Mars Comfort-Aire Century HKV Series User Manual Download

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Installation, Operation

and Maintenance

HKV Series

Summary of Contents for Comfort-Aire Century HKV Series

Page 1: ...www marsdelivers com Installation Operation and Maintenance HKV Series...

Page 2: ...TL Series Wiring Diagram Matrix 26 HKV084 150 3 4 5 with CXM Schematic 27 HKV084 150 3 4 5 with DXM2 Schematic 28 HKV168 300 3 4 5 with CXM Schematic 29 HKV168 300 3 4 5 with DXM2 Schematic 30 ClimaDr...

Page 3: ...model without the ClimaDry option in the heating mode Operating below these minimum entering air temperatures may result in nuisance faults H K V A 3 084 1 2 3 4 5 6 7 8 HK HEAT CONTROLLER LARGE COMM...

Page 4: ...units have been received Inspect the packaging of each unit and inspect each unit for damage Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill...

Page 5: ...ore units in an upright position Tilting units on their sides may cause equipment damage CAUTION CAUTION CAUTION CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet m...

Page 6: ...48 9 37 3 46 13 11 4 83 18 29 6 36 24 08 7 39 27 98 Condensate Connection Size FPT in mm 1 25 4 Air Coil Data Air Coil Dimensions H x W in cm 36 x 48 91 4 x 121 9 2 36 x 48 91 4 x 121 9 Air Coil Tota...

Page 7: ...on either side left or right of unit and is also available in the front on the left or right side of the unit 5 Overall Depth Add 3 12 8 cm for 1 2 5 cm or 2 5 cm Filter Frame 5 12 for 4 Filter Frame...

Page 8: ...e 4 168 240 300 2 FPT 2 1 2 FPT 2 FPT 2 1 2 FPT 1 FPT 13 8 3 49 cm 7 8 2 2 cm BSP Blower Service Panel CAP Control Access Panel CSP Compressor Access Panel MSP Motor Service Panel NRP Non Removable Pa...

Page 9: ...must be used when installing HKV units Failure to follow these guidelines could result in unsatisfactory unit performance and or premature failure of some unit components Comfort Aire Century will not...

Page 10: ...ct system with automatic or modulating dampers VAV boxes etc in the supply air system Never allow a situation where the total unit CFM can drop below the minimum required for proper unit operation The...

Page 11: ...joint compound employed Maximum allowable torque for brass fittings is 30 foot pounds 41 N m If a torque wrench is not available tighten finger tight plus one quarter turn Tighten steel fittings as ne...

Page 12: ...ected to the same condensate main since this may cause poor drainage for all units on the line WHEN A VENT IS INSTALLED IN THE DRAIN LINE IT MUST BE LOCATED AFTER THE TRAP IN THE DIRECTION OF THE COND...

Page 13: ...be included in the hose kit The piping system should be flushed to remove dirt piping chips and other foreign material prior to operation See Piping System Cleaning and Flushing Procedures The flow ra...

Page 14: ...should be used so that flow can be measured using the pressure drop of the unit heat exchanger in lieu of other flow measurement means Earth loop temperatures can range between 25 to 110 F 4 to 43 C...

Page 15: ...ining HFC 410A as system failures and property damage may result WARNING exchanger is recommended In ground water situations where scaling could be heavy or where biological growth such as iron bacter...

Page 16: ...Clogging Particulate Size and Erosion All 10 ppm of particles and a maximum velocity of 1 8 m s Filtered for maximum 841 micron 0 84 mm 20 mesh size 10 ppm 1 ppm sandfree for reinjection of particles...

Page 17: ...4 15 6 18 6 30 HKV150 3 208 3 60 197 254 A B C 1 48 1 245 0 9 2 57 3 69 3 110 3 208 3 60 197 254 D E 1 48 1 245 0 14 1 62 2 74 2 110 4 460 3 60 414 506 A B C 1 18 6 125 0 4 3 22 9 27 6 45 4 460 3 60 4...

Page 18: ...0 18 6 23 3 40 4 3 5 4 15 4 460 3 60 414 506 D E 1 18 6 125 0 18 6 23 3 40 7 0 8 8 15 5 575 3 60 518 633 A B C 1 14 7 100 0 14 7 18 4 30 3 4 4 3 15 5 575 3 60 518 633 D E 1 14 7 100 0 14 7 18 4 30 5...

Page 19: ...3 1 0 98 23 9 28 5 45 4 460 3 60 414 506 D E 1 18 6 125 0 7 0 1 0 98 26 6 31 2 45 5 575 3 60 518 633 A B C 1 14 7 100 0 3 4 1 0 78 18 9 22 6 35 5 575 3 60 518 633 D E 1 14 7 100 0 5 2 1 0 78 20 7 24 4...

Page 20: ...7 0 8 8 15 5 575 3 60 518 633 A B C 1 14 7 100 0 1 0 78 15 5 19 2 30 3 4 4 3 15 5 575 3 60 518 633 D E 1 14 7 100 0 1 0 78 15 5 19 2 30 5 2 6 5 15 HKV168 3 208 3 60 197 254 A B C 2 23 2 164 0 2 1 10 4...

Page 21: ...s must be made with a length of flexible conduit to minimize vibration and sound transmission to the building Thermostat Installation The thermostat should be located on an interior wall in a larger r...

Page 22: ...and ACC2 Each relay includes a normally open NO and a normally closed NC contact Accessory relays may be configured to operate as shown in the tables below Accessory Relay 2 Configuration Accessory Re...

Page 23: ...e 20 Taco SBV Valve Wiring From Water Source IN OUT NOTE Shut off valves strainers and other required components not shown Solenoid Valve Flow Regulator To Discharge Stage 1 Stage 2 Figure 21 Two Stag...

Page 24: ...Operation Maintenance HKV Series Figure 13a Typical Manual Changeover 2 heat 2 cool thermostat wiring with HKV unit CXM CXM 1 CXM 2 Typical T Stat 2 Heat 2 Cool Y W O G R C AL 1 Y W O G R C AL 1 Y O...

Page 25: ...tes with dehumidification airflows in the cooling mode when the dehumidification output from thermostat is active Normal heating and cooling airflows are not affected 2 DXM2 board DIP switch S2 7 must...

Page 26: ...al Control Agency HKV084 150 96B0113N01 208 230 60 3 460 60 3 575 60 3 CXM ETL 96B0113N02 DXM2 HKV084 150 with ClimaDry 96B0113N03 DXM2 HKV168 300 96B0113N07 CXM 96B0113N08 DXM2 HKV186 300 with ClimaD...

Page 27: ...l be Class 2 or Equivalent 3 Transformer wiring is voltage sensitive Use layout corresponding to the unit voltage 4 L Tl provides low temperature protection for WATER When using ANTI FREEZE solutions...

Page 28: ...he timer to one mark before 1 9 on the Motorized Valve 3 Transformer wiring is voltage sensitive Use layout corresponding to the unit voltage 4 L T l provides low temperature protection for WATER When...

Page 29: ...l be Class 2 or Equivalent 3 Transformer wiring is voltage sensitive Use layout corresponding to the unit voltage 4 L Tl provides low temperature protection for WATER When using ANTI FREEZE solutions...

Page 30: ...he timer to one mark before 1 9 on the Motorized Valve 3 Transformer wiring is voltage sensitive Use layout corresponding to the unit voltage 4 L T l provides low temperature protection for WATER When...

Page 31: ...pump Y O thermostats or non heat pump Y W thermostats The reheat mode requires eitherv a separate humidistat dehumidistat or a thermostat that has an integrated dehumidification function for activatio...

Page 32: ...ion used to divert the condenser water from the coax to the hydronic reheat coil during the reheat mode of operation The proportional controller signals the motorized valve based on the supply air tem...

Page 33: ...chematic COAX Note All components shown are internal to the heat pump unit TO WATER LOOP FROM WATER LOOP MODULATING MIXING VALVE ENTERING AIR INTERNAL PUMP EVAPORATOR COIL LEAVING AIR REHEAT COIL REFR...

Page 34: ...hes should only be changed when power is removed from the CXM control DIP switch 1 Unit Performance Sentinel Disable provides field selection to disable the UPS feature On Enabled Off Disabled DIP swi...

Page 35: ...he compressor relay can be selected to turn on with a stage 1 or stage 2 call from the thermostat This is used with dual stage units 2 compressors where 2 DXM2 controls are being used or with master s...

Page 36: ...able 7a Accessory DIP Switch Settings DIP Package 3 S3 DIP Package 3 has 4 switches and provides the following setup and operating selections 3 1 Communications configuration DIP 3 1 provides selectio...

Page 37: ...Active Fault LED Red Status LED Green Alarm Relay No Fault Since Power Up In Memory Flashing Code 1 Cycling Code 1 High Pressure Fault In Memory Flashing Code 2 Cycling Code 2 Low Pressure Fault In M...

Page 38: ...P8 IN NC P12 1 Note There is only one T1 connection 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Service tool connection Communicating stat connection Conventional stat connection Cabinet temperature sens...

Page 39: ...ay at power up The first time after power up that there is a call for compressor the compressor will follow a 5 to 80 second random start delay After the random start delay and anti short cycle delay...

Page 40: ...1 69 2 35 6 29 50 72 161 6 1 64 3 37 4 28 05 73 163 4 1 58 4 39 2 26 69 74 165 2 1 53 5 41 0 25 39 75 167 0 1 48 6 42 8 24 17 76 168 8 1 43 7 44 6 23 02 77 170 6 1 39 8 46 4 21 92 78 172 4 1 34 9 48...

Page 41: ...he high pressure fault recognition is immediate does not delay for 30 continuous seconds before de energizing the compressor High pressure lockout code 2 Example 2 quick flashes 10 sec pause 2 quick f...

Page 42: ...an the LT1 sensor Swapped LT1 LT2 thermistor code 9 ESD DXM2 only The ESD Emergency Shut Down mode can be enabled from an external common signal to terminal ESD to shut down the unit The green status...

Page 43: ...ht misalignment will cause premature belt failure Adjust sheave if needed Belt Tensioning Procedure HKV Blower motors for HKV models are slide base mounted To adjust the belt tension 1 Loosen the four...

Page 44: ...the forct applied from the bottom of the small O ring on the deflection force scale 6 Compare the force you have applied with the values given in the table below The force should be between the minim...

Page 45: ...8 3HP BX83 BK95 X 1 1VP50 X 1 1 8 5HP BX77 BK95 X 1 1VP65 X 1 1 8 5HP H F BX79 N BX81 168 Back or Front Top Back Front Front Back Blower Sheave Motor Sheave Motor Belt BK95H X 1 3 16 1VP44 X 7 8 2HP B...

Page 46: ...Open 4 5 3 2 5 5 5 4 3 2 1 5 5 5 1 4 5 4 3 2 5 2900 BHP 0 44 0 49 0 54 0 59 0 64 0 74 0 79 0 84 0 89 0 94 1 04 1 09 1 14 1 19 1 24 Sheave Mtr B B B A A A A A A C E E E E E RPM 440 481 517 551 586 618...

Page 47: ...5 5 4 5 3 5 2 5 1 5 1 5 6 5 4 3 5 2 5 2 3100 BHP 0 44 0 53 0 59 0 64 0 69 0 74 0 84 0 89 0 94 0 99 1 04 1 14 1 19 1 24 1 34 1 39 Sheave Mtr B B B A A A A A A A C C C C C C RPM 421 459 499 533 569 600...

Page 48: ...4 1 24 1 34 1 39 1 44 1 54 1 64 1 69 1 74 1 84 1 94 Sheave Mtr A A A A A A A A C E E E E E E RPM 525 556 586 617 645 674 701 726 753 778 804 827 850 875 897 Turns Open 6 5 5 4 5 4 3 2 5 1 5 1 5 5 5 4...

Page 49: ...04 1 09 1 14 1 24 1 34 1 39 1 44 1 54 1 59 1 64 1 74 1 84 Sheave Mtr B B B A A A A A A A A C C C C C RPM 511 544 578 608 637 668 695 722 748 776 800 825 849 874 897 920 Turns Open 4 5 3 5 2 5 6 5 5 4...

Page 50: ...E E E E E E RPM 698 725 749 772 795 819 836 862 883 906 926 946 968 Turns Open 3 5 3 2 5 2 1 5 1 6 5 5 5 4 5 4 3 5 3 4900 BHP 1 94 2 04 2 14 2 24 2 34 2 44 2 49 2 54 2 64 2 74 2 84 2 94 Sheave Mtr A...

Page 51: ...B A A A A A A A A C C RPM 633 666 697 726 755 782 806 832 857 881 904 927 950 973 Turns Open 6 5 4 3 5 5 5 4 3 5 3 2 5 1 5 1 6 5 5 4500 BHP 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 2 1 2 2 2 3 2 4 2 5 2 6 Sheave...

Page 52: ...3 74 3 84 3 94 4 09 4 19 Sheave Mtr A A A A A D D D E E E E E E E E RPM 750 775 799 824 849 874 898 921 944 964 986 1007 1027 1046 1068 1086 Turns Open 5 5 5 4 3 5 3 2 5 2 1 5 6 5 5 5 4 5 4 3 5 3 2 5...

Page 53: ...5 2 5 5800 BHP 0 88 0 98 1 08 1 18 1 28 1 48 1 58 1 68 1 78 1 88 2 08 2 18 2 28 2 38 2 48 Sheave Mtr B B B B B A A A A A D D E E E RPM 440 481 517 551 586 618 651 681 710 740 767 795 821 845 872 Turns...

Page 54: ...8 1 38 1 48 1 66 1 78 1 88 1 98 2 08 2 28 2 46 2 58 2 68 2 88 2 98 3 08 Sheave Mtr B B B B B A A A A A A A C C C E RPM 456 495 529 561 595 625 656 685 712 741 767 795 820 844 870 893 Turns Open 6 5 4...

Page 55: ...5 2 5 5 5 5 4 3 5 3 2 1 5 1 5 4 5 7000 BHP 1 48 1 68 1 78 1 88 2 08 2 18 2 28 2 48 2 58 2 68 2 88 3 08 3 18 3 28 3 48 Sheave Mtr B B B B A A A A A A A A C C C RPM 530 565 596 625 654 684 711 738 766 7...

Page 56: ...28 5 48 5 68 Sheave Mtr A A A A A A A A A C C C E E E E RPM 653 679 707 731 755 779 804 826 848 870 893 914 935 955 978 997 Turns Open 6 5 4 5 4 3 5 3 2 5 2 1 5 5 5 5 4 5 4 3 5 2 5 2 9200 BHP 3 18 3 2...

Page 57: ...3 2 5 1 5 1 3 2 5 9400 BHP 2 68 2 88 3 08 3 28 3 48 3 68 3 88 4 08 4 28 4 48 4 68 4 88 5 08 5 28 5 48 Sheave Mtr B B B B B A A A A A A A E E E RPM 637 666 697 727 755 783 809 835 858 882 905 928 951...

Page 58: ...D D D D D D E E E E RPM 738 763 788 813 839 864 888 911 934 955 977 998 1019 Turns Open 2 5 6 5 5 4 5 4 3 2 5 2 1 3 5 2 5 2 1 5 11800 BHP 4 88 5 08 5 28 5 48 5 78 6 08 6 28 6 48 6 68 6 98 7 28 7 48 S...

Page 59: ...0 30 450 0 29 0 33 475 0 35 500 0 38 525 0 41 550 0 45 575 0 48 All data is for wet coil Example Reheat coil loss can be determined from the above table Coil velocity FPM Airflow CFM Face Area sq ft...

Page 60: ...for units with hot gas bypass option Table 6 Building Commissioning Table 6A Unit Operating Limits Environment This unit is designed for indoor installation only Do not install in an area subject to...

Page 61: ...was bled from the system Check and adjust the water air level in the expansion tank 6 Set the boiler to raise the loop temperature to ap proximately 85 F 29 C Open the a drain at the lowest point in...

Page 62: ...ystem water Condenser coils never fully drain by themselves and will freeze unless winterized with antifreeze exchangers Unit Air Coil Filters Ensure filter is clean and accessible To obtain maximum p...

Page 63: ...ers 3 Adjust all valves to their full open position Turn on the line power to all heat pump units 4 Operate unit in cooling cycle Room temperature should be approximately 45 100 F 7 38 C DB For Start...

Page 64: ...ur without satisfying the thermostat Y input call then the control will go to Lockout mode The last fault causing the lockout will be stored in memory and can be viewed by going into test mode Consult...

Page 65: ...data entries before the system is put into full operation Externat Static Sheave Setting Turns OPEN Temperatures F or C Antifreeze Pressures PSIG or kPa Type Cooling Mode Heating Mode Return Air Temp...

Page 66: ...26 88 98 329 360 8 14 5 17 10 13 26 28 2 3 128 130 213 234 11 17 10 18 15 17 21 26 93 103 334 365 8 14 5 17 7 11 27 30 3 0 124 131 199 219 12 24 8 16 9 11 21 26 97 108 339 371 8 14 5 17 5 8 27 31 70...

Page 67: ...lectrostatic filters when dirty can exhibit a very high pressure drop for the fan motor and reduce air flow resulting in poor performance It is especially important to provide consistent washing of th...

Page 68: ...venting Check vent location X Moisture on sensor Check for moisture shorting to air coil X X Plugged air filter Replace air filter x X Restricted Return Air Flow Find and eliminate restriction Increa...

Page 69: ...xternal static Check static vs blower table X Reduced or no water flow in cooling Check pump operation or valve operation setting Check water flow Adjust to proper flow rate X Inlet water too hot Chec...

Page 70: ...ce Water In Pres 9 10 11 Source Water Out Pres 9a Press Drop 9b Flow Rate Return Air Temp Supply Air Temp Heat of Extraction Absorption or Heat of Rejection HE or HR Flow Rate x Temp Diff x Fluid Fact...

Page 71: ...s Follow All Warnings and Cautions in This Manual Before Attempting Conversion Top Discharge to Straight Discharge Convertible Blower Access Panel C Box Motor Access Panel Compressor Access Panel Step...

Page 72: ...eration Maintenance HKV Series Step 2 Remove Blockoff Air Handler as shown Loosen belt and remove Step 3 Remove bolts 4x off blower panel Remove bolts 4x 2x ea side from blower sides Blockoff Air Hand...

Page 73: ...4 Remove bolts 4x and take blower glides out Blower Glides 2x Step 5 Attach Blower Glides to Blower BTM Load Brackets as shown Use bottom set of holes 203 Dia on Blower BTM Load Brackets Blower Shaft...

Page 74: ...and in front and pull Blower ASM on to the ridge of the Blower Glides Step 7 Rotate Blower ASM using Blower Glides as a guiding track Step 8 When the Blower ASM is parallel to the floor push the Blowe...

Page 75: ...75 Installation Operation Maintenance HKV Series Step 9 Attach Blower ASM with bolts 4x as shown Step 10 Remove Bower Glides 2x and re attach back in compressor section Step 10...

Page 76: ...76 Installation Operation Maintenance HKV Series Important Step 11 Re bolt Blower ASM to Blower BTM load brackets Re attach belt and tighten 4 1 4...

Page 77: ...V Series Step 12 Re attach blockoff air handler as shown Step 13 Put 3x panels back on Reverse steps to change a straight discharge to a top discharge Blockoff air handler Blower filler panel C box mo...

Page 78: ...els as shown Front C Box Motor Access Panel Compressor Access Panel Back Compressor C Box Motor Access Panel Return Air Control Box Front Control Box Motor Access to Back Access Convertible Step 2 Rem...

Page 79: ...4x and A flip down B slide across and C flip up as shown using the guide rails inside as a guide Re attach control box with screws Right Side View Step 4 Loosen Belt tension and take Belt off Step 5 R...

Page 80: ...nt ASM to opposite side and re attach Step 7 Put Belt back on and tighten Put Control Box Cover and Motor Cover on return side Control Box Cover Motor Cover Step 8 Place panels back on unit Reverse st...

Page 81: ...et side that is not being connected 2 Electrical access is available on either side left or right of unit and is also available left or right in the front of the unit 3 25mm Filter frame can be field...

Page 82: ...TLV Units come with flex hose and 1 FPT condensate connection tied inside shown above Installer will untie flex hose and make an internal trap on either the left side shown above or on the right side...

Page 83: ...4 We will not be liable for damages or delays caused by events beyond our control including accident alteration abuse war government restrictions strikes fire flood or other acts of God 5 Owner respo...

Page 84: ...nformation Added 09 14 09 CXM DXM2 Controls and CXM DXM2 Safety Control Features Sec tions Added 07 29 09 Unit Commissioning Operating Conditions Data in tables corrected 06 09 09 Unit Starting Operat...

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