PATH freewatt HDJ Installation, Operation & Maintenance Manual Download Page 1

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Hydronic

freewatt Plus

System,

Model

HDJ

INSTALLATION,

OPERATION &

MAINTENANCE

MANUAL

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.

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

Check our website frequently for updates:

www.

freewatt

.com

www.ecrinternational.com

Summary of Contents for freewatt HDJ

Page 1: ...were in effect at time of printing of this manual ECR International reserves the right to discontinue change specifications or system design at any time without notice and without incurring any oblig...

Page 2: ...ead all freewatt PLUS System manuals for safety information and warnings DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a hazardou...

Page 3: ...components Under firing 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 Ope...

Page 4: ...tection Priority domestic hot water heating is available and must be properly selected in setup of Control Module and ECR zone controls Indirect water heater aquastat setting must be between 120 to 12...

Page 5: ...ration of MCHP unit and generation of electric power This is Bypass Mode of operation Full heating operation of hydronic freewatt PLUS System is not dependent on maintaining working connection to Inte...

Page 6: ...nts must be adhered to for installation May require additional controls or system components 2 4 Read All Documents Hydronic freewatt PLUS Model HDJ User s Information Manual freewatt FW95M 200 Boiler...

Page 7: ...95 AFUE Honda MCHP HI Module Boiler Outdoor Temperature Sensor freewatt Outdoor Temperature Sensor Honda MCHP Exhaust Gas Sensor Programmable Communicating HAI Thermosat freewatt System Control Module...

Page 8: ...ctual space heating demands Under radiated distribution systems that require high system water temperatures above 180 F during design coldest day outdoor temperature conditions will significantly comp...

Page 9: ...MCHP Hydronic Hybrid Integration Module Figure 2 4b Hydronic Hybrid Integration Module 2 INTRODUCTION Figure 2 4a Hydronic Hybrid Integration Module Figure 2 5 Typical freewatt PLUS Control Module Co...

Page 10: ...2 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 NOTE 1 Combustible floor approved but not c...

Page 11: ...11 Figure 2 8 MCHP Electrical Connection Details 2 INTRODUCTION Figure 2 9 MCHP Front Interface Details...

Page 12: ...ECR AR822 II relay control 3 4 HONDA MCHP Unit Honda MCHP Unit is custom engineered micro combined heat and power module integrated into Hydronic freewatt PLUS System MCHP unit designed to start and...

Page 13: ...ost 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 coolan...

Page 14: ...UPS It is recommended that UPS be plugged into front convenience outlet and therefore is powered by Circuit 1 4 2 Uninterruptible Power Supply UPS If using UPS to power uninterruptable loads plug UPS...

Page 15: ...p pump from losing power when in Backup Mode If sump pump and boiler may operate at same time power out ages during heating season and heavy rain events possible solutions include Battery backed sump...

Page 16: ...of the UTS6H 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 Syst...

Page 17: ...red across thermostat R and W terminals Impedance greater that 40 ohms is unacceptable and will not work reliably with freewatt PLUS System Thermostat not calling for heat W relay open Thermostat rela...

Page 18: ...electrical power output and proper operating conditions 6 freewatt TRANSFER SWITCH MODEL FTS 1 8 Figure 6 1 freewatt Transfer Switch freewatt Transfer Switch provides freewatt PLUS product line with...

Page 19: ...ne with largest heating demand but not domestic hot water zone Normally this would be largest space heating zone on first floor of two story home freewatt PLUS System will produce best electric power...

Page 20: ...base and MCHP not between base and floor Install equipment in location facilitating operation of venting and combustion air intake piping systems described in this manual Section 10 Advise owner to ke...

Page 21: ...y Shims should be used between boiler floor 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...

Page 22: ...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...

Page 23: ...return piping upstream from freewatt PLUS boiler Configuration ensures coldest return water be delivered to MCHP unit s hydronic hybrid integration HI module 8 PLACING THE SYSTEM Figure 8 2 shows fre...

Page 24: ...ecting 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 Onix tubing while a...

Page 25: ...ure with collet clip supplied with female swivel 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 bar...

Page 26: ...E 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 t...

Page 27: ...a proper installation 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 Onix tubing is...

Page 28: ...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 Thermostats for up to six zones mu...

Page 29: ...with Hydronic freewatt PLUS System and is intended for installation in close proximity of HONDA MCHP unit Figure 9 1 shows connections to Exhaust Gas Leak Sensor Exhaust Gas Sensor will automatically...

Page 30: ...error condition NOTICE LED indicator on Exhaust Gas Sensor must be solid green Sensor is initializing if it is flashing red and green Wait 3 minutes until LED is solid green before proceeding Confirm...

Page 31: ...BS DWV pipe and pipe cement SDR pipe is not approved in CANADA 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...

Page 32: ...Requirements Non direct vent exhaust for MCHP shall be installed in United States accordance with following requirements non direct vent exhaust piping lengths for MCHP are found in Honda MCHP Instal...

Page 33: ...pressures less than or equal to psig 3 5 kPa Recommend line pressure be within minimum and maximum values in Table 11 1 for proper operation of system Table 11 1 Gas Supply Pressures Gas tyoe Minimum...

Page 34: ...Mount module s enclosure on solid wall or partition after determining location of freewatt module Recommend enclosure be located close to freewatt PLUS Boiler Honda MCHP and HI Module within reach of...

Page 35: ...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 System Connect Coo...

Page 36: ...s of Zone 1 Zone 1 is central heating zone no indirect water heater is configured if Zone Valve Pump switch is Off only Zone 1 zone valve terminals are energized Place Zone Valve Pump Switch in OFF po...

Page 37: ...service personnel Figure 12 9 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 P...

Page 38: ...eewatt PLUS System transformer Route air conditioning system 24 VAC source freewatt PLUS Thermostat using spare grey wire in freewatt PLUS thermostat cable Use Y wire of thermostat cable to connect di...

Page 39: ...ime of installation from ECR Customer Service by freewatt dealer performing installation Original battery provided for each freewatt PLUS System will be shipped to installing dealer at no charge Follo...

Page 40: ...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 b...

Page 41: ...red by valve while system is operating Check for leaks and fix if necessary Pump Inspect pump and connections Check for leaks and fix if necessary Coolant Tubing and Connections Inspect coolant tubing...

Page 42: ...ean reuse when refilling system It is recommended to evacuate lines with aid of LOW pressure under 5 psi compressed air Alternatively hand pump can be used 14 MAINTENANCE AND CLEANING Shutdown Procedu...

Page 43: ...43 15 DETAILED SEQUENCE OF OPERATION...

Page 44: ...44 15 DETAILED SEQUENCE OF OPERATION...

Page 45: ...zone or any new heat demand zone is satisfied and freewatt control module determines it is not possible to either Operate Smart Zone without exceeding small temperature rise above Smart Zone setpoint...

Page 46: ...ration significantly 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 Sett...

Page 47: ...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 repl...

Page 48: ...ta and Codes Multiple means of accessing hydronic freewatt PLUS System operational data and error codes for purposes of troubleshooting Observe and count number of flashes of red Service Required LED...

Page 49: ...rol Module Connection Fuse in thermostat 24VAC Fuse in freewatt control module or Faulty wire connection No Honda MCHP operation See MCHP Manual Hydronic freewatt PLUS System consists of eight major c...

Page 50: ...ROR OCCURRED REPLACE CONTROLLER MODULE 14 EXHAUST GAS LEAK SENSOR FAILURE HONDA MCHP ERROR 39 0 EX_SENS_FAIL 15 EXHAUST GAS LEAK SENSOR POWER FAILURE HONDA MCHP ERROR 39 1 EX_SENS_POWER_ FAIL 16 EXHAU...

Page 51: ...ed per Hydronic Commissioning Procedure 16 TROUBLESHOOTING 16 6 Control Board LED Interpretation Observe green LEDs on control board by removing cover of freewatt Control Module Control Board LEDs are...

Page 52: ...S System Fuses 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 c...

Page 53: ...s CIRCULATOR With Isolation Flanges PRESSURE REDUCER VALVE FLOW CHECK VALVE BALL VALVE BACKFLOW PREVENTER AIR SEPARATOR ZONE VALVE HEAT EXCHANGER BOILER DRAIN VALVE 3 WAY MIXING VALVE EXPANSION TANK 1...

Page 54: ...54 17 2 Primary Secondary Piping With Zone Valves and Domestic Hot Water Priority Circulator 17 PIPING AND WIRING SCHEMATICS...

Page 55: ...55 17 3 Primary Secondary Piping With Circulators and Domestic Hot Water Priority Circulator 17 PIPING AND WIRING SCHEMATICS...

Page 56: ...56 17 4 Primary Secondary Piping With Hydro Air Handler and Domestic Hot Water Priority Circulator 17 PIPING AND WIRING SCHEMATICS...

Page 57: ...57 17 5 HDJ 240 VAC Wiring Only 17 PIPING AND WIRING SCHEMATICS...

Page 58: ...58 17 6 HDJ 120 VAC Wiring Only 17 PIPING AND WIRING SCHEMATICS...

Page 59: ...59 17 7 HDJ 120 VAC Wiring Control Module Zone Pumps 17 PIPING AND WIRING SCHEMATICS...

Page 60: ...60 17 8 HDJ 120 VAC Wiring Control Module Zone Valves 17 PIPING AND WIRING SCHEMATICS...

Page 61: ...61 17 9 HDJ 120 VAC Wiring Control Module Hydro Air 17 PIPING AND WIRING SCHEMATICS...

Page 62: ...62 17 10 HDJ Low Voltage Wiring Only 17 PIPING AND WIRING SCHEMATICS...

Page 63: ...63 17 11 HDJ Low Voltage Only Wiring Control Module and Zone Pumps 17 PIPING AND WIRING SCHEMATICS...

Page 64: ...64 17 12 HDJ Low Voltage Only Wiring Control Module Zone Valves 17 PIPING AND WIRING SCHEMATICS...

Page 65: ...65 17 13 HDJ Low Voltage Only Wiring Control Module Zone Valves with Expansion Zones 17 PIPING AND WIRING SCHEMATICS...

Page 66: ...66 17 PIPING AND WIRING SCHEMATICS 17 13 HDJ Low Voltage Only Wiring Control Module Hydro Air...

Page 67: ...67 17 PIPING AND WIRING SCHEMATICS 17 14 MCHP Low Voltage Wiring...

Page 68: ...An ISO 9001 2008 Certified Company Check our website frequently for updates www freewatt com www ecrinternational com...

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