IBC HPX 3 User manual

INSTALLATION AND
OPERATING MANUAL
Hydronic Heat Pump
HPX 3 (3 ton model #IHEXXF1-003T)
HPX 5 (5 ton model #IHEXXF1-005T)
WARNING
Risk of Electric shock. If the information in this manual is not followed exactly, a fire or
electricution may result causing property damage, personal injury, or loss of life.
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance.

Water quality
Warning
Water quality has a significant impact on the lifetime and performance of a boiler's heat
exchanger.
Improperly prepared water in a heating circuit may cause damage to the heat exchanger
through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential
for damage.
High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part
of the heat exchanger, impairing heat transfer and resulting in overheating and premature
failure. The amount of solids that may form on the heat exchanger will depend on the degree
of hardness and the total water volume in the system. A high water volume system with a low
hardness count may cause as much damage as a system with less volume and higher
hardness, so it is recommended to treat water so as to reduce dissolved solids to the
minimum 10 ppm, and to no more than 30 ppm. Water chemistry allowable limits are as
follows:
TDS 0.6 to 1.75 grains/ gal (10 to 30 ppm)
Acidity pH is to be between 6.6 and 8.5
Chloride is to be less than 125 mg/l
Iron is to be less than 0.3 mg/l
Cu less than 0.1 mg/l
Conductivity is to be less than 400μS/cm at 77°F (25°C)
Important: Ensure that these limits are acceptable for the other water-side components in
the system.
Shipped with the heat pump:
1 x remote display, P-1900
1 x remote display extension cable (approx. 50'), P-1904
1 x buffer tank temperature sensor, P-1902
4 x rubber feet

3
Contents
Safety information 5
2.0 Manual safety markings 5
Important safety instructions 5
Known contaminants 6
3.0 Specifications 7
3.1 Cabinet dimensions 8
HPX-Series dimensions 8
3.2 Connection specifications 9
3.3 Capacities and COPs 10
4.0 Introduction 15
4.1 Standard features and benefits 17
4.2 Warranty 18
5.0 Before installation 19
6.0 Installation 21
6.1 Code requirements 21
6.2 Determining location of the appliance 21
6.2.1 Installation clearances 22
6.3 Important Design Considerations 22
6.4 Water Piping 24
6.5 Hydronic heat pump circulator selection 25
6.6 Relief Valve 27
6.7 General piping best practices 27
6.7.1 System piping 27
6.7.2 Essential components 29
6.7.3 Glycol isolation with external heat exchanger 31
6.7.4 Glycol isolation with indirect / buffer tank 32
6.7.5 Buffer tank piping 33
6.7.6 Buffer tank sizing 34
6.7.7 Quick calculation for buffer tank sizing 34
6.7.8 Multiple hydronic heat pumps piping 35
6.7.9 Multiple heat sources with buffer tank 36
6.8 Electrical connections 37
6.8.1 Power management, quality and electrical protection 37
6.8.2 240VAC line-voltage hook-up 37

6.8.3 Hydronic heat pump circulator 38
6.8.4 Thermostat wiring 39
6.8.5 Control wiring overview 40
6.8.6 Other wiring 41
6.8.7 Buffer tank sensor wiring 41
7.0 About the hydronic heat pump controller 43
7.1 Use with the IBC Sky 35 Controller 43
7.2 Use in Stand-alone mode 43
7.2.1 Entering the Parameters menu for Stand-alone operation 43
7.2.2 Adjusting Temperature Units in the Parameters Menu 45
7.2.3 Adjustment in the Parameters Menu for Cooling 46
8.0 Before operating the hydronic heat pump 47
Checklist for electrical conditions and water connections 47
9.0 Heat Pump Operation 49
9.1 Starting and Shutting Down the Heat Pump 49
10.0 Service and maintenance 51
10.1 Maintenance checklist for homeowner 51
10.2 Maintenance checklist for heating contractor 51
11.0 Troubleshooting 53
11.1 Electronic components 53
11.1.1 Temperature sensors 53
11.2 Troubleshooting error messages 54
11.2.1 Temperature issues 56
11.2.2 Miscellaneous issues 57
11.2.3 Cycling issues 57
12.0 Exploded views of the HPXseries Heat Pumps 58
HPX 3 parts diagram 58
HPX 5 parts diagram 60
Installation & Commissioning Report 63
13.0 Appendices 65
Wiring diagrams 65
4
Section: Contents

5
Safety information
2.0 Manual safety markings
Danger
Points out an immediate hazardous
situation that must be avoided to
prevent serious injury or death.
Warning
Points out a potential hazardous
situation that must be avoided to
prevent serious injury or death.
Caution
Points out a potential hazardous
situation that must be avoided to
prevent possible moderate injury
and/or property damage.
Note
Points out installation, maintenance and
operational notes to enhance efficiency,
longevity and proper operation of the
hydronic heat pump.
Important safety instructions
Installation, start-up and servicing of IBC hydronic heat pumps must be performed by competent,
qualified, licensed and trained technicians.
Failure to read and comply with all instructions and applicable national and local codes may result in
hazardous conditions that could result in property damage and injury to occupants, and in extreme
cases to death. Keep instructions near the appliance for future reference.
Danger
Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or
any other appliance. If you smell gas vapors, do not try to operate any appliance - do not
touch any electrical switch or use any phone in the building.
Warning
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless they
have been given supervision or instruction concerning use of the appliance by a person
responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Warning
Do not use this hydronic heat pump if any part has been under water. Immediately call a
qualified service technician to inspect the hydronic heat pump and to replace any part of
the system that has been under water.

Warning
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury, or loss of life. Read and understand the entire
manual before attempting installation, start-up, operation, or service. Installation and
service must be performed only by an experienced, skilled installer or service agency.
Failure to follow all instructions in the proper order can cause personal injury or death.
Read all instructions, including all those contained in component manufacturers’
manuals before installing, starting up, operating, maintaining, or servicing the
appliance.
Warning
Disconnect power supply before any wiring/service is performed. Failure to do so could
result in damage to appliance and/or electric shock.
Caution
The hydronic heat pump must be installed so that electrical components are not
exposed to water during operation.
Known contaminants
Known Corrosive Contaminants to Avoid
Salt air of ocean-front properties Calcium chloride used for snow clearing
Cements and glues Sodium chloride or potassium chloride used for
water softening
Paint or varnish removers Chemicals in perming solutions
Adhesives used to fasten building products
and other similar products
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans
Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers
Hydrochloric acid or muriatic acid used in
household cleaning and stain removal
6
Section: Safety information

7
3.0 Specifications
Hydronic Heat Pump Specifications HPX 3 HPX 5
Rated Voltage / Frequency / Phase 208/230V 60Hz 1Ph
Heating Capacity Range * 9.6 - 44.2 MBH 14.4 - 56.6 MBH
Heating Capacity Range * 2.8 - 12.9 kW 4.2 - 16.6 kW
Cooling Capacity Range ** 15.5 - 34.5 MBH 21.4 - 47.6 MBH
Cooling Capacity Range ** 4.55 - 10.1 kW 6.3 - 14.0 kW
Total Load (@240V) 20.3 A 26.6 A
Noise measured at 1 meter 38 - 52 dB (A) 42 - 53 dB (A)
Weight (empty) 220 lb / 100 kg 320 lb / 145 kg
Compressor Rating Load 19.5 A 25 A
Fan Motor Rating Load 0.8 A 2 x 0.8 A
Minimum Circuit Ampacity 25.2 A 33 A
Max Fuse Size 40 A 50 A
Rated Water Flow 6.6 gpm / 1.5 m3/h 7.5 gpm / 1.7 m3/h
Water Pressure Drop (Head Loss) 7 feet / 2.1 m 9 feet / 2.7 m
Maximum Outlet Water Temp. (electronic hi-limit) 140°F/ 60°C
Design Water Pressure 30 psig / 207 kPa
Maximum Water Pressure 145 psig / 1,000 kPa
Minimum Water Pressure 8 psig / 55 kPa
Minimum Ambient Temperature -13°F / -25°C
Maximum Refrigerant Pressure (low side) 305 psig / 2.1 MPa
Maximum Refrigerant Pressure (high side) 638 psig / 4.4 MPa
Maximum Allowable Refrigerant Pressure 696 psig / 4.8 MPa 725 psig / 5.0 MPa
Refrigerant Type and Charge R410a / 2.2 kg R410a / 2.5 kg
Refrigerant Safety Group Classification A1
Moisture Resistance IPX4
* for conditions Ambient Temp = 45°F (7°C), Outlet Water Temp = 106°F (41°C)
** for conditions Ambient Temp = 95°F (35°C), Outlet Water Temp = 54°F (12°C)

3.1 Cabinet dimensions
HPX-Series dimensions
Figure 1 Front view- HPX 3 Figure 2 Side view- HPX 3
Figure 3 Top view- HPX 3
8
Section: Specifications

Figure 4 Front view- HPX 5 Figure 5 Side view - HPX 5
Figure 6 Top view- HPX 5
3.2 Connection specifications
Description HPX 3 HPX 5
Return water inlet 1" NPT-M 1¼" NPT-M
Supply water outlet 1" NPT-M 1¼" NPT-M
Supply power knock-out Dual 3/4" and 1"
Control wiring knock-out 1/2"
Table 1 Connections
9
3.2 Connection specifications

3.3 Capacities and COPs
10
Section: Specifications

Table 2 HPX 3 Capacityand COP tables
11
3.3 Capacities and COPs

12
Section: Specifications

Table 3 HPX 5 Capacity and COP tables
13
3.3 Capacities and COPs

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15
4.0 Introduction
Wiring connection area
Electrical connection rubber grommet (2)
Supply water connection
Heat Exchanger
Fan
Compressor
Outdoor finned coil
Return water connection
Figure 7 Interior view of HPX 3

Wiring connection area Outdoor finned coil
Electrical connection rubber grommet (2) Return water connection
Supply water connection Fan (1 of 2)
Heat Exchanger Compressor
Figure 8 Interior view of HPX 5
16
Section: Introduction

4.1 Standard features and benefits
Highly efficient heating and cooling
Enhanced Vapor Injection (EVI) design increases efficiency, lowers ambient temperature
operating range, and increases maximum supply water temperature
Renewable energy source
Modulating
Quiet operation
Easy set-up for Set-Point or Outdoor Reset heating
Flow-proving and high limit safeties built in
17
4.1 Standard features and benefits

4.2 Warranty
For residential applications, IBC offers a 2-year parts and a 5-year compressor limited warranty
against defects in materials or workmanship.
For commercial applications, IBC offers a 2-year parts and a 2-year compressor limited warranty
against defects in materials or workmanship.
To view the full warranty statement for the HPX-series, go to ibcboiler.com.
18
Section: Introduction

19
5.0 Before installation
Before installing the hydronic heat pump, it is important to review and observe the following checklist
of precautions:
Precautions Check
Care must be taken to properly size the hydronic heat pump for its intended use.
Prolonged full output run time, over-sizing or under-sizing, and incorrect flow rates can
lead to increased maintenance costs, equipment stress and premature failure.
□
Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated
hydrocarbons can reduce the life of a hydronic heat pump. Cleaners, bleaches, air
fresheners, refrigerants, aerosol propellants, dry-cleaning fluids, de-greasers, paint-
removers and airborne chlorides such as those released with the use of laundry
detergents are to be avoided.
□
Exposure to salt air can reduce the life of a hydronic heat pump. Ocean-front installations
are to be avoided.
□
Locate the hydronic heat pump's base at least 12" [30 cm] above the highest anticipated
snow line. An after-market permanent platform or wall mounting bracket may be used.
□
Locate the hydronic heat pump where water from the defrost cycle will drain freely and will
not cause a slip hazard under freezing conditions.
□
Do not install where operation noise may cause a disturbance. □
At a new construction site, or during renovations, protect the hydronic heat pump from dust
and other construction related contaminants. Do not seal case openings directly when
operating- allow for air circulation and ventilation in the immediate area.
□
Ensure that the pressure relief valve is installed. It is recommended to pipe relief discharge
into glycol fill tank. Make sure the relief valve outlet is piped with unobstructed piping
(minimum ¾" diameter) to a safe discharge location.
□

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