Space Pak SCM Installation, Operation & Maintenance Manual

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Page 1

MODEL SCM

INSTALLATION,

OPERATION

& MAINTENANCE

MANUAL

Air To Water Heat Pumps

Reverse Cycle Chillers

3 and 5 Ton

SCM2-1212

W30-WG0593

SECTION 1: READ BEFORE PROCEEDING

Model SCM overview .................................................................. 2

SECTION 2: SPECIFICATIONS AND RATINGS SECTION 3: DIMENSIONS SECTION 4: LOCATION & MOUNTING

Prepare the unit .......................................................................... 5

Location ...................................................................................... 5

Handling ...................................................................................... 5

Mounting pad .............................................................................. 5

SECTION 5: GLYCOL/WATER SYSTEM

Glycol/water system design ......................................................... 8

Glycol/water system installation .................................................. 8

SECTION 6: ELECTRICAL CONNECTIONS

Overcurrent protection & wire sizing ........................................... 9

Optional low ambient adjustment ................................................ 9

SpacePak heat pump/chiller wiring ............................................. 9

Multiple air handler applications .......................................... ........ 9

Qualiﬁ ed installer only —

This product must be installed

only by a qualiﬁ ed service techni- cian. The installation must be done using recognized industry practices, and in compliance with this manual and all applicable codes. Failure to comply could result in death, serious injury or substantial property damage.

SECTION 7: START-UP AND TEST

BEFORE starting the unit ............................................................ 11

Start the SpacePak heat pump/chiller ......................................... 11

Anti-freeze cycle ......................................................................... 11

24-Hour follow-up ........................................................................ 11

SECTION 8: TROUBLESHOOTING SECTION 9: MAINTENANCE

Glycol/water mixture ................................................................... 13

Perform annual inspection .......................................................... 13

Preparing the SCM for shut down ............................................... 13

To restart after shutdown ............................................................ 13

SECTION 10: REPLACEMENT PARTS SECTION 11: PERFORMANCE DATA

3-Ton SpacePak chiller ............................................................... 15

5-Ton SpacePak chiller ............................................................... 15

SECTION 12: LIMITED WARRANTY

For information not included in this

manual, see the following: This manual

includes only basic information for installation, operation and maintenance of SpacePak air to water heat pumps. For more advanced applications and information not shown in this manual, contact SpacePak Technical Support for assistance and supplemental instructions. Call 413-564-5530 in Westﬁ eld, MA or visit our website at www.spacepak.com to send an e-mail or review technical literature.

IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 800-465-8558 / FAX (413) 564-5815

IN CANADA: 7555 TRANMERE DRIVE, MISSISSAUGA, ONTARIO, L5S 1LR (905) 672-2991 / FAX (905) 672-2883

Page 2

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 1: READ BEFORE PROCEEDING

Hazard deﬁ nitions

The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product.

Indicates an imminently hazardous situation which,

if not avoided, WILL result in death, serious injury or substantial property damage.

Indicates an imminently hazardous situation which,

if not avoided, COULD result in death, serious injury or substantial property damage.

Indicates an imminently hazardous situation which,

if not avoided, MAY result in minor injury or property damage.

Used to notify of special instructions on installation,

operation or maintenance which are important to equipment, but not related to personal injury hazards.

Model SCM overview

The SPACE PAK Model SCM Heat pump/chiller is a self contained reverse-cycle heat-pump that provides a continuous supply of heated or chilled water for various purposes, such as: residential or small commercial building heating and cooling; and specialty applications, such as computer room cooling or industrial/agricultural conditioning and dehumidiﬁ cation.

Model SCM Chillers are available in three- and ﬁ ve-ton nominal capacities. Both use the same general design and operating principals.

Each chiller contains TWO isolated refrigeration systems of equal size to cool or heat the delivered water supply. The two systems can operate individually or in tandem to achieve 50% or 100% capacity. The major components of each system are:

• A hermetically sealed refrigeration compressor & motor.

• An outside coil to reject heat (in cooling) or absorb heat (in heating) from the surrounding ambient air.

• A fan and motor to force air over the outside coil; a shelland-tube refrigerant-to-water heat exchanger to absorb heat (in cooling) or supply heat (in heating) to the delivered water ﬂ ow.

• An electronic expansion valve to throttle the refrigerant ﬂ ow in both heating and cooling modes of operation, responding to varying load on the system.

• Additionally, each system contains a reversing valve (to select between heating and cooling operation) and sensors and safety circuits to monitor and protect the equipment from potentially damaging or dangerous operating conditions.

A single water circuit connects both internal heat exchangers, and contains sensors to measure entering and leaving water temperatures. A mechanical ﬂ ow switch safety ensures continuous water ﬂ ow while either of the two refrigerant systems is operating. All components are contained within a supporting structure and enclosure sufﬁ cient to allow stand- alone outdoor installation in all temperate climates.

All operation and protections are managed by a microprocessor controller which operates the individual systems, determines all operating parameters, and monitors the condition of each system. A simple interface communicates with the indoor air handler, heat exchanger, or other load.

Failure to comply with all of the guidelines

BELOW could result in death, serious injury or substantial property damage.

Codes and electrical requirements

• This product must be installed in accordance with all applicable codes. Where instructions in this manual differ from speciﬁ c local requirements, defer to the local codes.

• The electrical installation must also comply with the latest edition of: in the U. S. — National Electrical Code ANSI/ NFPA No. 70; in Canada — CSA C22.1 Canadian Electrical Code Part 1. Wiring must be N.E.C. Class 1. Use only copper wire, rated for 120°F and sized for the load listed in this manual.

• Electrical shock hazard — Disconnect all electrical power before servicing the unit. Also, the unit must be grounded in accordance with the Electrical Code listed above.

Refrigerant

• Refrigeration system is factory charged with R410A refrigerant, and requires no additional service during installation. Any repair, diagnosis or maintenance service to the refrigeration system must be performed by a qualiﬁ ed technician. No alternate refrigerants, lubricants or additives are approved for this unit. Any use of alternate or non-approved materials in the refrigeration system may result in personal injury or equipment damage, and will void the manufacturer’s warranty.

Liquid side

The ﬂ uid in the liquid side of the Model SCM

must be an anti-freeze/water mix.

• The antifreeze percentage must be at least 10%. Follow guidelines in this manual to ﬁ nd the required antifreeze mix for the application. Thoroughly ﬂ ush the system before ﬁ lling.

• The system must be supplied with a pump sized to provide the minimum ﬂ ow rates speciﬁ ed in this manual. Pump selection must consider the pressure loss through the system and its components plus the pressure loss through the SCM’s heat exchanger and internal components. The pump must be rated for use with chilled water/glycol mixture.

• Install a y-strainer at the liquid input of the heat pump as shown in this manual to prevent damage to the heat exchanger from sediment.

• DO NOT use for potable water heating. The single-wall heat exchanger is not suitable for the application.

Ambient limits

• See information in this manual for heating and cooling performance versus ambient temperature.

• For applications requiring cooling at outdoor temperatures below 55°F, contact SpacePak Technical Support for assistance.

• DO NOT disconnect power in cold temperatures. Power must be on to allow the anti-freeze cycle to operate.

SCM controller

• The SCM electronic controller is factory conﬁ gured. DO NOT adjust the control settings. If special operating characteristics are required, contact SpacePak Technical Support for availability and instructions.

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M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 2: Speciﬁ cations and ratings

Figure 1 Model SCM rating data

Item Units SCM-036 SCM-060 Item Units SCM-036 SCM-060

Cooling capacity (Note 2) Btuh / KW 34,000 / 10.0 46,000 / 13.5 Supply voltage VAC 230/1/60 230/1/60

Heating capacity

Fan speed RPM 850 850

Noise level dB(A) 56 56 MCA (Note 1) Amps 19.7 30.3

Water volume Gallons 2 2.5

Supply connection Inches NPT 1 1 Return connection Inches NPT 1 1

Minimum supply temperature

Minimum ﬂ ow GPM 7 10 Maximum ﬂ ow GPM 12 15

Pressure drop at minimum ﬂ ow

Net weight Lbs 337 386 Operating weight Lbs 354 407

Shipping weight Lbs 346 395 Shipping dimensions Inches 47 x 18 x 60 47 x 18 x 60

Note 1: Electrical ratings DO NOT include water pump amp draw. This pump is supplied by the installer. Add the current draw of the pump to

Note 2: Performance at 95° ambient temperature, 47° water Note 3: Performance at 45° ambient temperature, 115° water

(Note 3) Btuh / KW 44,000 / 13.0 60,000 / 17.0

°F 36 36

Feet WC 8 17

the values listed above. Adjust the MCA accordingly.

Running current, cooling (Note 1)

Running current, heating (Note 1)

Maximum supply temperature

Pressure drop at maximum ﬂ ow

Amps 17.6 26.4

Amps 13.1 21.3

°F 125 125

Feet WC 21 28

Figure 2 Model SCM coding

Typical model

Position 1 2 3 4 5 6 7 8

Designation Unit Type Capacity Series

Values

Examples

Standard equipment

• Heat pump/chiller, including two refrigeration systems, factory-programmed controller, fans and all required internal components

• Powder-coated enclosure

S C M 060 A 4

Refrigerant

SCM = SpacePak Heat Pump/Chiller Module

036 = 3 ton nominal 060 = 5 ton nominal

A = Series “A” 4 = R410A

SCM-036-A-4 = 3 ton nominal, series A, using R410A referigerant, SpacePak Heat Pump/Chiller Module

SCM-060-A-4 = 5 ton nominal, series A, using R410A referigerant, SpacePak Heat Pump/Chiller Module

Additional components required

• Pump and piping by others

• Expansion tank, properly sized for system volume

• SpacePak Chiller Interface Module

• Auxiliary electric immersion heater (3 KW, 230V/1/60) — requires separate electrical power circuit, 15-amp minimum breaker

type

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M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 3: DIMENSIONS

Figure 3 Model SCM dimensions (ALL DIMENSIONS IN INCHES)

A B D D1 D2 E F G H J K W W1 W2

Model

SCM-036

SCM-060

Leg

Front to

height

return

1 10 17

Cabinet

depth

Mounting

lug

depth

Mounting

lug

centers

Bottom

return

Bottom

supply

– 4 –

Base to

bottom edge

of lower fan

25 53 1" NPT 1" NPT 43

Overall

Height

Return

connec-

tion

Supply

connec-

tion

Overall

width

Mounting

lug

centers

Lug

center

to edge

Page 5

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 4: LOCATION & MOUNTING

Failure to comply with all of the guidelines

IN THE FOLLOWING could result in death,

serious injury or substantial property damage.

The installation must comply with all applicable

local codes.

Prepare the unit

• Inspect the unit for shipping damage. DO NOT use if there is a risk that the damage could affect unit operation.

• Make sure all required components are available.

• Install optional immersion heater, if used. See instructions provided with the heater.

Location

• DO NOT locate where the unit could be sprayed by sprinklers.

• DO NOT locate near swimming pools, spas or any location that could cause chlorine or other contaminant to enter the unit.

• DO NOT locate where water run-off from adjacent structures could impinge on the unit.

• Maintain the clearances shown in Figure 5.

• LOW AMBIENT conditions — Contact SpacePak Technical Support to obtain low ambient adjustment instructions if cooling operation below 55°F is required.

• CORROSIVE ENVIRONMENTS — Do not install the unit in an area subject to sea air or other potential corrosive contaminants.

• INDOOR INSTALLATION — If the unit is installed inside a building, the building must be equipped with air openings sufﬁ cient to ensure free discharge of heated (or cooled) air generated by the heat pump/chiller. All clearances must be maintained to ensure free air ﬂ ow into and out of the enclosure. Make sure no other equipment located in the space will be affected by the unit’s air ﬂ ow.

Handling

• See Figure 4.

• Place padding at pressure points to prevent damage to the enclosure.

• Use caution when handling. The unit is heavy and could cause severe injury or damage if dropped or handled incorrectly.

Figure 4 Handling with cables

Figure 5 Maintain clearances below

Minimum clearances (inches)

STUV

20 59 40 20

Mounting pad

• The SpacePak heat pump/chiller must be mounted on a level corrosion- and weather-resistant mounting surface, preferably concrete. The structural support must be suitable for the operating weight of the unit and attached components, its mounting pad, snow loading and any other expected loads.

• The mounting pad must not be attached directly to a structure where noise transmission would be objectionable.

• Vibration isolators supplied with the chiller may be installed when desired to reduce transmitted vibration.

• The unit must be bolted securely to the pad. Where required by local jurisdiction, the mounting must also be analyzed for seismic loading capability.

• The mounting must ensure that there will be no debris accumulation which might block air ﬂ ow through the enclosure openings. The lower edge of the lower fan

opening must be above the typical snow line, including allowance for drifting.

• There must be no accumulation of water that could reach the bottom of the unit’s enclosure.

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Page 6

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 5: Glycol/water system

Figure 6 SpacePak Chiller with single air handler (see page 7 for instructions)

1 SpacePak heat pump/chiller 2 Pump (by installer) — see instruc-

tions in this manual for sizing information

3 Drain valve 4 Isolation valve, typical — install

where shown (2 required)

5 Y-strainer — must be installed

where shown to prevent sediment from damaging or clogging the chiller heat exchanger

6 Expansion tank (diaphragm or

bladder type)

7 Air separator with automatic air

vent — install in two locations, as shown

8 Purge valve (external valve

required only when purge valve is not integral to the air handler

9 Air handler — Make sure the

chiller/heat pump is sized for the air handler load

10 Supply connection, 1" NPT 11 Return connection, 1" NPT 12 Pressure gauge

– 6 –

13 Balancing valves (2 per air handler)

— see Figure 7, page 7

14 3-way valves (1 per air handler) —

see Figure 7, page 7

15 (Not shown) — Install a hose bib

valve at a convenient location in the system. Use this valve to ﬁ ll the system with the required glycol/ water mixture.

16 Manual air vent.

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M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 5: Glycol/water system (continued)

Figure 7 SpacePak Chiller with two air handlers (parallel piping) (see page 7 for instructions) — see legend on page 6

Glycol/water system design

1. SpacePak heat pump/chiller capacity — The SCM capacity is reduced as glycol percentage increases. Multiply the rated capacity by the multiplier listed in Figure 8, page 8.

2. Select the recommended piping layout from either Figure 6, page 6 or Figure 7, page 7.

For system designs not covered in this manual,

contact SpacePak Technical Support for further information.

3. Other equipment in the system — Make sure the system design meets the requirements of air handlers, boilers and other components in the system.

4. Existing systems — Modify existing system piping and components as needed to comply with the recommendations in this manual.

5. Automatic ﬁ ll — SpacePak recommends NOT installing an automatic ﬁ ll line except where required by local codes. Where required, connect the ﬁ ll line to the expansion tank.

When an automatic ﬁ ll system is installed, the

cooling ﬂ uid (Glycol/water) must be inspected at least every three months, or whenever a leak is detected, to ensure the proper glycol concentration is maintained.

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M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 5: Glycol/water system (continued)

6. Size the piping and select the system pump using the ﬂ ow rate and pressure drop given in Figure 1, page 3. Adjust the pressure drop through piping and chiller using the glycol correction multipliers in Figure 8, page 8.

7. System volume and expansion volume – To ensure smooth temperature control and minimize cycling of refrigeration system, all installations must have total volumes equal to or greater than ﬁ ve gallons per nominal ton of the smallest staging increment. In other words, a three ton chiller is comprised of two, equal, 1 ½ ton refrigeration systems, each of which can operate independently. Therefore the minimum total system volume is 5x1.5=7.5 gallons. Similarly, a ﬁ ve ton chiller has two 2 ½ ton systems, so the minimum system volume is 5x2.5,

12.5 gallons. Multiple chiller installation that are operating in a staged conﬁ guration follow the same rule, so that only one- half of the smallest chiller tonnage needs to be considered.

Additionally, the system requires an expansion volume (air) of one gallon of open volume for every twenty gallons of actual system volume (not just minimum volume) A typical multiple chiller installation will generally have a volume far greater than the minimum required, and it is this entire volume that must be considered when sizing the expansion tank. Note that the nominal expansion tank volume is not the same as the expansion volume. If the actual air volume is not published, consider it to be no more than half the nominal volume. As an example, a single ﬁ ve ton chiller requires a minimum of 12.5 gallons of system volume. When the system installation is complete, the total liquid volume of plumbing, air handlers and heat exchanger is twenty gallons. A three gallon nominal expansion tank is selected, which provides 1 ½ gallons of expansion volume, but also adds 1 ½ gallons to the system volume. Therefore the total volume is now

21.5 gallons, 21.5÷20=1.08 gallons, the minimum expansion volume. The 1 ½ gallons of available expansion volume is greater than 1.08, so the 3 gallon expansion tank and the entire system, comply with these guidelines.

8. Air vents — Locate high-efﬁ ciency air vents as shown in the piping to prevent air from pocketing.

Glycol/water system installation

1. Obtain all components speciﬁ ed in Figure 6, page 6 or Figure7, page 7. Make sure all components and piping comply with applicable local codes.

DO NOT use galvanized pipe anywhere in the

system. Galvanizing will react with the glycol and can cause glycol degradation and sludge in the system.

1. Charge the expansion tank to 15 PSIG (with no water or pressure in the system).

2. Install the system piping. DO NOT connect the SpacePak unit to the system piping until the system has been cleaned as required below.

Figure 8 SCM glycol concentration (10% min, 50% max)

Ethylene glycol % 10 20 30 40 50

Min ambient temp, °F 23 14 2 –13 –36

SpacePak capacity multiplier .98 .96 .93 .91 .89

Pressure drop multiplier (cooling) 1.06 1.12 1.16 1.25 1.36

Pressure drop multiplier (heating) 1.06 1.12 1.16 1.22 1.28

Propylene glycol % 10 20 30 40 50

Min ambient temp, °F 26 18 8 –7 –29

SpacePak capacity multiplier .99 .98 .96 .93 .88

Pressure drop multiplier (cooling) 1.10 1.20 1.34 1.50 1.65

Pressure drop multiplier (heating) 1.10 1.20 1.34 1.46 1.50

Clean the system

1. The SCM must NOT be connected to the system during this process.

2. Connect a hose from a fresh water supply to the system ﬁ ll hose bibb. The hose bibb valve (not shown in piping diagrams) should be located low in the system near to the SpacePak connection.

3. Open the purge valve, (may be inside the air handler) while slowly ﬁ lling the system. Close the valve when air is removed from the system and water begins to ﬂ ow out of the valve.

4. Fill the system with fresh water and run water until the system has been thoroughly ﬂ ushed clean.

Pressure test the system

1. Add water to the system as needed to raise the pressure to 35 PSIG (verify that all system components are suitable for this pressure). Verify that the pressure remains constant for at least one hour. Locate and correct any leaks.

2. After successfully testing,drain the system and removed the fresh water hose.

Insulate the piping

1. After testing and draining the system, apply pipe insulation.

Fill system with glycol/water mixture

1. Calculate the system volume. (Find the SCM water volume in Figure 1, page 3.)

2. See Figure 8, page 8 for required glycol concentration for the minimum expected outside temperature.

3. Obtain the required volume inhibited glycol/water solution premixed or mix in a clean container. (The glycol must contain an inhibitor to prevent metal corrosion.)

4. Pump the glycol/water solution into the system, allowing air to escape through the purge valve(s).

5. After ﬁ lling the system, sample the system ﬂ uid and verify glycol and inhibitor percentages, following instructions provided with the glycol.

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Page 9

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 6: Electrical connections

The electrical installation must comply with the latest edition of: in the U.S. — National Electrical Code ANSI/NFPA No. 70; in Canada — CSA C22.1 Canadian Electrical Code Part 1. Wiring must be N.E.C. Class 1. Use only copper wire, rated for 120°F and sized for the load listed in this manual.

Electrical shock hazard — Disconnect

all electrical power before servicing the unit. Also, the unit must be grounded in accordance with the Electrical Code listed above.

Overcurrent protection & wire sizing

• Protect each circuit with a breaker or fuse rated for the load given in Figure 1, page 3.

The electrical loads given in Figure 1,

page 3 allow for a pump load of no more than 5 amps at 110 VAC (2.5 amps at 230 VAC). If the pump load exceeds this, provide a separate power source to the pump. DO NOT feed power to the pump from the SpacePak air handler panel.

• Provide a separate power source and overcurrent protection for the immersion heater. Refer to the Figures 11 and 12 of this manual for detailed wiring.

Figure 9 SpacePak Heat Pump/Chiller ﬁ eld wiring — SINGLE air

handler (See Figure 12, page 12 for ladder wiring diagram)

Optional low ambient adjustment

• If cooling is desired in low ambient conditions, follow the instructions supplied by SpacePak Technical Support.

SpacePak heat pump/chiller wiring

The SpacePak SCM chillers require a dry

contact (relay) signal to enable and select

between heating and cooling modes. They will not operate on the 24V signals from typical thermostats or air handlers. Connecting 24V to either of these points will result in erratic operation and may cause signiﬁ cant component damage.

• Connect Figure 9, page 9.

• Connect SpacePak Chiller Interface Module as shown in Figure 10, page 10.

• See Figure 12, page 12, for chiller electrical ladder diagram.

single air handler to chiller as shown in

multiple air handlers to chiller via

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Page 10

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 6: Electrical connections (continued)

Multiple air handler applications

• See Figure 10, page 10.

•

For multiple air handler applications, provide a zone valve or pump to control water the ﬂ ow to the air handler.

• When the zone thermostat activates the SCM, the valve will be activated by the SpacePak air handler.

• The total zone control load must not exceed 20 VA at 24 VAC. If a larger valve or zone pump is used, it must be switched by a power relay controlled from the 24 VAC output of the air handler.

• Refer to manual supplied with SCC-5 module for connection and operational details.

Figure 10 SpacePak Heat Pump/Chiller ﬁ eld wiring — Multiple air

handlers (see Figure 12, page 12 for ladder wiring diagram)

– 10 –

Page 11

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 6: Electrical connections (continued)

Figure 11 SpacePak Heat Pump/Chiller — Pictoral wiring diagram

– 11 –

Page 12

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 6: Electrical connections (continued)

Figure 12 SpacePak Heat Pump/Chiller electrical ladder diagram

– 12 –

Page 13

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 7: Start-up and test

PURGE VALVE

(MANUAL)

DRAIN VALVE

See the attached illustration; note this is not intended to include all components in the system, just the minimum to properly purge air from the chiller.

1. With the chiller isolated and dry, valves A & B closed, charge the “system”(that is, all the plumbing not shown), and remove as much air as possible through the air separator.

2. Apply a static pressure to the system, with all pumps off, of 15-25 PSI.

3. Very gradually open the lower ball valve, B, to allow water under pressure to begin to ﬁ ll the chiller from the bottom.

4. Crack the manual vent valve until you hear air escaping.

5. Allow the water to continue to ﬁ ll the chiller, displacing air. This should go very slowly, and could take a minute or more.

6. When all the air has been displaced and a steady stream of water is ﬂ owing out of the vent valve, fully open ball valve B.

7. Open ball valve A, a small amount of air might escape the vent valve from the chiller supply line.

8. When all the air has escaped, close the vent valve.

Note, this procedure ﬁ lls the chillers in the opposite direction of normal ﬂ ow, so it must be done when all pumps are off.

BEFORE starting the unit

Electrical shock hazard — Disconnect all electrical

power before proceeding with the following.

Verify that the system and all components have been

installed in accordance with this manual and all applicable codes and instructions.

Inspect the SpacePak heat pump/chiller and all other system

components. All components should be in good condition and operational.

Inspect the water piping for any signs of leakage.

Repair all system leaks. Leakage will cause pressure to drop, preventing the heat pump/chiller from operating. Leaks also allow introduction of excess make-up water, whether ﬁ lled automatically or manually.

Check system pressure. The pressure should be at least

15 PSIG with heat pump/chiller not in operation.

Check all wiring connections to ensure terminal connections

are tight and all wiring is in place.

Start the SpacePak heat pump/chiller

Start in cooling mode.

1. Apply power to the unit

2. The display (Figure 13, page 14) (should show the start sequence — uC2, then 2.0, then the current water temperature. No other symbol should appear.

3. When the display shows only temperature, lower the thermostat setpoint below the current room temperature.

4. This begins a call for cooling, and the pump symbol will begin to ﬂ ash.

5. After 1 to 2 minutes, the pump symbol will change to constant display, and the pump will begin circulating.

6. Assuming the water is outside of the cooling temperature range (above 42 deg) the refrigeration system will initiate and the 1, or 3, or both numerals will begin ﬂ ashing.

7. After 1 to 2 minutes, the 1, or 3, or both numerals will change to constant, the compressor symbol will turn on and one or both compressors will start.

8. Observe for any alarms, errors, or faulty operation (noises, vibration, etc)

9. When operation is deemed satisfactory, raise the thermostat set-point or turn it off.

10. The pump will run for approximately two minutes after the compressor shutdown.

Start in heating mode.

1. When the pump has stopped, change the thermostat to Heating (if applicable) and raise the set point above current room temperature.

2. This initiates a call in Heating mode. The pump symbol will begin ﬂ ashing.

3. After 1 to 2 minutes, the pump symbol will change to constant display, and the pump will begin circulating.

4. Assuming the water is outside of the heating temperature range (below 120 deg) the refrigeration system will initiate and the 1, or 3, or both numerals will begin ﬂ ashing.

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Page 14

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 7: Start-up and test (continued)

5. After 1 to 2 minutes, the 1, or 3, or both numerals will change to constant, the compressor symbol will turn on and one or both compressors will start.

6. Observe for any alarms, errors, or faulty operation (noises, vibration, etc).

Anti-freeze cycle

1. Should the water temperature drop to 34°F during periods of non-use, the pump will start and the antifreeze heater (if connected) will energize and continue to operate until the temperature reaches 38°F.

2. If the water temperature continues to fall and reaches 33°F, the Alarm symbol and Fault Code AL will be displayed, and the unit will automatically start in heating mode. It will continue to run until the water temperature reaches 38°F.

3. NOTE: This provides the maximum level of protection in all cases, but may use energy unnecessarily when a suitable concentration of glycol anti-freeze is installed. When freeze protection is sufﬁ cient, these value can be adjusted to lower temperatures. Contact technical support for guidance in re-conﬁ guring these parameters, however it must be understood that the installer is responsible for ensuring sufﬁ cient freeze protection to the lowest temperature allowed.

24-Hour follow-up

Approximately 24 hours after start-up and testing, return to the installation to verify proper operation. Perform the following checks.

Check system pressure. Add additional glycol/water mixture

if needed to restore pressure. (Pressure can drop as air is removed from the system by the air vents.)

Sample the glycol/water mixture in the system. Verify inhibitor

and glycol levels.

Inspect the piping and components to ensure there are no

leaks. Repair any leaks immediately.

Close the isolation valves on either side of the y-strainer at

the SpacePak heat pump/chiller return connection. Remove the screen and inspect for sediment. Clean if necessary.

• If the strainer has become clogged with sediment, determine whether the system needs to be drained, cleaned and re-ﬁ lled. Excessive sediment accumulation in the strainer will reduce ﬂ ow and cause the unit to shut down.

Cycle the system on heating and cooling. Verify that all

components operate correctly.

Figure 13 Controller display

– 14 –

Page 15

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 8: Troubleshooting

Figure 14 Troubleshooting suggestions

Condition Possible Causes Veriﬁ cation Solution

Incorrect power supply Check power supply Supply correct power

Unit will not start

Compressor running - insufﬁ cient cooling/ heating

High compressor discharge pressure in cooling

High compressor discharge pressure in heating

Low compressor suction pressure in cooling

Compressor will not run

Noisy compressor

Fan will not run

Compressor runs - no heating/cooling

Low outlet glycol/water temperature in cooling

Loose or broken wires Check wiring

Circuit breaker interrupted Check for short

Insufﬁ cient pipe insulation Check insulation Add/repair insulation

Dirty coil Check coil Clean Coil

Low water ﬂ ow Look for alarm symbol and FL fault code

Dirty coil Check coil Clean Coil

Low water ﬂ ow

Insufﬁ cient/no water ﬂ ow Look for alarm symbol and FL fault code

Cooling operation in low ambient

Power supply failure Supply correct power

Failed compressor contactor Replace contactor

Loose power cable Check power cable Tighten power cable

Compressor limit exceeded

Incorrect return water temperature setting Check return water temperature setting Adjust return water temperature setting

Low glycol/water ﬂ ow Look for alarm symbol and FL fault code

Liquid returning to compressor

Compressor failure

Fan relay failure Replace fan relay

Fan motor failure Replace fan motor

No refrigerant charge Check for leaks Add appropriate refrigerant

Damaged heat exchanger

Compressor failure Replace compressor

Improper temperature control setting

No load/rapid temperature drop

Measure water ﬂ ow through heat exchanger

Conﬁ rm outdoor ambient is lower than typical for cooling operation, e.g. <55°

Check for compressor symbols 1 and/or

3. If symbol is displayed but compressor

is inactive, thermal overload has been tripped.

Check for glycol/water leaks and/or refrigerant leaks

Check cooling temperature setpoint and differential

Ensure compressors are allowed to run a minimum of three minutes before reaching desired temperature

Repair or replace wiring

Clean strainer screen

Clear blockage

Remove air in piping

Verify operation/condition of water pump

Flow should be a minimum of 10 GPM for SCM060 or 8 GPM for SCM036

Clean strainer screen

Clear blockage

Remove air in piping

Verify operation/condition of water pump

If low ambient cooling is desired, contact Technical Support for procedure to modify fan operating parameters.

This will reset, however root cause must be determined

Clean strainer screen

Clear blockage

Remove air in piping

Replace compressor

Replace heat exchanger

Contact Technical Support for instructions to reset cooling setpoints

Verify cooling fuction when there is sufﬁ cient heat load to allow continuous operation.

– 15 –

Page 16

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 8: Troubleshooting (continued)

Figure 14 Troubleshooting suggestions (continued)

Condition Possible Causes Veriﬁ cation Solution

Low outlet glycol/water temperature in heating

Low glycol/water ﬂ ow

Dirty coil, damaged or improperly operating fans

Extremely low ambient temperature

Damaged or blocked plumbing or air handler

Defective or improper pump

Visually inspect coil condition and fan operation

Heating performance falls considerable as temperatures drop below 20-25°F

Check for blockage and/or air in piping, check operation/condition of water pump

Verify pump operation/condition. Measure water ﬂ ow through the heat exchanger

Clean coil, repair fan blade or motor as necessary.

Install supplemental heating for extreme low ambient conditions.

Clean strainer screen

Clear blockage

Remove air in piping

Replace or re-size pump to obtain a minimum of 10 GPM for SCM060 or 8 GPM for SCM036

Figure 15 Fault codes

FAULT CODE

E1 Water Inlet Temperature Sensor Failure Short Circuit or Sensor Open Check/Replace Sensor

E2 Evaporator #1 Water Outlet Temperature

E3 Outside Coil #1 Temperature Sensor Failure Short Circuit or Sensor Open Check/Replace Sensor

E4 Ambient Temperature Sensor Failure Short Circuit or Sensor Open Check/Replace Sensor

E5 Delivered Water Outlet Temperature Sensor

E6 Evaporator #2 Water Outlet Temperature

E7 Outside Coil #2 Temperature Sensor Failure Short Circuit or Sensor Open Check/Replace Sensor

AL Anti-Freeze Cycle Error / Cooling Water Temperature has Fallen Below

FL Flow Switch Error Inadequate Water Flow Rate Verify or Increase Glycol Concentration and Contact Mestek

HP1/HP2 High Pressure Alarm

LP1/LP2 Low Pressure Alarm

MALFUNCTION REASON ACTION

Short Circuit or Sensor Open Check/Replace Sensor

Sensor Failure

Short Circuit or Sensor Open Check/Replace Sensor

Failure

Short Circuit or Sensor Open Check/Replace Sensor

Sensor Failure

Check Flow Rate

System1/System2

Antifreeze Protection Setpoint

Discharge Pressure Exceeds Maximum Allowable

Suction Pressure Below Minimum Allowable

Check For Blockage in Piping

Technical Support for Instructions to Lower Alarm Setpoint

Cooling Mode:

Check for Dirty Coil

Check for Restricted Air Flow

Check for Excessive Ambient Temperature

Heating Mode:

Check for Sufﬁ cient Water Flow Rate

Cooling Mode:

Check for Sufﬁ cient Water Flow Rate

Heating Mode:

Check for Dirty Coil

Check for Restricted Air Flow

Check for Low Ambient Temperature

– 16 –

Page 17

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 9: Maintenance

Glycol/water mixture

The water system must contain a mixture of

inhibited glycol and water with thermal protection sufﬁ cient for the coldest expected temperature for the installation. The inhibitor level can degrade over time, and may need to be adjusted periodically. The inhibitor is essential to prevent the glycol from accelerating corrosion of metal components in the system. The glycol and inhibitor levels must be checked regularly (no less than once annually).

The minimum allowable concentration of glycol is

10% by volume in all installations.

Automotive glycol is not suitable for use in th Chiller

system. Over time it may leave deposits which will degrade Chiller performance and damage pumps or other devices in the system.

Use only ethylene glycol or propylene clycol

mixtures speciﬁ cally labeled for boiler or hvac use.

1. At least once annually, sample the system ﬂ uid to verify that the glycol concentrations meets the minimum value given in Figure 8, page 8. Also test the inhibitor concentration. Add glycol and inhibitor as needed to return the system to the correct concentrations.

2. Perform any and all other tests as recommended by the anti-freeze manufacturer’s instructions in order to ensure optimal performance and maintain warranty protection on all installed components.

Check operating pressure

1. Check the glycol/water system pressure. Operating pressure should be between 15 and 25 PSIG. Adjust ﬂ uid volume if needed to restore pressure.

2. If pressure is low, check system for evidence of leaks. Repair all leaks immediately.

Close the isolation valves on either side of the y-strainer at

the SpacePak heat pump/chiller return connection. Remove the screen and inspect for sediment. Clean if necessary.

Inspect all wiring and wiring connections. Tighten connections

if needed. Correct any problems found.

Check the fuses or breakers to ensure they are correctly

sized and properly installed.

Clean the SCM heat exchangers and air openings.

Cycle the system on heating and cooling. Verify that all

components operate correctly.

Preparing the SCM for shut down

DO NOT turn off power to the SCM heat pump/

chiller in the winter or any time when there is a possibility of freezing. Power must be ON for the automatic anti-freeze operation to occur. See information below for preparing the unit for shut down.

1. When the water temperature drops below 34°F during periods of non-use, the pump will start and the antifreeze heater (optional, when installed) will energize and continue to operate until the temperature reaches 38°F.

2. If SCM must be turned off or left idle during periods when freezing is possible, one of the following must be done:

a. Verify that sufﬁ cient glycol solution is present to protect

against most extreme anticipate conditions

b. — OR — Drain chiller and external piping completely

Perform annual inspection

Electrical shock hazard — Disconnect all electrical

power before proceeding with the following.

1. At least once annually, perform a complete inspection of the system, including at least the following.

Inspect the SCM for signs of dirt or debris accumulation.

Remove any debris and notify the building owner that the unit must be kept clean and unobstructed.

Inspect glycol/water system piping and components. Repair

or replace any defective components. Repair all leaks immediately.

To restart after shutdown

1. If unit was drained, reﬁ ll.

2. Follow start up procedure on page 13.

– 17 –

Page 18

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 10: Replacement parts

Figure 16 Replacement parts

PART NUMBER DESCRIPTION VENDOR PART NUMBER

SCS036 SCS060

20000-320009 Carel Temperature Sensor NTC015WP00 (IP68,-55F to 212F, 5 Ft., 10K Ohm)

20000-360006 Compressor Contactor HCC-1NU04AA

45W14RWG0061-01 Transformer, 24V BE321650GBA0015

2000-3136 Fan Motor On/Off Contactor (Carel) CONVON/OFF

2000-3137 Carel Expansion Module MCH2000020

2000-3138 Carel Controller MCH2000010

2000-3157 Soft Start PCB 2000-3157

2000-3501 Fan Motor Compacitor CBB61 (35μF/450VAC)

2000-3603 Low Pressure Switch H20PS (0.02MPa/0.15MP)

2000-3606 Water Flow Switch HF68P/1"NPT

2000-3619 Pump Control Relay JQX-105F-4 (220-240V, 30A)

2000-3711 Transformer, 24V 41X26.5F (220~230VAC,50/60Hz, 11.5VAC,0.6A)

2001-3605 High Pressure Switch H20PS (3.2MPa/4.4MPa)

2001-3608 Overload Pressure Switch H20PS (2.8MPa/3.6MPa)

2003-1402 Electronic Modulating Valve SPF-16D32 (9.5kW)

2004-1437 4-Way Valve C03C01S/SHF-9H-35U / STF-0203G (R410A)

3404-3301 Fan Motor GAL045H6-225-K01/ YDK-45X-6D

3500-2701 Propeller Fan 440×152 AS+20%GF

20000-110058 Compressor ATH290RN-C9LU

20000-110068 Compressor PA200M2CS-3MUU1

2000-3504 Compressor Capacitor CBB65 (35μF/450V)

2000-3505 Compressor Capacitor CBB65 (50μF/450V)

35018-120010 Heat Exchanger GAH04-CM×2

35018-120012 Heat Exchanger GAH03-CMF×2

35036-120011 Condenser Coil - Left 3 rows, Φ7.94mm

35036-120012 Condenser Coil - Right 3 rows, Φ7.94mm

40000-120006 Condenser Coil - Left 2 rows, Φ7.94mm

40000-120007 Condenser Coil - Right 2 rows, Φ7.94mm

20000-000025 Immersion Heater Element 240 VAC 3kW

– 18 –

Page 19

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 11: Performance data

3-Ton SpacePak chiller

Cooling (47°F water)

Ambient

Temp

Deg F BTU/hr Watts

82 38,553 2,523 4.47 15.28

95 29,694 3,873 2.25 7.67

105 22,880 4,912 1.36 4.66

Ambient

Temp

Deg F Deg F BTU/hr Watts

Capacity Chiller

Power

Heating

Water

Supply

Temp

Capacity Chiller

Chiller

COP

Power

Chiller

EER

Chiller

COP

5-Ton SpacePak chiller

Cooling (47°F water)

Ambient

Temp

Deg F BTU/hr Watts

82 61,526 5,150 3.50 11.95

95 54,621 5,881 2.72 9.29

105 45,668 6,643 2.01 6.87

Ambient

Temp

Deg F Deg F BTU/hr Watts

Capacity Chiller

Power

Heating

Water

Supply

Temp

Capacity Chiller

Chiller

COP

Power

Chiller

EER

Chiller

COP

45 115 35,536 3,855 2.70

32 110 26,295 3,472 2.22

20 105 20,245 3,103 1.91

45 115 60,256 6,919 2.55

32 110 42,770 5,927 2.11

20 105 24,769 4,125 1.76

– 19 –

Page 20

M Air to Water Heat Pump — Installation, Operation & Maintenance Manual

Section 12: LIMITED WARRANTY

Air to Water Heat Pump / Reverse Cycle Chiller

The “Manufacturer” warrants to the original owner at the original installation site that the Air to Water Heat Pump / Reverse Cycle Chiller (the “Product”) will be free from defects in material or workmanship for a period not to exceed one (1) year (parts) or two (2) years (compressor) from the startup. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective.

This limited warranty does not apply:

a) if the Product has been subjected to misuse or neglect, has been accidentally or

intentionally damaged, has not been installed, maintained or operated in accordance with the furnished written instructions, or has been altered or modiﬁ ed in any way.

b) to any expenses, including labor or material, incurred during removal or reinstallation of

the defective Product or parts thereof.

c) to any workmanship of the installer of the Product.

This limited warranty is conditional upon:

a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods

can only be returned with prior written approval from the Manufacturer. All returns must be freight prepaid.

b) determination, in the reasonable opinion of the Manufacturer, that there exists a defect

in material or workmanship.

Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.