® Hydronic freewatt Plus System, Model HDJ INSTALLATION, OPERATION & MAINTENANCE MANUAL Information and specifications in the manual 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 obligation, whatsoever. P/N # 240008214, Rev. C [01/2011] Check our website frequently for updates: www.freewatt.com www.ecrinternational.
TABLE OF CONTENTS 1 - Safety Information........................................ 3 Safety Symbols 2 - Introduction ................................................. 4 Manual contains important safety information. Read all freewatt PLUS System manuals for safety information and warnings. 3 - Components, Controls and Accessories ...........12 4 - APC Universal Transfer Switch .......................14 5 - Compatible Room Thermostats .....................17 ! 6 - freewatt Transfer Switch Model FTS-1.8 ..
1 - SAFETY INFORMATION 1.1 Safety Information ! WARNING • Check all applicable state, local building codes and utility company requirements before installation. Installation shall conform to these requirements in their entirety. In absence of these codes, use NFPA, National Gas and National Electric installation codes and authority having jurisdiction. Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.
2- INTRODUCTION 2.1 Hydronic freewatt PLUS system is gas-fired micro- 2.2 Application Notes combined heat and power (micro-CHP) system suitable for residential and light commercial space and water heating applications up to 200,000 Btu/hr. • Maximum design water temperature of 160°F. Heat emitters sized for heat output using maximum design water temperature of 160°F.
2- INTRODUCTION • Installation of UL and ULC recognized CO detectors with audible alarms (not supplied with system) are required part of freewatt PLUS installation. freewatt PLUS Exhaust Gas Detection System included part of freewatt PLUS System does not provide audible alarm for protection of building inhabitants from potentially dangerous high levels of carbon monoxide. Install both Exhaust Gas Detection System and separate, independent UL recognized CO Detectors. ! WARNING Burn and scald hazard.
2- INTRODUCTION 2.3 Save These Instructions Read this manual carefully and keep for future reference by service technician. Manual is considered permanent part of your Hydronic freewatt PLUS System and should remain with system. Manufacturer is not responsible for any field installation changes made to system installation that are not described or acknowledged in this manual. Product must be installed by licensed plumber or gas fitter when installed within Commonwealth of Massachusetts.
2- INTRODUCTION Figure 2-1 - freewatt PLUS System Components ( Zoned with Circulators) From DHW freewatt® PLUS System Components To HI Module Heating Zone Returns From HI Module To Boiler freewatt System Control Module From Boiler Zone Controls Heating Zone Circulators APC UTS6H Honda MCHP Exhaust Gas Sensor Programmable & Communicating HAI Thermosat freewatt Outdoor Temperature Sensor DHW Circulator Boiler Outdoor Temperature Sensor freewatt Transfer Switch W/Load Balancing Transformer HI Modu
2- INTRODUCTION Table 2-1 System Rating and Sizing Unit Honda MCHP Unit (0 - 3,300’) MCHP Mode Backup Mode Boost Mode Input (MBH) Heating Capacity (MBH) Overall Efficiency (%) Nominal Power (kWe) Weight (lbs) 18.4 12.3 12.3 1.2 180 18.5 - 26 12 - 17 12 - 17 0 - 1.8 180 26 17 17 1.8 180 80-200 76-190 95% - 284 Boiler Boiler Module (0 - 2,000’) Ratings are for sea level applications.
2- INTRODUCTION Figure 2-3 MCHP & Hydronic Hybrid Integration Module Figure 2-4b Hydronic Hybrid Integration Module Figure 2-4a Hydronic Hybrid Integration Module Figure 2-5 Typical freewatt PLUS Control Module Configuration 9
2- INTRODUCTION Figure 2-6 freewatt PLUS Control Module Details Figure 2-7 MCHP Dimensions System Clearances to Combustibles Dimensions Boiler Honda MCHP Top 1" ( 8" for service) 14" Sides 1" (24" for service) 0.4" (12" 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 carpet. 2.
2- INTRODUCTION Figure 2-8 MCHP Electrical Connection Details Figure 2-9 MCHP Front Interface Details 11
3 - COMPONENTS, CONTROLS AND ACCESSORIES Section provides brief description of components, controls, and accessories of hydronic freewatt PLUS System. 3.4 HONDA MCHP Unit • Honda MCHP Unit is custom-engineered microcombined heat and power module integrated into Hydronic freewatt PLUS System. MCHP unit designed to start and stop by means of digital signal from control module when control module senses there is heat demand in dwelling. 3.
3 - COMPONENTS, CONTROLS AND ACCESSORIES • Installations without uninterrupted supply of water during power outage (most 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 coolant loop. Dimensions of unit are 24” Length, 15” Width, and 36” Height. 3.
4 -APC UNIVERSAL TRANSFER SWITCH CONFIGURATION Circuit 5 & 6 • Although all UTS circuits do not need to be used, Circuits 5 & 6 must be connected to main circuit panel and must receive power for UTS to function. Circuits 5 & 6 must also be connected to circuits that are in opposite phases, so 240V is present across two circuits. Allows UTS6H to monitor Utility power supply.
4 - APC UNIVERSAL TRANSFER SWITCH CONFIGURATION Table 4-1 Typical UTS6H Circuit Setup without UPS Typical UTS Circuit Setup without UPS CIRCUIT I CIRCUIT 2 CIRCUIT 3 CIRCUIT 4 CIRCUIT 5 CIRCUIT 6 Other (condensate pump) Sump pump Boiler Computer Security System Refrigerator Source GEN GEN GEN GEN GEN GEN Delayable Yes Yes (1) No Yes Yes Yes Max time off (min) 30 1 30 5 60 30 Min time on (min) 30 2 30 5 60 15 Security Mode Off Off Off Off Off Off Amp Rating(A)
4 - APC UNIVERSAL TRANSFER SWITCH CONFIGURATION Table 4-3 Typical UTS6H Circuit Setup with UPS Typical UTS Circuit Setup with UPS CIRCUIT I CIRCUIT 2 CIRCUIT 3 CIRCUIT 4 CIRCUIT 5 CIRCUIT 6 Other (condensate pump) Sump pump Boiler Computer Security System Refrigerator Source GEN EITHER GEN EITHER EITHER GEN Delayable Yes Yes No Yes Yes Yes Max time off (min) 30 1 30 5 60 30 Min time on (min) 30 2 30 5 60 15 Security Mode Off Off Off Off Off Off Amp Rating(A) 1
5 - COMPATIBLE ROOM THERMOSTATS 5.1 freewatt Hydronic Zone Thermostat Requirements: Select heat or heat/cool thermostat with following properties, except Zone-2. Zone 2 must use HAI Smart Zone Thermostat. • Use isolated relay contacts to switch W call for heat signal. freewatt expects 24VAC “HOT” connected to thermostat’s “R” terminal to pass directly thru thermostat’s W relay to drive “W” signal back with minimal loss of signal voltage when calling for heat.
6 - freewatt TRANSFER SWITCH MODEL FTS-1.8 6.1 freewatt Transfer Switch Model FTS-1.8 • freewatt Transfer Switch provides freewatt PLUS product line with reliable means of providing backpower to critical loads while preventing electrical feedback to utility from MCHP. • freewatt Transfer Switch is specifically designed for use with freewatt PLUS micro-combined heat and power (micro-CHP) system. • freewatt PLUS provides backup power up to 1.
7 - BEFORE INSTALLING THE SYSTEM 7.1 Codes 7.2 System Sizing And Application See boiler manual for information pertaining to installation in State of Massachusetts. • Select system with proper capacity before continuing installation. Firing rate of system should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by system. See Section 2 for system ratings.
7 -BEFORE INSTALLING THE SYSTEM • Advise owner to keep venting and combustion air intake passageways free of obstructions. Both venting and combustion air intake piping systems connected to outdoors must permit flow through piping systems without restrictions for system to operate. 7.3 Considerations for System Location Before selecting location for system, following should be considered. Each system component considered for installation must be: • Supplied with correct type of gas.
7 -BEFORE INSTALLING THE SYSTEM 7.6 Condensate Drain Requirements 7.9 Requirements for Hydro-air Applications: • Install condensate drain lines with pitch down to floor at minimum of ¼” per foot. • Application of freewatt PLUS with Hydro-Air System Air Handler as Smart Zone requires Smart Zone Air Handler be of type powered with ECM blower motor. • External condensate pump (not furnished) may be used if floor drain is not available. One condensate pump can be used for both boiler and MCHP.
8 - PLACING THE SYSTEM 8.1 Place system to provide direct connections to: CAUTION Penetration or modifications of MCHP cabinet will result in potential electrical or fire hazard. Do not attach controls, wire, piping, conduit or other hardware to MCHP unit. • combustion air/vent piping system, • natural gas piping, • return and supply duct-work, • condensate removal system, • Place HONDA MCHP on base and secure MCHP unit to base with supplied hardware after base installed. See Figure 8-1.
8 - PLACING THE SYSTEM • Figure 8-2 shows freewatt PLUS distribution piping schematic for system zoned with zone valves for heating zones and priority pump for indirect water heater zone. Configuration of heating zones, boiler and MCHP heat sources shown is mandatory for proper operation of freewatt PLUS System. 8.3 freewatt PLUS System Piping • Place equipment in proper locations. • Configure system piping to connect boiler and HONDA MCHP to distribution piping.
8 - PLACING THE SYSTEM NOTICE 8.4 Design Tips • Install bottom of Hydronic HI Module at height of 32” to 42” above floor elevation where HONDA MCHP installed. Use only long life coolant supplied with freewatt PLUS System. Use of any other coolant will void warranty. System will not operate properly and permanent damage to Hydronic HI Module or HONDA MCHP may occur if followings steps are not followed. • Maximum 10ft. length of ½” Onix coolant tubing connecting Hydronic HI module and MCHP.
8 - PLACING THE SYSTEM Figure 8-4 MCHP Coolant Line Installation Instructions Figure 8-5 LLC Out Connection to HHI Module (BPHX) Figure 8-8 Female Swivel Fitting (NPT by IPS) using tubing clamp. • Long Life Coolant In Tubing Installation: [Pump to MCHP; Figure 8-6] • Cut section of Onix Tubing to extend from MCHP unit’s lower Coolant connection to coolant pump in HI Module. • Install barbed end of elbow (barb x IPS) fitting into open tube end of tubing and secure with SelfTite clamp.
8- PLACING THE SYSTEM 8.8 HHI Module to Distribution Manifold Figure 8-9 HI Module to Distribution Manifold Piping • Follow industry standards when installing distribution manifold. • Install MCHP hydronic pump below manifold to prevent circulator from air locking. • Size tubing or piping connecting Hybrid HI module with distribution manifold ½” NPT or larger to provide adequate flow for transfer of heat from MCHP’s coolant into hydronic water.
8 - PLACING THE SYSTEM • freewatt PLUS boiler and MCHP unit will produce condensate at rates up to 2 ½ US quarts per hour. Make provisions to drain condensate away from both boiler and MCHP to ensure proper operation. Boiler is supplied with factory-installed drain trap assembly with ½” dia. Sch. 40 PVC connection. Figure 8-12 Heat Rejection Connections to HHI Module (BPHX) • Install MCHP condensate line directly into condensate pump, located directly behind MCHP unit, if floor drain is not available.
8 - PLACING THE SYSTEM • Expand ECR control using appropriate ECR expansion relay controls if additional zones are needed. • All Onix and brass fitting surfaces must be clean and dry before making connection. • Avoid making connections or splices in inaccessible locations. • Two air handlers with circulators can be accommodated through use ECR ARH-3 control. • Repairing Onix having been in service in freewatt PLUS System requires special attention.
9 - EXHAUST GAS LEAK SENSOR • Figure 9-1 shows connections to Exhaust Gas Leak Sensor. Exhaust Gas Sensor will automatically stop operation of MCHP unit upon detection of potentially dangerous levels of carbon monoxide gas regardless of source of carbon monoxide gas. 9.1 EGLS Introduction • Exhaust Gas Leak Sensor System in addition to separate, independently installed and operating UL approved Carbon Monoxide Detector having audible alarm.
9 - EXHAUST GAS LEAK SENSOR NOTICE NOTICE Exhaust Gas Sensor’s cable connections must be installed properly or Hydronic freewatt PLUS System will not initialize and not operate (ERROR – 14 or 15 Flashes). 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. For more instructions on connecting Exhaust Gas Leak Sensor SEE MCHP IOM. 4.
10 - COMBUSTION AIR AND VENT PIPE • 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, 2” to 3” pipe coupling must be used at boiler connections. MCHP vent connection size is 2”. 2” or 1-1/2” vent size is permitted. Refer to freewatt PLUS Boiler Installation, Operation and Maintenance Manual and MCHP IOM for specific venting instructions. ! WARNING Read, understand and follow all instructions.
10 - COMBUSTION AIR AND VENT PIPE NOTICE Figure 10-1 Install boiler per Direct Venting requirements. Install MCHP per Non-Direct Venting Requirements. Distinction is noted to ensure proper location of vent terminations. Min. Separation 12” 3” Max Separation • Clearance from bottom of termination to grade shall be 12” or increased to maintain 12” above anticipated accumulated snow level.
11 - GAS SUPPLY PIPING CAUTION Table 11-1 Gas Supply Pressures Units cannot operate properly or safely using fuels outside normal commercial standards. Connect boiler and HONDA MCHP units only to gas supplied by commercial utility or supplier. Private gas wells do not generally provide gas with consistent, uniform and predictable heating values and densities. Many non-commercial wells contain impurities such as sulphur, which may damage furnace or HONDA MCHP. Gas tyoe Minimum (in. w.c.) Nominal (in.
12 - ELECTRICAL WIRING & CONNECTIONS ! WARNING Figure 12-1 Typical freewatt PLUS Control Module Configuration Electric shock hazard. For your safety, turn off electrical power supply at service panel before making any electrical connections. Failure to do so can cause severe personal injury or death. 12.1 Codes Installation must comply with National Electrical Code, authority having jurisdiction, and in Canada, with CSA C22.1 Canadian Electrical Code and authority having jurisdiction.
12 - ELECTRICAL WIRING & CONNECTIONS • Route 120 VAC power wiring from service switch to ECR AR822-II and attach to 120 VAC power terminals. Figure 12-2 Boiler 120 VAC Connections (Refer to Electrical Schematic) • Route 120 VAC power wiring from junction / switch box to ECR ARM-6P (or AZ-6CP or ARH-3). Wiring can be routed through ½” offset nipple connector and into control module enclosure.
12 - ELECTRICAL WIRING & CONNECTIONS • External controls with their own 24VAC transformer may be used on zones 3-6. Steering relays can be used through freewatt control module jumpers JPZ3, JPZ4, JPZ5 and JPZ6 (for zones 3-6 respectively). These jumpers are located on the center of the freewatt control board. • IMPORTANT: “Priority Selection Switch” must be in “ON” position when “Zone/Valve Pump” Switch is in “ON” position.
12 - ELECTRICAL WIRING & CONNECTIONS 12.10 Honda MCHP Unit - Line Voltage Connections Figure 12-5 MCHP Connection Details • Refer to Honda MCHP Installation Manual – Electrical Connections Section before performing installation in this section. • Recommend Breaker: 2-pole; 15 Amp breaker. • Remove cover plate, install blanking plate, connect 240 VAC power cable to terminal block on Honda MCHP unit. Figure 12-5 and 12-10 and Honda MCHP IOM for details.
12 - ELECTRICAL WIRING & CONNECTIONS should not less than about 25% of total for building). Figure 12-9 Generator Warning Label • Connect thermostat cable to thermostat. Use Honeywell Genesis Cable, Model Number 22 AWG 10/C STR CM-CL2 (or equal) for HAI Smart Zone thermostat. Cable is 22 AWG, 10 Conductor, stranded cable meeting UL Standards 13 & 144, NEC Article 725. Refer to freewatt PLUS HAI thermostat Installation manual for additional thermostat connection and option details.
12 - ELECTRICAL WIRING & CONNECTIONS 12.15 MCHP Battery Installation Please see the Honda MCHP manual for installation of the MCHP battery. • Honda MCHP1.2D/MCHP1.2DP unit requires battery to provide power to start up in backup power mode. • Battery is provided for freewatt PLUS System, however to insure proper battery storage and charge level, battery is not packaged with system. • Battery must be ordered at time of installation from ECR Customer Service by freewatt dealer performing installation.
13 -COMMISSIONING AND STARTUP 13.1 For System 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 basic freewatt PLUS system sequence of operation.
14 - MAINTENANCE AND CLEANING • Coolant Level: Check coolant level in coolant tank and fill with coolant, if necessary. ! WARNING Disconnect electrical power supply to freewatt PLUS System before attempting any maintenance. Failure to do so can cause electrical shock resulting in personal injury or loss of life. • Mixing Valve: Check coolant temperature being delivered by valve while system is operating. Check for leaks and fix, if necessary. • Pump: Inspect pump and connections.
14 - MAINTENANCE AND CLEANING 14.2 1. Shutdown Procedure: Draining Procedure A. Preferred Method: Set thermostat to OFF by pressing Mode button until display reads OFF. Turn SYSTEM POWER switch to off after shut down cycle of approximately three minutes is completed. B. Emergency Method: Turn SYSTEM POWER and BYPASS switch to OFF. MCHP may overheat and flash error message due to coolant pump turning off. It may be necessary to drain system during maintenance operations.
15 - DETAILED SEQUENCE OF OPERATION 43
15 - DETAILED SEQUENCE OF OPERATION 44
15 - DETAILED SEQUENCE OF OPERATION • Operate domestic water heating zone without causing unacceptably high temperature in MCHP coolant. Boiler burner operation is disabled immediately upon end of call for heat. 15.1 MCHP Operation: • freewatt PLUS System is designed to preferentially provide heat to home and indirect water heater by operating MCHP unit.
15 - DETAILED SEQUENCE OF OPERATION 15.3 Achieving Best freewatt PLUS System Performance • Select Smart Zone and configure if necessary, so it represents at least 25% of total heat demand of home. Homeowner dollar, carbon dioxide emissions, and energy saving with freewatt PLUS is maximized by adjusting operating parameters of boiler and thermostat to achieve maximum preferential operation of MCHP unit (and minimum firing of boiler). Following steps will help in maximizing benefit of freewatt PLUS System.
16 - TROUBLESHOOTING • Only trained, experienced service technicians should service control systems. Follow “Sequence of Operation” for normal light off sequence after troubleshooting. ! WARNING Fire, explosion or risk of shock hazard may cause severe injury or death. Do not attempt to modify characteristics of this home heating appliance in any way. • If two consecutive controls appear to fail or appear defective, control is probaly not defective.
16 - TROUBLESHOOTING 16.3 Accessing freewatt PLUS System Operational Data and Codes ! WARNING Electrical shock hazard may cause serious injury or death. Avoid touching live electrical contacts. Service shall be performed by trained, experienced service technician. 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 on front of freewatt control module.
16 - TROUBLESHOOTING Hydronic freewatt PLUS System consists of eight major components: • Boiler, • freewatt Control Module, • Hydronic freewatt PLUS Hybrid Integration (HI) Module, • Honda MCHP, • freewatt HAI Thermostat, • freewatt Transfer Switch, • Load Balancing Transformer and 16.
16 - TROUBLESHOOTING Table 16-1 Alarm Codes for Service Required LED on freewatt Control Module ERROR INDICATES CHECK OR REPAIR CODE 1. CHP MODE SWITCH IN ON POSITION 2. CABLES AND CONNECTIONS BETWEEN THE THERMOSTAT AND THE HI MODULE 1 THERMOSTAT COMMUNICATIONS ERROR 3. LOWER FURNACE ACCESS PANEL INSTALLED 4. IMPROPERLY PROGRAMMED THERMOSTAT 2 1. CHECK OUTDOOR SENSOR AND CONNECTION OR INTERNAL 20k OHM DEFAULT RESISTOR OUTDOOR SENSOR ERROR 1.
16 - TROUBLESHOOTING 16.6 Control Board LED Interpretation Table 16-2 • Observe green LEDs on control board by removing cover of freewatt Control Module. • Control Board LEDs are valid only in Combined Heat and Power Mode (CHP Mode switch “ON”). They are not used when system is in Bypass Mode (CHP Mode switch “OFF”). • Do not use Control Board LEDs as indicator of system status when in Bypass Mode.
16 - TROUBLESHOOTING 16.6 freewatt PLUS System Fuses ! WARNING Do not jumper fuse. Replace specified as listed. Failure to comply could result in severe personal injury, or death. ! 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 comply could result in severe personal injury or death.
17 - PIPING AND WIRING SCHEMATICS 17-1 Piping Schematic Symbols CIRCULATOR (With Isolation Flanges) AIR SEPARATOR BALL VALVE 3 WAY MIXING VALVE PRESSURE REDUCER VALVE HEAT EXCHANGER BACKFLOW PREVENTER ZONE VALVE FLOW CHECK VALVE EXPANSION TANK BOILER DRAIN VALVE 53
17 - PIPING AND WIRING SCHEMATICS 17-2 Primary/Secondary Piping With Zone Valves and Domestic Hot Water Priority Circulator 54
17 - PIPING AND WIRING SCHEMATICS 17-3 Primary/Secondary Piping With Circulators and Domestic Hot Water Priority Circulator 55
17 - PIPING AND WIRING SCHEMATICS 17-4 Primary/Secondary Piping With Hydro-Air Handler and Domestic Hot Water Priority Circulator 56
17 - PIPING AND WIRING SCHEMATICS 17-5 HDJ - 240 VAC Wiring Only 57
17 - PIPING AND WIRING SCHEMATICS 17-6 HDJ - 120 VAC Wiring Only 58
17 - PIPING AND WIRING SCHEMATICS 17-7 HDJ - 120 VAC Wiring - Control Module & Zone Pumps 59
17 - PIPING AND WIRING SCHEMATICS 17-8 HDJ - 120 VAC Wiring - Control Module & Zone Valves 60
17 - PIPING AND WIRING SCHEMATICS 17-9 HDJ - 120 VAC Wiring - Control Module & Hydro Air 61
17 - PIPING AND WIRING SCHEMATICS 17-10 HDJ - Low Voltage Wiring Only 62
17 - PIPING AND WIRING SCHEMATICS 17-11 HDJ Low Voltage Only Wiring - Control Module and Zone Pumps 63
17 - PIPING AND WIRING SCHEMATICS 17-12 HDJ Low Voltage Only Wiring - Control Module & Zone Valves 64
17 - PIPING AND WIRING SCHEMATICS 17-13 HDJ Low Voltage Only Wiring - Control Module & Zone Valves with Expansion Zones 65
17 - PIPING AND WIRING SCHEMATICS 17-13 HDJ Low Voltage Only Wiring - Control Module & Hydro Air 66
17 - PIPING AND WIRING SCHEMATICS 17-14 MCHP Low Voltage Wiring 67
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