FHP HR000 Installation Manual

601 N.W. 65TH COURT • FT. LAUDERDALE, FL 33309 • PHONE: (954) 776-5471 • FAX: (800) 776-5529 http://www.fhp-mfg.com heat pumps 970-196 Rev. 10/04 ISO 9001:2000 Certified Are uncontrollable humidity problems costing you a bundle? Why put up with humidity problems when you can have true climate control with the installation of an FHP water source heat pump with the Hot Gas Reheat Option (Humidimiser option). When your FHP unit contains this Underwriters Laboratory (UL) approved optional feature...your normal air conditioning cycle converts, as required, to an air drying operation. Your FHP unit with the Humidimiser option will provide cooling, heating, and dehumidifcation by setting our combination thermostat/humidistat control.** This option is available on the full range of FHP products. This option is ideal for any application where a high level of dehumidifcation is required. Typical applications are: Indoor Pool Areas* Outside/Make-Up Air Applications** Computer Rooms Hotel rooms during non-occupancy * Note: Special coil and/or cabinet coating may be necessary ** Note: Cooling always takes priority over dehumidifcation. HOT GAS REHEAT OPTION

Model Nomenclature ....................................................................................................1 Inspection..........................................................................................................................2 Application........................................................................................................................2 Field Mounting HR .........................................................................................................2 Water Tank Preparation ................................................................................................3 HR Water Piping...............................................................................................................3 Typical Installation..........................................................................................................3 Water Tank Refill..............................................................................................................4 Installation Start-Up.......................................................................................................4 Trouble Shooting............................................................................................................4 Electrical Diagram...........................................................................................................4 Capacity Data...................................................................................................................4 MODEL NOMENCLATURE HR OO1 -1 HEAT RECOVERY PACKAGE HEAT EXCHANGER DESIGNATOR 208/230-1-60 HEAT RECOVERY PACKAGE

before beginning installation. Follow the instructions precisely to insure proper operation of the system. The instructions are to be left with the homeowner for future reference if needed. All local, state and national codes supercede these instructions and must be strictly adhered to. UNCRATING AND INSPECTION: Check for shipping damage, both visible and concealed if there exists any indication of damage immediately file a claim with the shipping company. You are the only one to file a claim regardless of why the damage was incurred or by whom. Remove the access cover and check all of the components parts to make sure they are properly secured before installing the unit. Parts broken loose from their secured position with resultant damage is considered damage during shipment. APPLICATION: The Heat Recovery unit is a forced pumped unit that employs a circulating pump to move water through a double wall/vented heat exchanger and returns the heated water to the water tank. The water is heated by superheated refrigerant discharge gas from the compressor. This waste heat of the cooling mode captured by the heat recovery increases the capacity and efficiency of the heat pump unit. If the air temperature is uncomfortable coming from the air vents in the heating mode the heat recovery may need to be turned off. In the heating mode the heat recovery captures heat that would normally be used for space heating. NOTE: The performance of the heat recovery package is based on a variety of variables and may vary from unit to unit and from application to application based on the operating conditions of the complete system. When the HRP is applied to highly efficient heat pumps, especially the newly released high efficiency 2-step scroll R410A units, the capacity of the HRP will be reduced due to lower condensing temperatures and resulting lower discharge gas temperatures and available super heat levels for hot water heating. Reduced HRP capacity will also be evident when the heat pump is applied to low water temperature systems such as low temperature open wells and when ground loops are changing over in the spring months from the heating to the cooling mode. HRP capacity is also a function of heat pump run times. In the milder months the heat pump run time will be reduced based on reduced loads thus the ability to heat hot water is also reduced. This same result could be noticeable on units that are over sized for the served loads thus resulting in short cycling of the heat pump and HRP package. The HRP is equipped with a LGL (low discharge gas limit) that disables the HRP pump from operating until discharge gas temperatures are above the required levels to insure proper operation. This eliminates the possibility of actually absorbing heat from the water in the hot water tank. This safety feature could also reduce HRP run time and further diminish HRP performance. FIELD MOUNTING EM/EC SERIES HR KIT: It is recommended that the heat recovery package be factory mounted at the time the heat pump is purchased. This eliminates field intrusion into the refrigeration circuit of the heat pump and the associated problems that may arise. If the heat recovery package is to be field installed the following steps must occur: 1. Disconnect all power supplies to the unit before servicing. More than one power supply may be present. 2. Remove the lower left side heat pump access panel. This is where the heat recovery kit will be attached. (Figure #1) 3. Mark and drill holes in panel where heat recovery package hot gas in and out lines will enter and exit. Allow enough space for lines not to touch panels. 4. Mount heat recovery package to panel using sheet metal screws. CAUTION: Do not mount heat recovery unit to panel while on unit. Refrigerant containing components are present and may be damaged. 5. Remove refrigerant from heat pump utilizing standard refrigerant recovery techniques. WARNING: Recovery of this substance is mandatory and State/ Federally regulated. Failure to recover this refrigerant properly can/will result in serious penalties including substantial fines and/or prison sentences. 2 (Figure #1) (Figure #2) HEAT RECOVERY

GT/GS SERIES WITH INTERNAL HRP (Figure #3) 6. Cut the hot gas discharge line between the compressor discharge port and the reversing valve inlet. Connect the discharge line from the compressor to the line marked “Refrigerant in” on the heat recovery coil. Connect the line marked “Refrigerant out” of the heat recovery coil to the reversing valve inlet line. (Figure #2) 7. Make the wiring connections from the heat recovery package to the compressor contactor as shown. (Figure #4) 8. It is imperative that the refrigerant system remain clean and dry during the above operations. If there is doubt of this a bi-flow liquid line dryer must be installed. 9. Evacuate the unit and recharge according to unit nameplate. WARNING: If heat recovery unit is installed in an area where freezing may occur the unit must be drained during winter months to prevent heat exchanger damage. Heat exchanger ruptures that occur due to freezing will void the heat recovery package warranty along with the heat pump warranty. WATER TANK PREPARATION: 1. Turn off electrical or fuel supply to the water heater. 2. Attach garden hose to water tank drain connection and run other end of hose out doors or to an open drain. 3. Close cold water inlet valve to water heater tank. 4. Drain tank by opening drain valve on the bottom of the tank, then open pressure relief valve or hot water faucet. 5. Once drained the tank should be flushed with cold water until the water leaving the drain hose is clear and free of sediment. 6. Close all valves and remove the drain hose. 7. Install HR water piping. NOTE: Use of Heat Recovery Packages with Smart Hot Water Tanks is not recommended. Application of a Heat Recovery Package with a“Smart”electric hot water tank may cause nuisance fault errors in the tank’s on-board diagnostics. In operation, a Heat Recovery Package can raise the water temperature in the hot water tank, even if the tank’s on-board system is not calling for heat from the tank’s internal heater elements. This rise in tank water temperature while the tank is idle may be interpreted as a heater element that is stuck “on” by a smart tank’s diagnostic system. If this occurs, the Heat Recovery Package may need to be turned off at the heat pump. HR WATER PIPING: All hot water piping should be a minimum of 3/8" O.D. copper tube to a maximum distance of fifteen (15) feet. For distances beyond fifteen feet but not exceeding sixty (60) feet use 1/2" copper tube. Separately insulate all exposed surface of both connecting water lines with 3/8" wall closed cell insulation. Install isolation valves on supply and return to the heat recovery. (Figure #3) HEAT RECOVERY

POSSIBLE CAUSE No Power On/Off Switch Position Compressor Contactor Broken or loose wires Air Lock Stuck pump shaft/impeller Defective pump Kinked or under sized water piping Water temp limit closed Scaled or fouled heat exchanger CHECKS AND CORRECTIONS Check power supply Set switch to“ON”position Engage heat pump contactor Repair or tighten wires Purge air from piping system Remove pump cartridge and clean Replace pump Repair kink and check for proper line size Stuck limit switch Sensor not attached securely to line Clean heat exchanger CAPACITY DATA * Capacity based on entering domestic water temperature of 80° F, entering superheated discharge gas temperature 180° F, and leaving saturated vapor temperature 105° F. R-22 refrigerant shown. Use: .950 multiplier for R410A. (See page 2 - Application) 970-299 Rev. 3/08 4 LINE VOLTAGE CONTROL DIAGRAM WATER TANK REFILL: 1. Open the cold water supply to the tank. 2. Open a hot water faucet to vent air from the system until water flows from the faucet, then close. 3. Depress the hot water tank pressure relief valve handle to ensure there is no air remaining in the tank. 4. Carefully inspect all plumbing for water leaks . Correct as required. 5. Purge all air from HR by depressing the schrader valve on the HR Unit. Allow all air to bleed out until water appears at the valve. 6. Before restoring the power or fuel supply to the water heater, adjust the temperature setting on the tank thermostat(s) to ensure maximum utilization of the heat available from the refrigeration system and conserve the most energy. On tanks with both upper and lower elements and thermostats, the lower element should be turned down to 100° F, while the upper element should be adjusted to 140° F. Depending upon the specific needs of the customer, you may need to adjust the upper element differently. On tanks with a single thermostat lower the thermostat setting to 140° F or the “LOW” position. 7. After thermostat adjustments are completed, replace access cover and restore electrical or fuel supply to water heater. INITIAL START-UP: 1. Make sure all valves in heat recovery water piping system are open. NEVER OPERATE HR PUMP DRY. 2. Turn on the heat pump. The HR pump should not run if the compressor is not running. 3. Turn HR switch to the “ON” position. The pump will operate if entering water temperature to HR is below 140° F. 4. The temperature difference between the water entering and leaving the heat recovery should be 5° to 15° F. 5. Allow the unit to operate for 20 to 30 minutes to ensure it is functioning properly. The pump should shut off when the water temperature entering the heat recovery reaches 140°F. MODEL HR000 HR001 HR002 HR003 1.0 1,430 .50 .4 1.5 2,140 .75 .7 1.0 2,858 .50 .8 1.5 4,287 .75 1.3 2.0 5,716 1.00 1.7 2.5 7,146 1.25 2.1 3.0 8,575 1.50 2.5 3.5 10,004 1.75 2.9 4.0 11,433 2.00 3.4 4.5 12,862 2.25 3.8 5.0 14,292 2.50 4.2 NOMINAL HR CAPACITY GHR GPM UNIT TONS (BTU/HR.) FLOW RATE POTENTIAL SAVINGS PER HOUR EQUIV. - Kwh (Figure #4) HEAT RECOVERY TROUBLE SHOOTING