrical

freewatt PLUS

System.

System low voltage

System electrical

12.6 ECR Zone Relay Controls

Install appropriate ECR Zone Relay Control for temperature • control of different heating zones and accommodation of indirect water heater (if used). Refer to Electric Schematics for speciﬁ c wiring details.

Figure 12-2 Boiler 120 VAC Connections (Refer to Electrical Schematic)

Figure 12-3 Control Module 120 VAC Connections

Figure 12-4 Control Module Conﬁ guration DHW or CH Jumper

Use ECR ARM-6P control for • zoned with circulators ARM-6P control will accommodate up to six zones. Expand ARM-6P with additional ARM controls if more zones are needed.

Use six-zone ECR AZ-6CP For • zoned with valves. AZ-6CP can be expanded up to ten zones with water heating priority with additional AZ control.

Use three zone ECR ARH-3 control, expanded with additional • ARH controls for handlers (hydro-air).

DHW priority dipswitch on zone control applies only in • bypass mode. DHW priority in MCHP mode is determined by ﬁ rmware setting in freewatt control module accessible via MINT software. Default setting is priority ON when DHW

enabled.

freewatt PLUS

Systems with air

Systems

System’s

Page 36

12 - ELECTRICAL WIRING & CONNECTIONS

External controls with their own 24VAC transformer may • be used on zones 3-6. Steering relays can be used through freewatt control module jumpers JPZ3, JPZ4, JPZ5 and JPZ6 (for zones 3-6 respectively). These jumpers are located on

the center of the freewatt control board.

Control board will use 24V power from external A. transformer attached to that zone when jumpers are installed across pins.

Control board will use 24V power that board re-B. ceives from connector J17 (1 Amp maximum, 24-

30 VAC) if jumper is not installed across pins.

Connect G signal from air handler to zone 4 on freewatt control module when using ARH-3 with air handler on smart zone.

Refer to freewatt PLUS electrical schematics for wiring instructions.

12.7 Circulator Zoned System - ECR ARM-6P Dipswitch Settings

Priority Switch:

Conﬁ gure ECR ARM-6P for Domestic Hot Water (DHW) • Priority when hot water tank. Place priority switch to ON position. Zone 1 is heating priority. Zone 1 calls for heat all other zones are temporarily deactivated (Priority LED illuminated), priority switch is ON.

Timer automatically shuts off this feature if priority • zone (Zone 1) calls for heat longer than 30 minutes, allowing all zones to operate. Cycle repeats in 30 minutes until priority zone is satisﬁ ed.

Match priority switch setting on ARM-6P to priority • setting in

and MINT Software tool.

freewatt PLUS

freewatt

control module. Set using laptop

System includes indirect

12.8 Valve Zoned System - ECR AZ-6CP Dipswitch Settings

Set four AZ-6CP control “Option” switches as follows:

“Zone Valve/Pump Selection Switch” Set to “ON” • when using Indirect Water Heater on Zone 1. Switch allows operation of separate water heating “priority” pump of Zone 1, conﬁ gure for use with indirect water heater having its own “priority” circulator pump and all remaining zones are conﬁ gured with single “primary” circulating pump and individual zone valves. “Zone/ Valve Pump” Switch is in “ON” position for operation of water heating “priority” pump in water heating applications of Zone 1. Zone 1 is central heating zone (no indirect water heater is conﬁ gured) if “Zone/Valve Pump” switch is “Off”, only Zone 1 zone valve terminals are energized. Place “Zone/Valve Pump” Switch in “OFF” position if indirect water heater is not connected as Zone 1.

IMPORTANT: “Priority Selection Switch” must be • in “ON” position when “Zone/Valve Pump” Switch is in “ON” position. Install jumper wire between terminals 3 and 4 of “Zone 1” output of AZ-6CP control when setting “Zone/Valve Pump Selection Switch” in “ON” position,. Jumper not required when using zone valve (no indirect water heater with separate “Priority” circulator) on Zone 1. Wiring see “ Low Voltage Wiring: Primary/Secondary Piping with Zone Valve and Domestic Hot Water Priority Circulator”.

Set “Priority Selection Switch” “ON” when using indirect • water heater on Zone 1. Use switch to set operational priority to domestic water heating when used with Zone 1. Switch in “ON” position, call for heat by Zone 1 (indirect water heater) activates “Priority” pump connecting to indirect water heater other zones will temporarily deactivate. Temporarily, no space heating supply in response to any space heating thermostats. Priority LED on AZ-6CP will illuminate when priority function is active. After 30 minutes priority is terminated all zones will operate normally. Water heating demand of Zone 1 not satisﬁ ed, 30 minute temporary deactivation of all other zones will resume and cycle will repeat. Set “Priority Selection Switch” to “ON” for water heating priority and “OFF” for no water heating priority on Zone 1.]

“ZR-ZC Selection Switch”: Set to “OFF”• “DPM-2 Selection Switch”: Set to “OFF”•

12.9 Hydro-Air Zoned System - ECR ARH-3 Settings

Priority Switch:

freewatt PLUS• System includes indirect hot water tank. Conﬁ gure ECR ARH-3 for Domestic Hot Water (DHW) Priority. Place Priority Switch to ON position. Water heating zone, is similar to description above for ARM-6P control

Priority operation of Zone 1.

NOTICE

Recommended Breaker: 2-pole. 15 Amp breaker. Flexible metal conduit is required to provide

vibration isolation for Honda MCHP. 240 VAC dedicated circuit should conform to NEC

and be minimum 4-conductor, 14 AWG ﬂ exible metal conduit.

Page 37

12 - ELECTRICAL WIRING & CONNECTIONS

12.10 Honda MCHP Unit - Line Voltage Connections

Refer to Honda MCHP Installation Manual – Electrical • Connections Section before performing installation in

this section. Recommend Breaker: 2-pole; 15 Amp breaker.•

Remove cover plate, install blanking plate, connect • 240 VAC power cable to terminal block on Honda MCHP unit. Figure 12-5 and 12-10 and Honda MCHP IOM for details.

Provide and install 240 VAC disconnected switch and • junction box onto side of boiler or adjacent wall, route circuit from main service panel to switch and back to Transfer Switch, see electrical schematics. Route 240 VAC circuit from electrical terminal block per Honda MCHP IOM. Do not attach disconnect switch or junction box onto MCHP unit cabinet. Do not make penetrations in MCHP cabinet.

Flexible metal conduit is required to provide vibration • isolation for Honda MCHP. Use NEC conforming, minimum 4-conductor, 240 VAC dedicated circuit 14 AWG ﬂ exible metal conduit.

Afﬁ x Generator warning label provided to main distribution • panel where it is clearly seen by any service personnel.

Figure 12-9.

freewatt

Transfer Switch to Honda MCHP’s

freewatt

Figure 12-5 MCHP Connection Details

Figure 12-6 T-Stat Connection to Controller

12.11 HONDA MCHP Unit - Communication Connections

Connect Honda MCHP to control module with system-• supplied RS 232 communication cable (with attached 9-pin male connector). Plug connector in upper female 9-pin connector on exterior of right side of freewatt Control Module. Route MCHP communications cable to Honda MCHP and connect to communication port on Honda MCHP.

Install strain relief just outside lower compartment. • Figure 12-8.

12.12 Smart Zone Thermostat Connections

Refer to instructions supplied with “Zone 2 - Smart Z one” communicating thermostat for installation and operating instructions. Connect thermostat cable to thermostat terminal block, Figure 12-7. Thermostat cable extends from thermostat to control module, routed through low voltage knockout on control

module enclosure, Figure 12-6.

Install thermostat on inside wall away from inﬂ uences • of drafts, hot or cold water pipes, lighting ﬁ xtures, televisions, sun rays, or ﬁ replaces. Install “Zone 2 - Smart Zone” thermostat in accordance with guidance provided in Section 2 and 3. (Heating load for Zone 2

Figure 12-7 Thermostat Connections

Figure 12-8 MCHP Low Voltage Wiring Strain Relief

Page 38

12 - ELECTRICAL WIRING & CONNECTIONS

Figure 12-9 Generator Warning Label

should not less than about 25% of total for building). Connect thermostat cable to thermostat. Use Honeywell •

Genesis Cable, Model Number 22 AWG 10/C STR CM-CL2 (or equal) for HAI Smart Zone thermostat. Cable is 22 AWG, 10 Conductor, stranded cable meeting UL Standards 13 & 144, NEC Article 725. Refer to Installation manual for additional thermostat connection and option details.

Route cable to control module. Cable will enter control • module’s enclosure through top knockout opening. Connect to control module’s TSAT connections.

Wire all other compatible zone thermostats (new or existing) • and Indirect Water Heater aquastat per instructions provided by manufacturer. First six zones (including DHW if used) connect directly on circuit board of module. All other zones connect directly to ECR zone relay control.

freewatt PLUS

freewatt

HAI thermostat

control

Figure 12-10 MCHP Line Voltage Connections

When set in the COOL MODE, • may be used to control air conditioning system. Remove left terminal strip metal jumper between Terminal 1 (RC) and Terminal 2 (RH) on with ECR ARM-6P or AZ-6CP zone relay controls and separate cooling 24 VAC transformer (additional to System transformer) .

Route air conditioning system 24 VAC source •

PLUS PLUS

to connect directly to Y input of air conditioning system (do not connect Y to Use external isolation relay for switching cool signal from thermostat, if supplied thermostat does not have terminal for RC.

Wire thermostat for heating and cooling as indicated in wiring • diagrams for ARH-3 zone relay control with air handler.

12.13

Mount supplied Tekmar 070 outdoor sensor on outside • exterior wall per sensor manufacturer’s instructions, shield from direct sunlight or ﬂ ow of heat or cooling from other sources. Northern exposure is preferred.

Thermostat using spare grey wire in thermostat cable. Use Y wire of thermostat cable

Outdoor Temperature Sensor

freewatt PLUS

System conﬁ gurations

freewatt PLUS

control board).

System conﬁ gurations using

thermostat

freewatt

Route sensor’s wires through exterior wall into house and • through knockout on top of control module. Do not combine wires of Tekmar Outdoor sensor with Boiler Outdoor Sensor in single cable, electrical interference

will result. See Electrical Schematics.

freewatt PLUS

12.14 Internet Connection

Control module has RJ 45 network connection. Connection found at right of control module’s enclosure. Connection point accepts

CAT 5e cable.

Page 39

12 - ELECTRICAL WIRING & CONNECTIONS

12.15 MCHP Battery Installation

Please see the Honda MCHP manual for installation of the MCHP battery.

Honda MCHP1.2D/MCHP1.2DP unit requires battery to • provide power to start up in backup power mode.

Battery is provided for • freewatt however to insure proper battery storage and charge level, battery is not packaged with system.

Battery must be ordered at time of installation from • ECR Customer Service by freewatt dealer performing installation.

Original battery provided for each • freewatt System will be shipped to installing dealer at no charge.

Following information must be provided to obtain • battery:

Either Honda MCHP Serial Number or A. freewatt

PLUS

System Serial Number.

Your B. freewatt dealer name or dealer number. Desired ship-to address.C.

Call ECR freewatt Customer Service toll free at 866-9446247 to order battery.

PLUS

System,

PLUS

NOTICE

IMPORTANT - Honda MCHP unit will not operate without a battery. Use only battery speciﬁ cally designed for use in Honda MCHP.

Page 40

13 -COMMISSIONING AND STARTUP

13.1 For System commissioning and startup procedures,

refer to literature packet document “Hydronic freewatt PLUS System, Model HDJ Commissioning Procedure”.

You may also refer to the Commissioning Procedure Manual for basic operation.

freewatt

PLUS system sequence of

Page 41

14 - MAINTENANCE AND CLEANING

WARNING

Disconnect electrical power supply to freewatt PLUS System before attempting any maintenance. Failure to do so can cause electrical shock resulting in personal injury or loss of life.

WARNING

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always verify proper oper ation after servicing.

Review maintenance and cleaning procedures as outlined in Installation, Operation and Maintenance Manuals of boiler and Honda MCHP before proceeding with procedures below.

Regular service and maintenance by qualiﬁ ed service agency must be performed to assure safe, trouble-free operation and maximum efﬁ ciency. Service or inspect

system at least once every 12 months.

Honda MCHP unit requires periodic inspection by certiﬁ ed service professional to maintain acceptable performance and ensure safe operation. Inspection/service procedures are outlined in unit’s Installation, Operation and Maintenance Manual. Services are required every 6,000 hours, operating time of unit will directly impact service interval. Inspections include, but are not limited to:

14.1 Beginning of Each Heating Season

Schedule annual service by certiﬁ ed service agency, to include:

Examine boiler as described in annual inspection, • service procedures outlined in boiler Installation, Operation and Maintenance Manual. Inspections

include, but are not limited to:

Heat Exchanger’s Flue Passageways• Burner• Combustion Fan• Circulator• Electrical Connections• Condensate Drain• Intake Air and Exhaust Piping• Boiler Operation (Safety, Temperature Rise & Burner •

Ignition)

Examine control module/HI Module per annual • inspection/service procedures outlined below:

Control Module: Using laptop computer or PDA • check control module’s functions. Detailed procedures found in MINT Tool Supplement.

Communication/Electrical Connections: Inspect • connections to and within Control Module and HI Module. Verify they are secure and connected properly.

Bypass Switch: Place CHP Mode Switch in OFF • position and operate boiler to verify CHP mode switch is working properly. Place CHP mode switch in ON position after veriﬁ cation is complete.

freewatt PLUS

dealer or

MCHP Owner’s Manual outlines speciﬁ c maintenance intervals (6,000, 12,000, 18,000 & 24,000 hours) and requirements for each interval. Maintenance should be performed by service professional to maintain performance and ensure safe operation of your Honda MCHP.

Coolant Level: Check coolant level in coolant tank • and ﬁ ll with coolant, if necessary.

Mixing Valve: Check coolant temperature being • delivered by valve while system is operating. Check for leaks and ﬁ x, if necessary.

Pump: Inspect pump and connections. Check for • leaks and ﬁ x, if necessary.

Coolant Tubing and Connections: Inspect coolant • tubing and connections for leaks and ﬁ x, if necessary.

Brazed Plate Heat Exchanger: Inspect heat • exchanger for leaks and ﬁ x, if necessary.

Starting Ease• Oil Leakage• Engine Coolant• Breather Tube• Condensate and Condensate Drain• Air Cleaner Element• Intake Air and Exhaust Piping• Ventilation Air Inlet and Outlet• Coolant Tubing and Connections• Electrical System and Connections• Communication System and Connection• Replace:•

Engine Oil and Drain Washer.

Engine Oil Filter Cartridge.

Spark Plugs.

Adjust Clearance Between Tappets.

Page 42

14 - MAINTENANCE AND CLEANING

14.2 Draining Procedure

It may be necessary to drain system during maintenance operations. Follow procedure below:

NOTICE

Use caution while servicing and disposing of coolant in proper manner. MCHP coolant is 50/50 ethylene glycol solution and is toxic. Glycol is specially formulated with bittering agent to discourage ingestion.

Wait for coolant to cool down if system has been operating. Several hours may be necessary to cool coolant ﬂ uid to safe working temperature.

Use precautions while collecting coolant. Coolant may ﬂ ow at high rate due to pressure in system.

Shutdown Procedure:

Preferred Method: Set thermostat to OFF by A. pressing Mode button until display reads OFF. Turn SYSTEM POWER switch to off after shut down cycle of approximately three minutes is completed.

Emergency Method: Turn SYSTEM POWER and B. BYPASS switch to OFF. MCHP may overheat and ﬂ ash error message due to coolant pump turning off.

Inspect coolant connections on MCHP unit and integral

brass drain valve when coolant achieves a safe working temperature.

Place towel under drain valve.

Verify valve’s position is OFF, slowly remove drain cap.

Connect short hose to drain valve and extend to

coolant container pan. Open valve and evacuate coolant from system.

Coolant tank’s cap may need to be taken off to remove vacuum.

Verify tubing loops are open to prevent any vacuum effect to adversely impact draining operation. If coolant has under 24,000 hours of operation and is clean, reuse when reﬁ lling system.

It is recommended to evacuate lines with aid of LOW pressure (under 5 psi) compressed air. Alternatively, hand pump can be used.

Page 43

15 - DETAILED SEQUENCE OF OPERATION

Page 44

15 - DETAILED SEQUENCE OF OPERATION

Page 45

15 - DETAILED SEQUENCE OF OPERATION

15.1 MCHP Operation:

freewatt PLUS

• System is designed to preferentially provide heat to home and indirect water heater by operating MCHP unit.

Boiler is operated as supplemental heat supply as • needed to maintain comfort.

Preferential operation of MCHP is achieved by • allowing MCHP to operate at times when thermostat does not speciﬁ cally call for heat, but, based on outdoor temperature, continuing need for heat can be established. Homeowner should expect MCHP to “run” longer and more often than boiler, even when thermostat may not indicate call for heat.

freewatt PLUS

• System designed to maintain close control of building temperature. Variations in room temperature should be less than traditional thermostats

with operating temperature dead band.

15.2 freewatt PLUS

System Response to Heat

Demands:

freewatt PLUS

call for heat from thermostat or aquastat on indirect water heater. Does not directly respond to electrical power demands in home. Response of heat calls follows:

Upon demand for heat from any space heating • zone, hydronic water ﬂ ow to zone “radiators” is initiated, MCHP unit is started and boiler operation is enabled. Burner in boiler will ﬁ re as necessary to maintain current required hydronic loop temperature as determined by programmed outdoor reset control of boiler. Boiler initially ﬁ res at lowest input rate and modulates to higher levels as determined by temperature response of hydronic loop temperature.

Smart Zone operation of MCHP unit, initiated by call for • heat, will continue beyond speciﬁ c call for heat from Smart Zone thermostat as long as outdoor temperature sensor indicates general need for heating of building (i.e. outdoor temperature about 55° F). Boiler operation is disabled immediately at end of call for heat from Smart Zone Thermostat. Operation of MCHP unit is terminated only when there is small temperature rise above current set temperature of Smart Zone Thermostat.

System heating function is activated by

freewatt PLUS

System to

Operate domestic water heating zone without • causing unacceptably high temperature in MCHP coolant. Boiler burner operation is disabled

immediately upon end of call for heat.

For zones with room thermostats wired directly to • ECR relay control or any ECR expansion relay control, operation of MCHP and boiler burner will terminate with end of heat call (either from initiating zone or any other zone.)

Call for heat by Aquastat of indirect water heating • tank Zone 1, when Zone 1 is conﬁ gured for heating of domestic water. Water heating zone pump starts, MCHP operates, boiler burner is enabled to maintain temperature programmed as domestic water heating temperature (

33). Boiler burner is disabled and MCHP continues to operate when Aquastat is satisﬁ ed, until control module has determined it is not possible to:

Operate Smart Zone without exceeding small • temperature rise above Smart Zone spacing heating setpoint or

Operate domestic water heating zone without • causing unacceptable high temperature in MCHP coolant.

MCHP coolant temperature is monitored internally and • reported to terminates automatically by and disabled for period of time ranging from 15 minutes to three hours if MCHP coolant reaches 185°F. Occurs when current target temperature of boiler control is high (about 160° F or above.). Can also occur if boiler temperature boost mode is not disabled as recommended. In either case, module logic takes into account frequency which 185°F coolant temperature is reached and determines how long to disable operation of MCHP unit. Operational logic limits number of times MCHP is started and stopped in presence of high hydronic loop temperature.

Default setup of • minute priority to DHW heating when DHW jumper is in place. Priority action pertains to achieving satisfaction of indirect water heater aquastat (not virtual heat call operation of MCHP unit.) Priority action can be

deactivated by using Mint Service Tool.

freewatt PLUS

freewatt

control module. MCHP operation

freewatt

boiler parameter 1 +

freewatt

control module provides 30

control module

freewatt

control

For other heating zones with room thermostats wired • directly to MCHP will continue until initiating zone, or any new heat demand zone is satisﬁ ed and module determines it is not possible to either

Operate Smart Zone without exceeding small • temperature rise above Smart Zone setpoint or

freewatt

control module, operation of

freewatt

control

Page 46

15 - DETAILED SEQUENCE OF OPERATION

15.3 Achieving Best

freewatt PLUS

System

Performance

Homeowner dollar, carbon dioxide emissions, and energy saving with operating parameters of boiler and thermostat to achieve maximum preferential operation of MCHP unit (and minimum ﬁ ring of boiler).

Following steps will help in maximizing beneﬁ t of

PLUS

Set top target temperature of boiler reset operating • temperature control (parameter 4) at lowest possible temperature that will meet heating needs of home on coldest days of year. Recommended maximum top target temperature is 160°F per Commissioning Procedure. Setting top target temperature greater than 160°F will signiﬁ cantly reduce operation of MCHP unit and resulting electric power production. Set target temperature lower if possible.

Set Aquastat on indirect water heater no greater than • 125°F.

Although it is contrary to modern heating system • practice, it is recommended to avoid using setback with freewatt PLUS System. Using setback will typically cause Honda MCHP to shut down during setback hours as thermostat will be satisﬁ ed, particularly during early stages of setback. This reduces MCHP run hours and power generation signiﬁ cantly, thus reducing electric bill savings and cost effectiveness of freewatt system. Coming out of setback requires the freewatt boiler to run more to make up additional heat demand. Setting thermostat at a constant temperature and leaving in there will maximize comfort, power generation and electric bill savings. Set it, forget it, and save.

freewatt PLUS

System.

is maximized by adjusting

freewatt

Select Smart Zone and conﬁ gure if necessary, so it • represents at least 25% of total heat demand of home.

Set individual zone thermostats so Smart Zone set • point is about (1 or 2 degrees) above other zones in home will help maximize production of electricity by

freewatt PLUS

Set •

freewatt PLUS

Commissioning Procedure. Turns off temperature boost feature of boiler control. If occupants are dissatisﬁ ed with response of heating system to thermostat set point adjustments, consider altering outdoor reset curve, using Parameters 4, 5, 6, and 7 before adjusting Parameter 11 to non-zero setting. Keeping parameter 11 at zero is beneﬁ cial when there are heating zones that do not have critical heating comfort requirements but will produce nearly constant call for heat. Near constant call for heat can result from heating zone being “under radiated” or heat convectors being closed off.

freewatt PLUS

zones have appropriate amount of radiation.

System.

boiler parameter 11 to zero per

performs best when all heating

Page 47

16 - TROUBLESHOOTING

WARNING

Fire, explosion or risk of shock hazard may cause severe injury or death. Do not attempt to modify characteristics of this home heating appliance in any way.

16.1 Troubleshooting Tools

Voltmeter with settings to check: 240 VAC, 120 VAC, • 24 VAC and 12 VDC;

Continuity Tester;• Contact Thermometer; (Non-Contact Infrared •

Thermometer) Manometer with range of 0 to 20” of water column.•

Laptop Computer Loaded with MINT Software Tool.•

16.2 Initial Service Checks

Verify appropriate 120 VAC and 240 VAC circuit • breakers at main service panel are ON. Check outdoor disconnect switch, where applicable, is ON.

Verify 240 VAC and 120 VAC electric service switches • are turned ON.

Check for 120 VAC (minimum 108 VAC to 132 VAC) to • system.

Check for 240 VAC (minimum 216 VAC to 264 VAC) to • Honda MCHP.

Verify thermostat in Heat Mode.• Verify thermostat is calling for heat on system control. •

If not, inspect thermostat connections to ensure proper contact.

Verify external safety controls are installed and working • properly.

Verify natural gas supply valve is open at gas meter, • manual shutoff valves and gas control valve. Gas pressures are maximum of 10” w.c. (natural gas) or 14” w.c. (propane) with no ﬂ ow or with system operating and minimum of 4” w.c.(natural gas) or 10” w.c. (propane) with gas ﬂ owing at maximum ﬁ ring rate of

freewatt PLUS

with boiler and Honda MCHP operating simultaneously). Check wire connectors at control module, boiler control •

and Honda MCHP are securely plugged in or connected. If any component does not function properly, verify it is •

correctly installed and wired before replacing it. Static electricity discharge can damage control module •

and boiler control. Touch metal surface to discharge static electricity before touching either control.

The control module and boiler control cannot be • repaired. If either or both controls malfunction, the control unit must be replaced.

boiler (verify during system startup

Only trained, experienced service technicians • should service control systems. Follow “Sequence of Operation” for normal light off sequence after troubleshooting.

If two consecutive controls appear to fail or appear • defective, control is probaly not defective. Another problem may give appearance controls are defective or fail (for example, electrical short burning out transformer).

Check coolant tubing extending from Honda MCHP • to Hydronic Hybrid Integration Module is securely connected and not plugged or damaged.

Check coolant operating temperature. Using MINT • tool, conﬁ rm coolant entering MCHP unit is in range of 152-154° F. Check coolant tank in Hydronic Hybrid Integration Module verify ﬁ lled to above MIN. level line.

(Preferred level is just below MAX line.)

Page 48

16 - TROUBLESHOOTING

WARNING

Electrical shock hazard may cause serious injury or death. Avoid touching live electrical contacts. Service shall be performed by trained, experienced service technician.

WARNING

WHAT TO DO IF YOU SMELL GAS Do not try to light or start any appliance. Do not touch any electric switch or use any phone in

the building. Immediately call your gas supplier from a neighbor’s

phone. Follow gas supplier’s instructions. If you can not contact your gas supplier, call ﬁ re

department.

WARNING

Fire or explosion hazard. Use only your hand to turn gas control knob. Never use tools. If knob will not turn by hand, don’t try to repair it. Force or attempted repair may result in a ﬁ re or explosion.

WARNING

Fire or explosion hazard. If overheating occurs or gas supply fails to shut off, do not turn off or disconnect electrical supply to boiler or hydronic hybrid integration module. Shut off gas at location external to appliance.

16.3 Accessing

freewatt PLUS

System

Operational Data and Codes

Multiple means of accessing hydronic System operational data and error codes for purposes of

troubleshooting.

Observe and count number of ﬂ ashes of red “Service • Required” LED on front of See Table 16-1 “Alarm Codes for Service Required LED on

freewatt

Observe ﬂ ash rate of green LED on front of • c

ontrol module labeled “Combined Heat and Power”. (See Table 16-2 “Alarms Codes for Combined Heat and Power LED on

Observe status (lighted or not) of 10 LEDs on •

freewatt

(Remove cover to observe.) See Table 16-3. Read boiler operation error code on •

boiler electronic front panel per Control Manual and Troubleshooting Guide.

Use MINT software on portable computer connected to •

freewatt

operating data and error codes for System and Honda MCHP unit per MINT software Manual.

Remove metal cover of control panel on MCHP (located • upper left side of unit) and read error codes per Honda MCHP Installation and Operation Manual.

freewatt PLUS

• systems operate with RC-1000 HAI thermostat, note color of thermostat display (red for fault/alarm condition) and read module error message display. Error messages same as “Alarm Codes for System Service LED on Control Module”.

control module”.

freewatt

control board in

control module to display

freewatt

control Module”.

freewatt PLUS

control module.

freewatt

control module.

freewatt PLUS

freewatt

Boiler

control

freewatt

WARNING

Fire or explosion hazard. Do not use system if any part of gas control system (boiler or MCHP unit) has been underwater. Contact qualiﬁ ed service agency to inspect system and replace any part of control system and any gas control which has been underwater.

Call ECR • representative.

freewatt PLUS

Technical Support

Page 49

16 - TROUBLESHOOTING

16.4 General Troubleshooting

If And Check or repair

No Control module or HI Module operation

No boiler operation

Honda MCHP overheats

No power to thermostat

Display is blank

120 VAC electrical connections Blown fuse on control module circuit board

Thermostat settings Check Boiler per

PLUS

and Troubleshooting Guide

Check Control Module Connection Fuse in thermostat 24VAC Fuse in module or Faulty wire connection

Boiler Control Manual

Coolant Pump • functioning Properly

Circulators Functioning • Properly

Air in Coolant Line• Coolant Line Blocked• Coolant lines piped •

correctly into Honda MCHP

Mixing valve setting•

freewatt

control

Hydronic components:

• Control Module,

• HAI Thermostat,

• Transfer Switch,

Each major component has its own installation and service manual outlining troubleshooting information regarding individual component.

Make corrective action. Turn off power and restart system to clear error conditions.

Use BYPASS MODE, (CHP MODE OFF) to sustain heating operation while resolving MCHP unit errors or malfunctions.

freewatt PLUS

Boiler, •

freewatt

Hydronic • Module,

Honda MCHP, •

freewatt freewatt

Load Balancing Transformer and • APC Universal Transfer Switch •

freewatt PLUS

System consists of eight major

Hybrid Integration (HI)

freewatt

control module or

No Honda MCHP operation

See MCHP Manual

Page 50

16 - TROUBLESHOOTING

Table 16-1 Alarm Codes for Service Required LED on freewatt

ERROR

CODE

4 5 6

7 8

9 10 11 12

13 14

17 18

19 20 21 22 23 24 25

26 27 28

29-98

THERMOSTAT COMMUNICATIONS ERROR

MCHP COMMUNICATIONS ERROR

MCHP DEVICE ERROR (MCHP ASSERTING “FAILURE” STATUS, IE. A HARD ERROR) CHECK HONDA MCHP DIAGNOSTICS

MCHP DEVICE WARNING (MCHP ASSERTING “WARNING” STATUS, IE. A SOFT ERROR)

freewatt

SYSTEM POWER SWITCH OFF, UNABLE TO ENTER BACKUP MODE (NOTE: NOT DEFINED IN HY-

MCHP PLACED IN LOCKED MODE BY SERVICE TECH, PREVENTS MCHP OPERATION

LOW DWELLING TEMPERATURE. BOILER DOWN OR THERMOSTAT “OFF” BY MISTAKE

VIRTUAL WATCHDOG TIME-OUT. AN UNEXPECTED FIRMWARE EXECUTION ERROR

EXHAUST GAS LEAK SENSOR FAILURE, HONDA MCHP ERROR 39.0 (EX_SENS_FAIL)

EXHAUST GAS LEAK SENSOR POWER FAILURE, HONDA MCHP ERROR 39.1,(EX_SENS_POWER_

EXHAUST GAS LEAK SENSOR ALARM, COMBUSTION GAS DETECTED, HONDA MCHP ERROR 10.1,

NO DC POWER SUPPLY VOLTAGE DETECTED IN BACKUP MODE. (LOAD_PWR_FAULT)

DETECTED A freewatt

DETECTED A freewatt DETECTED A freewatt

VOLTAGE DETECTED ON THE freewatt

VIRTUAL WATCHDOG TIME-OUT OCCURRED 5 OR MORE TIMES. MULTIPLE UNEXPECTED FIRM-

PLUS

EXHAUST GAS LEAK SENSOR TEST BUTTON PRESSED

MISSING L1 OR L2 OF AC POWER (fTS_AC_FAULT)

WARE EXECUTION ERRORS OCCURRED.

INDICATES CHECK OR REPAIR

OUTDOOR SENSOR ERROR

FLASH PARAMETER INTEGRITY CHECK ERROR SERVICE REQUIRED

DRONIC SYSTEM)

RESERVED FOR FUTURE USE

ERROR CODE 10 NOT USED

RESERVED FOR FUTURE USE

OCCURRED.

FAIL)

(EX_LEAKAGE_FAIL)

PLUS

TRANSFER SWITCH COMMUNICATIONS FAILURE Check fTS communications cable

PLUS

TRANSFER SWITCH DEVICE ERROR see freewatt

ERROR CODE 20 NOT USED

PLUS

TRANSFER SWITCH STATE ERROR see freewatt

RESERVED FOR FUTURE USE

PLUS

TRANSFER SWITCH CONTACTOR #1 ERROR see freewatt

PLUS

TRANSFER SWITCH CONTACTOR #2 ERROR see freewatt

PLUS

BACKUP POWER MODE

RESERVED FOR FUTURE USE

TRANSFER SWITCH ISLAND NODES (I1 OR I2) IN

Control Module

1. CHP MODE SWITCH IN

2. CABLES AND CONNECTIONS BETWEEN THE THERMOSTAT AND THE HI MODULE

3. LOWER FURNACE ACCESS PANEL INSTALLED

4. IMPROPERLY PROGRAMMED THERMOSTAT

1. CHECK OUTDOOR SENSOR AND CONNECTION OR INTERNAL 20k OHM DEFAULT RESISTOR

1. RESET SYSTEM POWER

2. POWER TO MCHP

3. CABLES AND CONNECTIONS BETWEEN HONDA MCHP AND HI MODULE

REPLACE CONTROLLER MODULE

INDICATES A FAULT IN 120V LOAD CIRCUIT

transfer switch IOM

transfer switch IOM transfer switch IOM

see freewatt

BLOWN FUSE, FAULTY WIRING, UTILITY FAULT

REPLACE CONTROL MODULE

transfer switch IOM

POSITION

Page 51

16 - TROUBLESHOOTING

Table 16-2

16.6 Control Board LED Interpretation

Alarms Codes for Combined Heat and Power LED on

freewatt

Combined Heat Power

LED Status

Rapid Flash

(~5 per second)

Control Module

Condition

MCHP operation suspended

on detection of high coolant

temperature

Steady ON Normal MCHP Operation

16.5 MCHP Suspended Mode

Table 16-3

MCHP operation will be suspended if there is detection of high coolant temperature, indicated by rapidly ﬂ ashing Combined Heat and Power LED. MCHP Suspend Mode prevents MCHP unit from cycling in overheat situation in which it cannot run. Condition may be due to boiler temperature set higher than recommended, improperly commissioned system, or high aquastat setting on indirect hot water tank. Perform following tasks if suspend

condition is encountered.

Check boiler parameters• . Hydronic freewatt system has maximum recommended design water temperature of 160° F. Suspend mode will occur and effect overall

MCHP ENB MCHP enabled MCHP disabled

MCHP runtime and power generation, if boiler water temperature is higher than 160° F.

Check aquastat on indirect water tank is set no • higher than 125° F. MCHP may not run while boiler

is satisfying indirect hot water tank, if aquastat must be set higher for hot water recovery.

Ensure ﬂ ow is presen• t in coolant loop and hydronic loop (check for working pumps).

Ensure system is properly commissioned• per Hydronic Commissioning Procedure.

Observe green LEDs on control board by removing • cover of

freewatt

Control Module.

Control Board LEDs are valid only in Combined Heat • and Power Mode (CHP Mode switch “ON”). They are not used when system is in Bypass Mode (CHP Mode switch “OFF”).

Do not use Control Board LEDs as indicator of system • status when in Bypass Mode.

Controller Board LED’s indicate:

LED ON LED OFF

Z1 Zone 1 circulator ON Zone 1 circulator OFF Z2 Zone 2 circulator ON Zone 2 circulator OFF Z3 Zone 3 circulator ON Zone 3 circulator OFF Z4 Zone 4 circulator ON Zone 4 circulator OFF Z5 Zone 5 circulator ON Zone 5 circulator OFF Z6 Zone 6 circulator ON Zone 6 circulator OFF

X1X2

MyEND

PUMP1

PUMP2

PUMP3 Not used Not used

Relay XX end switch relay closed

freewatt

Module closed either DHW or CH input to boiler, requesting boiler operation

24 VDC coolant pump in HI Module energized

120 VAC Hydronic circulator connected to HI Module energized through external relay switch

Control

Relay XX end switch relay open

freewatt

Module not requesting boiler operation

24 VDC coolant pump not energized

120 VAC Hydronic circulator not energized

Control

NOTE: One or more zone circulators may be activated without speciﬁ c call for heat by room thermostats or DHW aquastat consequence of control logic anticipating heat demand and attempting to maximize MCHP run time.

Page 52

16 - TROUBLESHOOTING

16.6 freewatt

PLUS System Fuses

WARNING

Do not jumper fuse. Replace speciﬁ ed as listed. Failure to comply could result in severe personal injury, or death.

WARNING

Label all wiring prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Disconnect power to system before servicing. Failure to comply could result in severe personal injury or death.

NOTICE

Check control module fuses before replacing control module or other major component (pump, motor, etc.). Blown fuse may prevent system control module or other components from operating.

NOTICE

On board fuses are not available from ECR International. Service technicians should provide fuses for

freewatt

PLUS service from local suppliers.

Refer to Table 16-4.

Table 16-4 freewatt PLUS System Fuses

Location QTY Amp Voltage Spares Shape Size

Control Module (Control board, GDB Fuse) 1 2 250 0 Cylinder 5mm X 20mm Boiler (Control Board F1, Lower RH Corner) 1 5 250 2 Cylinder 5mm X 20mm Boiler (Control Board F3, Middle Right Side) 1 4 250 2 Cylinder 5mm X 20mm MCHP* 1 1 650DC 0 Cylinder 6.35mm x 32mm MCHP * 2 20 600AC 0 Cylinder 10.3mm x 38.1mm APC UTS6H Control Board

(Use Littlefuse KLKR15 or eqiv.) * Refer to MCHP Shop Manual

6 15 600AC

Cylinder 10.3mm x 38.1mm

Page 53