Zehnder Rittling HP Series Installation, Operation And Maintenance Manual Download Page 5 | Manualshive

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General
information

Pre-installation:

Installation,

operation and maintenance
instructions are provided with
each pallet. Horizontal equipment
is designed for installation
above false ceiling or in a ceiling
plenum. The installation site
chosen should include adequate
service clearance around the
unit. Before unit start-up, read
all manuals and become familiar
with the unit and its operation.
Thoroughly check the system
before operation.

Prepare units for installation
as follows:

n

n

Compare the data on the unit
nameplate with ordering and
shipping information to verify
that the correct unit has been
received.

n

n

Keep the cabinet covered with
the original packaging until
installation is complete and
all plastering, painting, etc. is
finished.

n

n

Verify refrigerant tubing is
free of kinks or dents and that
it does not touch other unit
components.

n

n

Inspect all electrical
connections. Connections
must be clean and tight at the
terminals.

n

n

Remove blower shipping
support packaging, if
applicable.

n

n

Some airflow patterns are field
convertible. Locate the airflow
conversion section of this
manual for instructions.

All three phase scroll
compressors must have direction
of rotation verified at start-
up. Verification is achieved by
checking compressor amp draw.
Amp draw will be substantially
lower compared to nameplate
values if wired incorrectly.
Additionally, reverse rotation
results in an elevated sound level
compared to correct rotation.
Reverse rotation will result in
compressor internal overload
trip within several minutes.
Verify compressor type before
proceeding.

Do not

store or install units in

corrosive environments or in
locations subject to temperature
or humidity extremes (e.g.,
attics, garages, rooftops, etc.).
Corrosive conditions and high
temperature or humidity can
significantly reduce performance,
reliability, and service life. Always
move and store units in an
upright position. Tilting units on
their sides may cause equipment
damage.

Cut hazard:

Failure to follow

this caution may result in
personal injury. Sheet metal
parts may have sharp edges
or burrs. Use care and wear
appropriate protective clothing,
safety glasses and gloves when
handling parts and servicing heat
pumps.

3

General information

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Summary of Contents for HP Series

Page 1: ...i Installation Operation and Maintenance Horizontal Heat Pump Hydronic Heating Fan Coils Radiant ceiling systems Water Source Heat Pumps ...

Page 2: ... data 20 Wiring diagrams 21 Microprocessor control system 27 Dip switch settings and operation 28 Standard 24VAC sequence of operation 29 Communicating thermostat 30 Unit starting and operating conditions 33 Piping system cleaning and flushing 34 Unit and system checkout 35 Unit start up procedure 36 Preventive maintenance 38 Troubleshooting 40 Lockout modes 41 Start up log 42 Troubleshooting work...

Page 3: ... 009 A A 1 X X S 1 EL A AA Nomenclature HP series Special option codes AA Standard Placeholder Revision level A Rev 1 Supply air return air configuration EL End left horizontal only ER End right horizontal only SL Side left horizontal only SR Side right horizontal only TL Top left vertical upflow only TR Top right vertical upflow only LR Left right vertical upflow only RL Right left vertical upflo...

Page 4: ...perly trained technicians who meet local state and federal requirements To avoid equipment damage do not use these units as a source of heating or cooling during the construction process The mechanical components and filters will quickly become clogged with construction dirt and debris which may cause system damage and or void the warranty The installation of water source heat pumps and all associ...

Page 5: ...e airflow patterns are field convertible Locate the airflow conversion section of this manual for instructions All three phase scroll compressors must have direction of rotation verified at start up Verification is achieved by checking compressor amp draw Amp draw will be substantially lower compared to nameplate values if wired incorrectly Additionally reverse rotation results in an elevated soun...

Page 6: ...Electrical knockouts in 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 2 x 1 Air coil data Total face area ft 1 84 1 84 2 66 2 66 3 76 3 76 4 92 4 92 6 29 6 29 6 29 Tube size in 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 Fin spacing FPI 14 14 14 14 14 14 14 14 14 14 14 Number of rows 3 3 3 3 3 3 3 3 3 3 3 Dimensional and mass data Cabinet length in 43 3 8 43 3 8 51 1 4 51 1 4 61 61 6...

Page 7: ...ectrical knockouts mm 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 2 x 25 Air coil data Total face area m 0 17 0 17 0 25 0 25 0 35 0 35 0 46 0 46 0 58 0 58 0 58 Tube size mm 9 52 9 52 9 52 9 52 9 52 9 52 9 52 9 52 9 52 9 52 9 52 Fin spacing fins cm 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 Number of rows 3 3 3 3 3 3 3 3 3 3 3 Dimensional and mass data Cabinet length cm 1...

Page 8: ...discharge view A B 2 4 6 1 0 9 2 3 G K J L 3 0 7 6 Blower outlet End discharge view R P N S Front Air coil view Top view T U W 0 9 2 3 1 0 2 5 Top view Units 1 to 8 Front T U 3 7 9 4 1 0 2 5 1 0 2 5 Front Top view Units 9 0 A Model Overall cabinet Water and electrical connections Discharge connection integral duct flange Return connection filter rack duct flange Hanger locations A Width B Height C...

Page 9: ...and accessories which make up the installation shall be in accordance with the regulations of all authorities having jurisdiction and must conform to all applicable codes It is the responsibility of the installing contractor to determine and comply with all applicable codes and regulations Follow these guidelines when selecting unit location n n Provide a hinged access door in concealed spline or ...

Page 10: ...des of the coil A thorough water rinse should follow Installation note ducted return Many horizontal heat pumps are installed in a return air ceiling plenum application above ceiling A filter track is included on Zehnder Rittling Heat Pumps for the purposes of holding the filter and providing a flange for duct connection Canvas or flexible connectors should be used to minimize vibration between th...

Page 11: ...or service access panel and set aside side or end n n Unplug blower motor at quick disconnect n n Lift and rotate the discharge panel to the desired position The supply air duct height will change slightly to allow blower motor serviceability n n Reconnect blower motor at quick disconnect n n Check blower wiring and connections for tension or contact with sheet metal edges Re route and secure if n...

Page 12: ...based upon the amount of ESP capability of the blower In general 1 1 2 inch 38mm trap depth is the minimum Each unit must be installed with its own individual trap and connection to the condensate line main or riser Provide a means to flush or blow out the condensate line Do not install units with a common trap and or vent Always vent the condensate line when dirt or air can collect in the line or...

Page 13: ...om ductboard for the first few feet Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit s performance may be adversely affected At least one 90 elbow should be included in the supply duct to reduce air noise If the unit is connected to existing ductwork a previous check should have been made to ensure that the ductwork has the capacity to handle...

Page 14: ...never on the threads of the flare side of a fitting Prevent sealant from reaching the flared surfaces of the joint Maximum allowable torque for brass fittings is 30 ft lbs 41 N m If a torque wrench is not available tighten finger tight plus one quarter turn Tighten steel fittings as necessary Optional pressure rated hose assemblies are available for use with Zehnder Rittling units Similar hoses ca...

Page 15: ...res in this manual The flow rate is usually set between 2 25 and 3 5 gpm per ton 2 9 and 4 5 l m per kW of cooling capacity Zehnder Rittling recommends 3 3 gpm per ton 4 3 l m per kW for most applications of water loop heat pumps To ensure proper maintenance and servicing P T ports are imperative for temperature and flow verification as well as performance checks Loop conditions Water loop heat pu...

Page 16: ...reign objects and purge to remove all air Loop conditions When entering loop conditions meet values specified in Table 3 below or where piping will be routed through areas subject to freezing antifreeze is required Alcohols and glycols are commonly used as antifreeze however your local sales representative should be consulted to determine the antifreeze best suited to your area Freeze protection s...

Page 17: ...onal acid flushing Water quality standards Table 6 should be consulted for water quality requirements Scaling potential should be assessed using the pH calcium hardness method If the pH 7 5 and the calcium hardness is less than 100 ppm scaling potential is low If this method yields numbers out of range of those listed the Ryznar Stability and Langelier Saturation indicies should be calculated Use ...

Page 18: ...evices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line Slightly closing the valve will spread the pressure drop over both devices lessening the velocity noise Water coil low temperature limit setting Zehnder Rittling s heat pump controller includes a user configurable switch DIP switch 2 on the PCB controller to change...

Page 19: ...els only Moderate levels Corrosion 1 Corrosion inhibiters 2 pH control 3 Proper materials of construction 1 Corrosion inhibiters high concentrations 2 Proper materials of construction pH 7 0 8 5 5 10 Hydrogen sulfide 10 PPM 10 50 PPM CO2 50 PPM 50 75 PPM Chloride 300 PPM 300 600 PPM Total dissolved solids 100 PPM 1000 1500 PPM Slime and algae Slime and algae can form under certain environmental co...

Page 20: ... 253 9 0 71 0 3 5 3 5 12 5 15 0 14 8 23 8 25 25 D 460 60 3 414 506 5 6 38 0 3 5 3 0 8 6 15 0 10 0 15 6 15 15 042 A 208 230 60 1 187 253 16 7 79 0 3 5 3 5 20 2 30 0 24 4 41 1 40 40 B 265 60 1 239 292 13 5 72 0 3 5 3 0 16 5 20 0 19 9 33 4 35 35 C 208 230 60 3 187 253 10 4 73 0 3 5 3 5 13 9 15 0 16 5 26 9 25 25 D 460 60 3 414 506 5 8 38 0 3 5 3 0 8 8 15 0 10 3 16 1 15 15 052 A 208 230 60 1 187 253 19...

Page 21: ... all four power wires are directly connected to the contactor Power connection Line voltage connection is made by connecting the incoming line voltage wires to the L side of the contactor as shown in Figure 13 or to the optional service disconnect when provided Consult electrical data tables for correct fuse size Transformer All 208 230 volt units are factory wired for 208 volts If supply voltage ...

Page 22: ...1111 1001 848 Low 943 942 940 942 942 943 942 922 914 906 893 042 High 1380 966 1699 1695 1686 1674 1671 1659 1650 1642 1634 1615 1586 1569 1520 1489 1452 1395 1272 1206 Low 1159 1173 1172 1176 1180 1184 1185 1183 1182 1172 1159 1142 1120 1093 1057 1002 052 High 1700 1190 1842 1848 1855 1868 1878 1883 1880 1879 1883 1865 1846 1818 1809 1781 1752 1712 1670 1617 1520 1237 Low 1589 1636 1653 1663 167...

Page 23: ... BACnet or Lonworks card See Note 6 Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Screw terminal CC Compressor contactor BR1 Fan enable relay BR2 Fan speed relay HP High pressure switch LP Low pressure switch FP1 Freeze protection water side FP2 Freeze protection air side C...

Page 24: ...r Lonworks card See Note 6 MOTOR HARNESS SEE MOTOR CHART SEE MOTOR CHART SEE MOTOR CHART Wire colors Discrete speeds Power leads 1st spd 2nd spd Comm L1 L2 3 4 HP Red Blue Brown Black White 1 4 HP Purple White Blue Black Red Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Scr...

Page 25: ...acitor Blower speed Unit size Brown Black Blue Red 009 Low High 012 Low High 015 Low High 018 Low High 024 Low High 030 Low High 036 Low High 042 Low High 052 Low High 062 Low High 072 Low High Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Screw terminal CC Compressor conta...

Page 26: ...NESS TWO 24VAC DISCRETE SPEEDS Grn ECM Blower Motor See Motor Chart See Motor Chart Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Screw terminal CC Compressor contactor BR1 Fan enable relay BR2 Fan speed relay HP High pressure switch LP Low pressure switch FP1 Freeze protec...

Page 27: ...ard 277v 1ph Motor Capacitor Blower speed Unit size Brown Black Blue Red 009 Low High 012 Low High 015 Low High 018 Low High 024 Low High 030 Low High 036 Low High 042 Low High 052 Low High 062 Low High 072 Low High Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Screw termin...

Page 28: ... 24VAC DISCRETE SPEEDS Grn ECM Blower Motor See Motor Chart See Motor Chart Factory low voltage wiring Factory high voltage wiring Field low voltage wiring Field line voltage wiring Optional accessory Internal PCB connection Quick connect terminal Screw terminal CC Compressor contactor BR1 Fan enable relay BR2 Fan speed relay HP High pressure switch LP Low pressure switch FP1 Freeze protection wat...

Page 29: ...vent nuisance safety trips n n 24V output to cycle a motorized water valve or other device with compressor contactor n n Water coil low temperature sensing dip switch selectable for water or anti freeze n n Two speed fan control of cooling and heating modes n n Removable thermostat connector n n Two dry contact accessory relays that can be cycled with the compressor or the fan n n Ability to work ...

Page 30: ...at selection Dip switch 3 is used to select the type of thermostat that will be used to control the unit A digital communicating thermostat can be purchased with the unit that will allow all fault signals to be displayed on the thermostat This allows for efficient troubleshooting and does not require that the technician access the electrical control box to determine the unit error If a digital com...

Page 31: ...efore it recognizes the inputs as valid Once the input signals are determined to be valid the reversing valve will energize de energize after 5 seconds The microprocessor will then verify that the anti short cycling delay has been satisfied Once the anti short cycling delay has been satisfied the compressor will cycle on The blower will cycle on in high speed 15 seconds after the compressor is cyc...

Page 32: ...or proper communicating thermostat operation Dip Switch Position Description 1 On 2 Varies depends on system temperatures 3 Off 4 On 5 On 6 Off 7 Off 8 Off Temperature adjustment Failure code display area On off power button Communicating thermostat Fan high low On off power button Sleep mode Temperature adjustment Mode heat cool or fan Electrical shock can cause personal injury or death When inst...

Page 33: ...nd the timing will change to the hour To select the day of the week push the day button until the desired day of the week appears In this menu push the cancel button to cancel the timing of power on for that day If there is no timing of power on for that particular date will be displayed in the time display To exit the timed power on setting mode push the mode button two times Set or change the ti...

Page 34: ... corner of the thermostat display If no failure code s are present the area on the thermostat display will be blank 1 Refrigerant hi pressure failure lockout after three times 2 Refrigerant low pressure failure lockout after three times 3 Not used 4 Freeze protection water side FP1 temperature failure lockout after three times 5 Freeze protection air side FP2 temperature failure lockout after thre...

Page 35: ...ot normal or continuous operating conditions but may be used to bring the building space up to occupancy temperatures Units are not designed to operate under these conditions on a regular basis Table 10 Air limits Standard range units Extended range units Cooling Heating Cooling Heating Ambient air Minimum 50 F 10 C 50 F 10 C 50 F 4 C 50 F 4 C Maximum 100 F 38 C 85 F 29 C 100 F 38 C 85 F 29 C Ente...

Page 36: ... other equivalent approved cleaning agent Reset the boiler to raise the loop temperature to 100 F 38 C Circulate the solution for a minimum of 8 to 24 hours At the end of this period shut off the circulating pump and drain the solution Repeat system cleaning if desired n n When the cleaning process is complete remove the short circuited hoses Reconnect the hoses to the proper supply and return the...

Page 37: ... filters Ensure that filter is clean and accessible Clean air coil of all manufacturing oils System checkout n n System water temperature Check water temperature for proper range and verify heating and cooling setpoints for proper operation n n System pH Check and adjust water pH if necessary to maintain levels indicated in Table 6 Proper pH promotes longevity of hoses and fittings n n System flus...

Page 38: ... n n Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate Verify that the compressor is on and that the water flow direction is correct by measuring pressure drop through the heat exchanger Units have a 3 5 minute time delay in the control circuit that can be eliminated on the microprocessor control board See test mode described in the dip switch ...

Page 39: ...ing section If the check described fails to reveal the problem and the unit still does not operate contact a trained service technician to ensure proper diagnosis and repair of the equipment When testing is complete set system to maintain desired comfort level Be certain to fill out and forward all warranty registration papers to Zehnder Rittling When the disconnect switch is closed high voltage i...

Page 40: ... needed for closed loop systems However if the piping is known to have high dirt or debris content it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system Open cooling towers requiring heavy chemical treatment and mineral b...

Page 41: ... Periodic maintenance oiling is not recommended as it will result in dirt accumulating in the excess oil and cause eventual motor failure Conduct annual dry operation check and amperage check to ensure amp draw is no more than 10 greater than indicated on serial plate data Air coil The air coil must be cleaned to obtain maximum performance Check once a year under normal operating conditions and if...

Page 42: ... incorrectly set n n Air trapped in risers heat mode n n Ball valves closed heat mode n n Faulty zone valve heat mode n n Main water pump inoperable heat mode n n Dirty water strainer heat mode n n Refrigerant charge quantity below factory recommendation OFF X OFF OFF Er 5 Freeze protection air side 35 F n n Blower fan inoperable cooling n n Dirty air filter cool mode n n Airflow bypassing air coi...

Page 43: ...will then be de energized and the blower will de energize fifteen seconds after the compressor is de energized Condensate overflow 1 lockout CO1 The unit contains one condensate overflow sensor located in the chassis drain pan below the air coil A condensate lockout will occur if the sensor senses condensate for thirty continuous seconds The compressor will then be de energized and the blower will...

Page 44: ...oting and costly system failures Allow the unit to run for fifteen minutes in each mode before recording data Do NOT connect gauge lines Fan motor speed s Antifreeze type Temperature F or C Antifreeze Pressures psig or kPa Cooling mode Heating mode Return air temperature DB WB DB Supply air temperature DB WB DB Air temperature differential Entering fluid temperature Leaving fluid temperature Fluid...

Page 45: ...temperature supply F Water side Water inlet temperature F Pressure psig Water outlet temperature F Pressure psig Refrigeration side Compressor suction side temperature F Compressor discharge side temperature F Compressor suction side pressure psig Compressor discharge side pressure psig Expansion valve temperature entering valve F Expansion valve temperature leaving valve F Heating Cycle Air side ...

Page 46: ...ded only to the original purchaser from Zehnder Rittling Extended warranties may be available please contact the factory for warranty options and pricing 716 827 6510 Important Obligations of purchaser not included in this warranty n n Failure to start due to voltage conditions blown fuses or other damage due to inadequacy or interruption of electrical service n n Filter replacement or cleaning of...

Page 47: ...SMART IDEAS Always the best climate for ...

Page 48: ...tling 100 Rittling Boulevard Buffalo NY USA 14220 T 844 934 6337 844 ZEHNDER F 716 827 6523 sales zehnder rittling com www zehnder rittling com Zehnder Rittling April 2016 English subject to change without notice ...

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