CGC IKV008 Owner's manual

R090303July7th,2010
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Installation
Operation
Maintenance
HybridVerticalStack
HeatPump
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Innkeeper/Homekeeper
Models:IKV008–IKV018
HKV020–HKV036

R090303July7th,2010
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TableofContents
1.INFORMATION.................................................................................................................................1
Handling/Storage..........................................................................................................................................1
Weight/Dimension/Clearances.....................................................................................................................2
2.INSTALLATION..................................................................................................................................3
GeneralInstallationChecklist.......................................................................................................................3
CondensateHoseConnection.......................................................................................................................4
Location/Placement/RiserBundle................................................................................................................5
Finish.............................................................................................................................................................6
3.OPERATION(INSUITE).....................................................................................................................7
FanOperation...............................................................................................................................................7
StandardHeatingOperation.........................................................................................................................7
CoolingOperation
.........................................................................................................................................8
TimeDelays...................................................................................................................................................8
Recommendations........................................................................................................................................8
4.OPERATION(DETAILED)..................................................................................................................10
BoardDescription.......................................................................................................................................10
Fan...............................................................................................................................................................11
CoolStartUp...............................................................................................................................................11
CoolOperation............................................................................................................................................12
OperationalAlgorithm................................................................................................................................14
ThermostatConnection..............................................................................................................................14
ShutdownOutput........................................................................................................................................15
FaultAlarms................................................................................................................................................15
5.COMMISSION&STARTUP.............................................................................................................17
6.MAINTENANCE...............................................................................................................................19
IKV008‐IKV018WiringDiagram.................................................................................................................20
HKV020‐HKV036WiringDiagram..............................................................................................................21

HybridVerticalStack–InstallationOperationMaintenanceManual


INFORMATION

R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage1
Handling
Caremustbetakeninhandlingthecabinet,chassis,risersandotheraccessoriestoensurethat
thisequipmentdoesnotsustainanydamage.Itisrecommendedthatthechassisandcabinet
betransportedindividuallyonatwo‐wheelcart.

Theprotectiveshippingpackagingshouldremainonthechassisandcabinetuntiltheyare
readyforinstallation.Duringconstruction,theunitmustnotberunandshallbeshelteredfrom
contaminantsanddebrissuchasdrywalldust,woodchips,andpaintthatcoulddamagethefan
orblockthecooling/heatingcoilwhichmayresultindiminishedperformance.
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Storage
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Thechassismustbestoredinanuprightpositionatalltimeswiththecompressorsection
towardsthegroundandthefansectionorientedupwards.
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Failuretomaintainthechassisinanuprightpositionmayresultinpermanentdamagetothe
unit.Droppingthechassisorexposingittoextremeshockorvibrationmayalsoresultin
permanentdamagetotheinteriorcomponentsandpiping.
Boththechassisandcabinetshouldbestoredinanon‐corrosiveenvironmentshelteredfrom
conditionsofextremetemperatureorhumidity.Subjectingtheunittoconditionsofthisnature
mayresultinsignificantlyreducedperformance,reliability,andoperationallife.
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Theunitisintendedforinterioruseonlyandshouldbestoredindoorsatalltimestoprotectit
fromtheelementsandtohelpeliminatethepotentialgrowthofindoorairquality(IAQ)
contaminants.
Ifindoorstorageisnotpossible,theequipmentmaybestoredoutdoorsduringthesummer
monthsonly,ifthefollowingprovisionsaremet:
1. Theequipmentmustbeplacedonadrysurface,orraisedoffthegroundinamanner
whichallowsforair‐circulationbeneaththeunit.
2. Awaterprooftarpmustbeusedtocovertheequipmentinordertoprovideprotection
fromtheelements.
3. Continuousventilationtotheunitsmustbeprovidedtohelppreventmoisture
accumulationontheinteriorandexteriorsurfaces.Moisturebuildupon,orwithinthe
unit’sinsulationmayresultinmicrobialgrowththatcanleadtoodorsandserious
health‐relatedIAQproblems.
4. Thechassisunitsmustbestoredintheiroriginalpackaging.

HybridVerticalStack–InstallationOperationMaintenanceManual
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
INFORMATION
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage2
5. Theindividualunitsshallnotbestackedontopofoneanother.
6. Iftheunitwaspreviouslyinuse,ensurethatallwaterinthecoilhasbeenblownoutand
thatallhoseconnectionsarepluggedduringstorage.
Weight/Dimension/Clearance
UnitWeight:

Model008010012015018020024030036
Weight
(lb)115120120135145210225225240
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UnitDimension:
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Models008‐018
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Models020‐036
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UnitClearance:
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Theverticalstackproducthasasound‐dampeningfrontcoverpanelandreturnairboot.The
sound‐dampeningpanelslidesoffwithminimalserviceclearance,however,intheeventof
chassisreplacementthefrontserviceentrancemustpermitstraighthorizontalremovalofthe
chassis.Thereturnairbootmustbeunobstructedduringoperation.
Theinstallationofallverticalstackproductandcomponentsandaccessoriesmustbein
accordancewithalllocalcodeandregulationsofallgoverningauthoritieshavingjurisdiction.
Themanufacturerrecommendsthefollowinginstallationprocedures.Itistheresponsibilityof
theinstallingcontractortocomplywithallapplicablecodesandregulations.
Figure1Figure2

HybridVerticalStack–InstallationOperationMaintenanceManual
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INSTALLATION
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage3
Theinformationbelowdetailsthecorrectinstallationprocedureforaverticalstackunit.Please
readthisdocumentinitsentiretypriortoproceedingwithunitinstallation.
Specificsiteconditionsmaywarrantvariationsinlocationsanddimensions.
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GENERALINSTALLATIONCHECKLIST
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1. Removepackagingandinspecttheunit.Carefully
checkforshippingdamageormaterialshortage;file
afreightclaimandnotifyappropriatesales
representativeifdamageisfound.
NOTE:Thechassis,frontpanel,andreturnairboot
shipseparatelyfromthecabinetandrisers.
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2. Verifythecorrectmodelandvoltageasindicatedby
themodelnumber.
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3. Verifytheinstallationlocationoftheunitusingthe
sheetmetaltemplatethatisprovided.

4. Verifythatthepowersupplycomplieswiththe
nameplatespecification.
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5. Connectproperlysizedandprotectedpowersupply
wiringtotheelectricalreceptacleinthecabinet.

6. Installpropergroundingwirestoanearthground.
Figure3

HybridVerticalStack–InstallationOperationMaintenanceManual
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INSTALLATION
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage4
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HybridVerticalStack–InstallationOperationMaintenanceManual
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INSTALLATION
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage5
LOCATION
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1. Determinecabinetlocationusingthe
manufacturer‐suppliedtemplate.
2. AsdepictedinFigure4,locatecoreholes
forrisersusingsuppliedtemplate.
3. Locatetheunitinanindoorarea.The
ambienttemperaturesurroundingthe
unitmustnotbelessthat45°F(7°C).Do
notlocatetheunitinareasthatmaybe
subjectedtofreezingtemperatures.

PLACEMENT
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1. Reviewtheriserscheduletoidentify
cabinettypeandlocation.
2. Positioncabinetandfastentofloor.
3. Toleveltheunit,loosenthefourbolts
thatarelocatedatthebottomofthe
cabinetontheleftandrighthand
sides(refertoFigure5).Leveland
plumbtheunitandthentightenthe
fourboltstoholdthecabinetinposition.
4. Connectrisers‐showninFigure6‐using
95/5tin‐antimonysolder,orbrazewith
Sil‐Fos.
5. Performleaktestonrisers.
6. Connectpowertocabinetelectricalbox
andrunthermostatwire.

RISERBUNDLE

1. Matchunitlocationwithriserbundle
nomenclatureasindicatedbythe
manufacturersuppliedriserschedule,andthe
labelaffixedtotheriserbundle.
2. Hangriserbundleatunitknockoutpanel.
Figure4
Figure5
Figure6

HybridVerticalStack–InstallationOperationMaintenanceManual
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INSTALLATION
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage6
FINISH

1. Attachdrywalltocabinet(leftside)or
installdrywallstuds(rightside).Fasten
cabinettostuds.Installationofacoustic
insulationinstudwallisrecommended.
2. Glueorattachdrywallwithscrewsto
studwallandfrontofcabinet,asshown
inFigure7.
3. Mountthermostatandconnectto
thermostatwire.Ensurethatthe
thermostatisnotmountedindirect
sunlight,orwithinthesupplyairstreamof
theheatpumpunit.
4. Installandconnectchassis.Wire
thermostattocontrolboard.
5. Connectsupply/returnhosesand
condensatelinetorisers.
6. Performaleaktestandensurethatthe
hoseclamponthecondensatelineistight.
7. Hangreturnairbootonlowerclips,shown
inFigure8.
8. Connectpowercordatcabinetelectrical
box.
9. Hangacousticallyinsulatedfrontpanelon
upperclips.

Figure7
Figure8

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION–INSUITE
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage7
CAUTION:
Toavoidfouledmachinery,extensiveunitcleanup,andvoidwarranty,donotoperateunits
withoutairfiltersinplace,anddonotoperateunitsduringtheconstructionprocess.

TheCGCGrouphybridheatpumpprovidesyearroundcoolingandheatingcontrolledbyyour
in‐suitewallmountedthermostat.

TheCGCGrouphybridheatpumpprovidesDXcoolingwithawater‐cooledrefrigerationcircuit,
andhydronicheatingwithahotwatercoil.Thecompressoroperatesinthecoolingmodeonly
andshutsdownduringtheheatingmode,providingforquieteroperation,extended
compressorlife,andareductioninenergyconsumption.

Toensurecorrectoperation,centralizedequipmentlocatedwithinthebuildingmechanical
roomisautomaticallycontrolledtoprovideeachheatpumpunitwithwaterthatisatthe
propertemperature.

FanOperation:

Eachheatpumphastwo‐speedfanoperation.Thefanoperatesasfollows:

LOWSpeed ‐Firststageofheatingmode(ThermostatSetting:FanAutomatic)
‐Fanonlyoperation(ThermostatSetting:FanOn)

HIGHSpeed ‐Thesecondstageofheatingmode
‐Coolingmode

StandardHeatingOperation:

Eachheatpumphastwostagesofheatoperation.Thecompressordoesnotoperateineither
stage.

Toenableheatingoperation,ManualChangeOverthermostats(MCO)mustbesetto“Heat”
mode.AutomaticChangeOver(ACO)thermostatsshouldbesetto“Auto”mode.Tostart
heatingoperation,thesuitetemperaturemustfallbelowtheheatset‐pointtemperature.

Thethermostatwillautomaticallystopheatingoperationoncethespacetemperaturerisesup
totheheatset‐pointtemperature.

HybridVerticalStack–InstallationOperationMaintenanceManual

OPERATION–INSUITE
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage8
Stage1Heating:Fanoperatesatlowspeedfor10minuteswithminimalnoiseinanattemptto
elevatesuitetemperaturetodesiredlevel.
Stage2Heating:After10minutes,ifset‐pointtemperatureisnotreached,fanwill
automaticallystepupandoperateathighspeed.

CoolingOperation:

Eachheatpumphasawatercooledrefrigerationcircuitthatoperatesonlyduringthecooling
mode.

Toenablecoolingoperation,MCOthermostatsmustbesetto“Cool”mode.TheACO
thermostatsshouldbesetto“Auto”mode.Inorderforthecoolingoperationtobecome
activated,thesuitetemperaturemustriseabovethecoolset‐pointtemperature.

Thethermostatwillautomaticallystopcoolingoncethespacetemperaturedropsbelowthe
coolset‐pointtemperature.

Cooling:Thefanalwaysoperatesathighspeedduringthecoolingoperation.
Thecompressoralsooperatesduringthecoolingoperation.

TimeDelays:
‐Thermostattimedelayupto5minutesuponinitialpowerup.
‐Thermostattimedelayupto5minuteswhenswitchingbetweenheat/cool/off
modes.
‐Heatpumptimedelayupto5minutesuponinitialstartup.
‐Heatpumptimedelayupto5minutesfromtheendofacoolingoperationto
thestartofthenextcoolingoperation.

Recommendations:

1. SetthethermostatfantoONforcontinuousfanoperationwhileyoursuiteisoccupied.
Thiswillhelptoensurethatthetemperatureisuniformthroughoutthesuite.

2. Inordertoprovidespaceconditioningwhileyouareaway,keepthethermostatsystem
switchintheappropriateheatorcoolmode.Theheatpumpwillnotheatorcoolifthe
thermostatsystemswitchissettothe“OFF”position.
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HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION–INSUITE
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage9
3. Whenawayforashortduration,setthethermostatasfollows:
a. SetfantoAUTO
b. Setthermostattoappropriateheatorcoolmode(basedonseasonalconditions).
c. Setheatorcoolset‐pointtoyourdesiredsuitetemperature(ie.72°For22°C).

4. Whenawayforanextendedperiod,setthethermostatasfollows:
a. SetfantoAUTO
b. Setthermostattoappropriateheatorcoolmode(basedonseasonalconditions).
c. Duringcoolerseasonssetyourthermostattoaminimumsetpointof65°F(18°C)
d. Duringwarmerseasonssetyourthermostattoamaximumsetpointof78°F
(26°C)

Thiswillhelptoensuretheunitoperatesminimally;preventingyoursuitefrombecoming
excessivelycoldorhot.

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HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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Theunitcircuitboardincorporatessixrelayoutputswiththefollowinguses:

•K1–Auxiliaryrelayforcoolingvalveonatwo‐valveunitorheatvalveonadehumidification
unit.
•K2–HeatingRelay
•K3–AlarmRelay
•K4–CompressorRelay
•K5–LowFanorFanRelayforbeltdriveunits
•K6–HighFanorCompressor#2onbeltdriveunits
Eachoftheserelayshaveinparallel,agreenLEDindicatorthatlightsupwhentherelayis
energized.
Theboardincorporatesdigitalinputsthatareopto‐coupledtoa24VACsource.Theseinputshave
amberLEDindicatorsthatwilllightupwhenaninputispresent.Theseinputsinclude:
•HighPressureSwitch
•LowPressureSwitch
•HeatCall(Wonthermostatterminal)
•CoolCall(Yonthermostatterminal)
•FanCall(Gonthermostatterminal)
•Auxiliary(Aonthermostatterminal)
•Compressorshutdown(24VACsignalthruO/O).
Providingacontinuous24VpotentialtoO/Owillterminateandpreventcompressor
operation.Thiscanbeusedfordutycycling,orforminimizingpowerconsumption
duringapowerfailure,whilemaintainingtheheatingfunction.
•Unitshutdown(24VACsignalthruA/O).Providingacontinuous24VACpotentialto
A/Owillterminateandpreventunitoperation.Thiscanbeusedforasimplenight
shutdown.Onbotharrangementsasingle24VACsignalcanshutdownmanyunits.¼
vaisrequiredperunit.
Theboardalsohasfouranaloginputsprovidedviathermistors.Theseinputsareasfollows:
•Ta–DischargeAirTemperature
•Tr–RefrigerantTemperature
•Tw–OutgoingWater(systemfluid)Temperature
•Co–CondensateLevel
Ta,Tr,AndTware10kOhmNTPthermistors,whileCoisa100OhmNPTthermistor.TheseInputs
donothaveLEDindicators.

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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FAN
1. Acallon“G”forfanonthethermostatterminalstripwillcausethefantooperate
continuouslyonlowfanspeedthroughK5onmultispeedunits.
2. Acallon“W”forheatonthethermostatterminalstripwillalsocausethefanto
operateonlowspeed.After10minutesofacontinuousheatingcall,themultispeed
unitswillbeswitchedtohighspeedthroughRelayK6.
3. Acallon“Y”forcoolingonthethermostatterminalstripwillcausethefanonmulti
speedunitstostepuptohighspeedthroughRelayK6.
4. Fanoperationwillterminatewheneverheatingorcoolingcallsaredropped.
5. BothrelaysandtheirassociatedLED’sareenergizedwhenthefanisinhighspeed.

HEAT

1. Acallon“W”forheatwillturnonthefanatlowspeed.Simultaneously,itwillenergize
theheatrelayK2andit’sLED.TherelayK2willprovide24VACfusedpowerdirectlyto
theheatvalve.

COOLSTARTUP

1. Acallon“Y”forcoolinginitiatesaseriesofcheckspriortothestartupofthe
compressor.Thesechecksinclude:
a. PowerONtimer–Compressoroperationisdelayedforapproximately5minutes
afterrestorationofpower.Thispreventsallunitscomingon‐lineatthesame
timeoncepowerisrestored.Italsopreventscompressorjoltingasaresultof
intermittentpower.
b. Anti‐Recycletimer–Thereisa5‐minuteanti‐recycledelaytimerthatallowsthe
refrigerationcycletoachievepressureequalizationsothatthecompressoris
unloadeduponstartup.
c. HighPressureSwitch–Thehighrefrigerantpressureswitchmustbeclosedprior
tostart.LED11willbeON.
d. LowPressureSwitch–Thelowpressureswitchoperatesprimarilyasalossof
chargeprotector.ItmustbeclosedforcompressorstartupandLED12willbe
ON.Thepressureswitchhasa5minuteignoresubsequenttostart‐up.Insome
situations,particularlywhentheunitiscold,thepressureswitchwillopenduring

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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R090303InstallationOperationMaintenanceManualissubjecttochangewithoutnoticePage12
start‐up.Iftheswitchdoesnotremakewithinthe5minuteignoreperiod,the
compressorwillbeimmediatelystopped.
e. AirTemperatureSensorTa–SensorTawillpreventcompressoroperationifthe
airflowingthroughtheunitisbelow60°F(15°C).
f. WaterTemperatureSensorTw–SensorTwwillpreventcompressoroperationif
theoutgoingsystemfluidtemperatureisabove140°F(60°C).
g. RefrigerantTemperatureSensorTr–SensorTrwillpreventcompressor
operationifthecoiltemperatureisbelow35°F(2°C).
h. AnyoftheabovefaultswillbeindicatedwiththeDiagnosticCodedescribed
underDIAGNOSTICS

COOLOPERATION

2. Monitoringoftherefrigerantcyclecontinuesduringoperationofthecompressor.The
followingmalfunctionswillcausethecompressortoshutdown:
a. Iftheheadpressureexceedsthesetpointofthehighpressureswitch,itwill
open,andthecontrolboardwillterminatethecompressoroperationwithin10
seconds.Atthistimetheflashcode6willbeinitiatedonthereddiagnosticLED.
Compressoroperationwillberestoredinaccordancewiththe“IntelligentReset”
algorithm.
b. Ifthesuctionpressuredropsbelowthesetpointofthelowpressureswitch,the
switchwillopenandifitremainsopenbeyondthe5minuteignoreperiodafter
startup,compressoroperationwillbeterminatedwithin10seconds.
Compressoroperationwillberestoredinaccordancewiththe“IntelligentReset”
algorithm.Aflashcodeof5onthereddiagnosticLEDwillbeinitiatedatthis
time.
c. IntelligentResetAlgorithm–Ifaloworhighpressureswitchopens,the
compressorwillbeshutdown.Thereisa20minutedelaybeforethesystemis
automaticallyreset,afterwhichifthereisacoolcallinplaceandallother
enablersarewithinthestartparameters,thecompressorwillagainbeputinto
operation.Shouldeitherofthepressureswitchesopenagain,theshutdown
procedurewillcycleagain,followedbyarestart.Theintelligentresetwillallow
twoopenswitchshutdownsandrestartsina24hourperiod,butathird
shutdownwithin24hourswillputtherefrigerationsystemintoafullandhard
lockoutrequiringapowerdowntoreset.Iftwoorlessswitchopenshutdowns
occurwithina24hourperiod,theywillbeerasedfrommemoryandwillnot
contributetoafuturehardlockout.(Ahardlockoutwillpreventcompressor

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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operationuntilthecontrolsarepowereddownforatleast20seconds,whilea
softlockoutisacompressorshutdownthatwillberestoredoncetheconditions
causingtheshutdownhavebeenrectified.
d. Duringcompressoroperation,refrigeranttemperature,systemfluid
temperatureanddischargeairtemperaturearecontinuouslymonitored.Ifthe
refrigeranttemperaturedropsbelow35°F,compressoroperationwillbe
disabled.After10minutesanautoresetoccursandthecompressorwillbe
enabledassoonasthetemperaturerisesabove60°F.Actualcompressorrestart
willbedelayedaminimumof5minutesbytheanti‐recycletimer.Aflashcodeof
2willbeinitiateduponalowrefrigeranttemperatureshutdown.
e. Iftheoutgoingsystemfluidtemperaturerisesabove140°F,compressorstartup
willbedisabled.After10minutesanautoresetoccursandthecompressorwill
beenabledassoonasthetemperaturedropsbelow115°F.Theoutgoingsystem
fluidsensorismountedontheleavingfluidpipe.Actualcompressorrestartwill
bedelayedaminimumof5minutesbytheanti‐recycletimer.Aflashcodeof3
willbeinitiateduponahighoutgoingsystemfluidtemperatureshutdown.
f. Ifthedischargeairtemperaturedropsbelow50°Fcompressoroperationwillbe
disabled.After10minutesanautoresetoccursandthecompressorwillbe
enabledassoonasthetemperaturerisesabove60°F.Thedischargeair
temperaturesensorismountedonthefanhousing.Actualcompressorrestart
willbedelayedaminimumof5minutesbytheanti‐recycletimer.Aflashcodeof
4willbeinitiateduponalowdischargeairtemperatureshutdown.
g. Thecondensatelevelsensorisa100ohmthermistorthatisheatedfor15
secondsevery4minutes.Itstemperatureismeasuredatthebeginningofthe
heatcycle,andagainattheendoftheheatingcycle.Ifthecondensatelevelrises
abovethesensoritwillnotwarmupduringthewarmupcycle,andthe
temperaturechangewillbeinsignificant.Itisthislackoftemperaturechange
thatthecontrollerseesasanimpendingcondensateoverflow.Whenhigh
condensatelevelisdetected,compressoroperationisimmediatelyterminated,
andatthesametimethefanisstoppedfor30seconds,andthenrestarted.At
thistimeaflashcodeof7willbeintiated.The4minutecyclewillcontinueuntil
thecoolingcallisnolongerinplace.Ifthecondensateleveldropsbelowthe
sensor,compressoroperationwillbereturnedtonormal.However,ifthe
condensatelevelstaysabovethesensorformorethan15minutes,thefault
alarmwillbetriggered.Thisfaultsignalwillautomaticallyresetoncethe
condensatelevelgoesbelowthesensor.


HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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Note:Thelastflashcodewillbemaintainedinmemoryfor1weekoruntiltheunitcontrolsare
powereddown.Theflashcodewillcontinueuntiltheproblemhasclearedandthecompressorhas
beenputintooperation.Ifacoolingcallisinplace,itmustbedisengagedbeforethecauseofthe
lastalarmshutdowncanbeidentified.

OPERATIONALGORITHM

Thereareseveralcontrolalgorithmstopreventcyclingandproblematicoperation.Theseare:
1. DoubleCall–Ifthermostatconnectionsorsetupisincorrectresultinginasimultaneous
callforbothheatingandcooling,theunitwillnotoperate.Thisconditioncanbe
observedonthethermostatconnectionLEDs.(Note:Aheatpumpthermostatwill
presentthisscenario)
2. ReverseCycleCall–Poorlylocatedautomaticchangeoverthermostats(ie.thermostats
mountedonawalloppositeadischargegrill,orathermostatinadoorwaytooutside)
cantriggerheatingandcoolingmodechangesmanytimesanhour.TheCGCcontroller
hasa10‐minuteanti‐modechangetimerforbothheatingandcoolingmodechanges.
Thecontrollerwillnotacceptachangeinmodeuntil10minuteshaveelapsedsince
terminationoftheoppositecall.

THERMOSTATCONNECTIONS

TheCGCcontrolboardhasbeendesignedtooperatewithmoststandard24VACthermostats.
ThesearepoweredfromtheCGCboardwith24VACandsimplyswitchpowerONtoeachofthe
Heat(W),Cool(Y),Fan(G)orAux(A).Whilemostpresentdaythermostatsoperateinthismanner
thereareothersthatmayormaynotworkproperly.Thefollowingshouldbecheckedoutfor
satisfactoryperformancepriortoinstallation:
1. HeatPumpThermostat–Someheatpumpunitsdonothaveheatrelays(thereforeare
notcompatiblewithstandardthermostats)andrequire“HeatPumpThermostats”.
Thesethermostatscallforbothheatingandcoolingononeofthesignalwires.These
thermostatsarecompletelyincompatiblewithCGC’scontroller.
2. Mercurybulbthermostat‐Thistypeisproblematicbutcanbeused.Unfortunately,the
anticipatorsareaproblem.Heatanticipatorsmustbeinserieswithahighcurrentrelay
orvalvetofunction,sodonotperformonanelectroniccircuit.Thiswillresultinlarger
thannormaltemperatureswings.Thecoolanticipator,ifoversized,canbleedenough
currenttoindicateacoolingcallevenafterithasbeenterminated.
3. Batterypoweredthermostats–Thesethermostatsweredevelopedasreplacementsfor
oldmercurybulbthermostatsthathad4wireconnectionswhile24Velectronic

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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thermostatsrequired5wires.ThesewillworkwithaCGCboard,althoughCGCdoesnot
recommendthem.Theyrequireperiodicbatteryreplacement,whichissomethingthat
shouldbeavoidedifpossible.
4. Powerstealingthermostats–Thistypeofthermostatiselectronicandwasalso
developedasareplacementforoldmercurybulbthermostats.Thesetooare
problematicinthattheybleedasmallamountofcurrentdownthesignalwiresandthis
maybeinterpretedasasignalforheatorcool.
5. Triacswitchedcontrollers–Thisisacommonlyusedswitchingdeviceandallcontrollers
testedtodatehavefunctionedflawlessly.CGCrecommendsthatpriortoinstallationof
athirdpartysuppliedcontroller,itbecheckedforcompatibility.CGCcanconfirmthis.
6. Relayswitchedcontrollers–ThistypeofcontrollerworkswellwithCGCdevices.

SHUTDOWNOUTPUT

TheCGCboardhasanoptionalinputterminalstripthatallowsfortwotypesofremoteshutdown.
Thesearea)compressorshutdownandb)unitshutdown.
Theadvantageoftheseinputsisthatmanyunitscanbeconnectedinparallelandwhenpowered
byanindependent24VACsignaloneorbothoftheseactionscanbeimplemented.Commonuses
are:
a. Dutycyclingfordemandcontrol
b. Globalnightsetback
c. Heatingonlymodeduringemergencypowerperiods

TheCGCcontrollerisalsosetupsotheseshutdownfunctionscanbeinitiatedindividuallywithon
board24Vpower.Thiscapabilityallowsunitorcompressorshutdownbasedonadoorswitch,a
lightswitch,oroccupancyswitch.Aseparate24Vpowersupplyisrequirediftwoormoreunitsare
beingshutdown.

FAULTALARMOUTPUT

TheCGCboardisprovidedwithafaultalarmindicationandoutput.Thefaultalarmrelay
providesnormallyopenandnormallyclosedcontactsforuseintransmittingfaultconditions.
NOTE:ThefaultalarmisenergizedforNORMAL,andde‐energizedforfault.Assuch,iftheunit
isnotpowered,iftheboardfuseisblown,oriftheelectronicsaredamaged,afaultcondition
willbeindicated.

ThefaultrelayisparalleledwiththeFaultLEDwhichwillbeONwhennofaultconditionexists.

HybridVerticalStack–InstallationOperationMaintenanceManual
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OPERATION‐DETAILED
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Otherfaultconditionsare:
d. Hardlockoutduetohighorlowpressureswitchbeingopenfor10minutesorlonger.
e. Hardlockoutduetothreehighorlowpressureshutdownsina24hourperiod.
f. Highlevelcondensateforaperiodinexcessof15minutes.


HybridVerticalStack–InstallationOperationMaintenanceManual
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COMMISSION&STARTUP
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SystemFlushing:
Propersystemcleaningandflushingisanimportantaspectofthecommissioningandstartup
procedureforhybridunits.Ensurethesystemhasbeenflushedproperly.Thispreventsfouling
oftheunit’sheatexchangers.

NOTE:Hydroniccoilsarenot100%drainable.

SystemFluid:
Ensurethatsystemwatertemperatureiswithinanacceptablerangetofacilitatestart‐up(80‐
120°F)forcoolingand(100–140°F)forheating.

SystemWaterpH:
SystemwatershouldhaveaneutralpHbalanceofapproximately7.5whichwillextendthelife
ofthehoses,heatexchangers,andotherwatersideaccessories.

WaterFlowRate:
Openallisolationvalvestotheunit.Ensurethattheenteringandleavingfluidtemperaturesof
thehybridunitinoperationareacceptable.Thereistypicallyan8to12degreedroporrisein
temperature,dependingonwhethertheunitisincoolingorheating.Underextreme
conditions,slightvariancesinthetemperaturemaybenoted.

FreezeProtectionfromWaterSystem:
Ensurethatfreezeprotectionisprovidedfortheoutdoorportionoftheloopwatersystem.
Inadequatefreezeprotectioncanleadtocoildamage.

NOTE:Apotentialissuemayariseduringconstructionwherethesystemfluidloopisdrained
afterbeingcleaned,flushedandtested.Hybridverticalstackunitswillnotcompletelydrain
andmayholdfluidinthecondenserorheatingcoil.Extensivedamagemayresulttointernal
componentsifthesystemfluidfreezesunlessadequateglycolisadded.

RemoveAirfromSystemFluidLoop:
Airinthesystemimpairsunitoperationandcancauseerosioninthesystempiping.

HybridVerticalStack–InstallationOperationMaintenanceManual
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COMMISSION&STARTUP
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CleanUnitFilters:
Confirmthattheunitfiltersthatarebeingusedareclean.Thiscontributestotheproper
operationoftheunitbyensuringthatthereisadequateairflowacrossthecoil.
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FanRotation:
Inspectthefansectiontoensurethatitisfreeandclearofanydebrisandthatthefanrotates
freely.
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NOTE:ThisequipmentisdesignedforindoorinstallationONLY.