Heat Pipe Technology BKPOOL 300 Manuale del proprietario

MANUAL 8/12/05

INSTALLATION, OPERATION & MAINTENANCE

Commercial High Efficiency

Heat Pipe Dehumidifier

Model BKPOOLTM 300

Model BKPOOLTM 300-AC

Model BKPOOLTM 400

Model BKPOOLTM 400-AC

Model BKPOOLTM 500

Model BKPOOLTM 500-AC

Heat Pipe Technology, Inc.

6904 Parke East Blvd. Tampa FL 33610

Tel: (813) 470-4250

http://www.heatpipe.com

E-mail: [email protected]

Model BKPOOLTM 300, 300-AC, 400, 400-AC 500, 500-AC

INSTALLATION, OPERATION & MAINTENANCE

1. GENERAL DESCRIPTION

The BKPOOLTM s are commercial high efficiency dehumidifiers. They are radically different from other

dehumidifiers because of the proprietary heat pipe used to exchange heat between the warm intake air

and the cold air discharge from the evaporator. This process precools the incoming air and allows more

moisture to be condensed for less energy spent. The heat pipes are passive devices that use no energy.

The BKPOOLTM standard unit comes pre-charged with refrigerant. The BKPOOLTM AC model is shipped

in two sections which must be piped together, evacuated and then charged as a unit.

The BKPOOLTM AC models which are equipped with outdoor remote condensers have a cooling mode

to reject heat to the outdoors.

The BKPOOLTM comes with a dehumidistat and a thermostat for the unit with outside remote

condenser. Condensate water is removed by gravity drain. The unit comes with an intake and supply air

duct flanges. Pleated 2 in. air filters are standard and can be accessed through a separate cover from

either side of the unit.

2. INSPECTION

All HPT products are carefully tested and inspected prior to shipment. Each unit is in good working

condition when packaged. If the package is damaged in any way, check the contents immediately; note

damage on shippers Bill of Lading and have him/her sign your statement to insure prompt claim

processing. Notify the carrier immediately of the damage so he can come out and inspect the product

and packaging. The carrier alone is responsible for handling and settling your claim.

HPT will cooperate in assessing damage if unit is returned to the factory prepaid.

Unpack the unit. The following will be included: BKPOOLTM dehumidifier, dehumidistat, thermostat (for

the unit with outside remote condenser), user's manual and warranty card.

3. INSTALLATION

The BKPOOLTMs can be placed as a stand-alone unit in an environment such as above the ceiling or in a

mechanical room. The BKPOOLTMs are designed to operate in conditioned space with temperatures

ranging from 60°F to 95°F. Special factory options may be ordered for operation above or below these

limits.

3.1 DUCTING

The BKPOOLTMs can be used with suitable metal or fiberglass ducts using approved methods. The ducts

must be sized appropriately for the airflow listed. A good quality air filter of equal or larger size may be

installed in the inlet register and located for ease of maintenance. The duct must not add more than

0.5" E.S.P. inclusive of both supply and return ducts.

When the BKPOOLTM is used to handle outside fresh air, a branch of the intake can be ducted to outside.

The BKPOOLTM is designed to handle as much as 25% fresh air and will remove most of the moisture

from the air before admitting it to the building. Additionally, the supply dry air can be ducted or injected to

the supply duct of another air handler for the space, providing the back pressure from the other air

handler does not reduce the air flow through the BKPOOLTM . The blower of the main air handler may also

need to be interlocked to the BKPOOLTM so that the blower runs when the BKPOOLTM runs to distribute

the air. A back draft damper will also be needed for the BKPOOLTM to prevent the main AC from blowing

back through the BKPOOLTM when it is not running.

3.2 CONDENSATE DRAIN

The BKPoolTMs are supplied with a condensate gravity drain outlet. For the gravity drain, the pipe must

have a downward slope for the entire distance to the outside. If installed above the ceiling, the pipe must

be supported every 3 or 4 feet to prevent sagging. If the line has any level runs or dips, it will not drain

properly. Ensure that the drain line has a trap to prevent outdoor air from being aspirated into the

BKPoolTM and prevent draining. If the piping goes underground and back up outside, this is considered an

adequate trap. Do not double trap. This may prevent the condensate from draining due to the air pocket

between two traps. Due to the high static pressure across our dehumidifier coils, a 2 inch minimum trap is

required.

BKP BKP

Min. 2 in.

This will not drain!

Fig 3.2 Condensate trap

For installation above the ceiling or above the ground floor, it is recommended that the BKPOOLTM be

installed over a separate drain pan, which is piped to a separate drain point.

3.3 UNITS WITH A REMOTE CONDENSER

Install the remote condenser in an outdoor, well ventilated and preferably well shaded area. Ensure that

the hot air discharge is not obstructed. Install on a concrete pad or as required by local codes.

CAUTION: Coil is pressurized with a few PSI of nitrogen. Punch hole in copper to relieve pressure before

cutting off end to connect line.

3.4 CONDENSER PIPING

The BKPOOLTM with remote condenser is shipped with a holding charge of dry nitrogen. Release the

pressure before un-sweating the caps from the tubing connection. Connect the BKPOOLTM to the remote

condenser using refrigerant tubing of the sizes listed in Table BKPOOL01. The tubing needs not be

insulated except in exposed areas where the hot gas line might cause harmful burn. Solder the

connections with suitable silver brazing alloy and leak check. An additional Refrigeration charge will have

to be added to the nameplate charge depending on the liquid line size and length. See section 4.

Charging the BKPoolTM

Table BKPOOLTM 01

Model

300-AC 400-AC 500-AC

Liquid

3/8 3/8 3/8

Vapor

1/2 1/2 1/2

Note:

This BKPOOLTM -AC remote line sizing applies to most applications, up to 50 feet horizontal, and within 10 feet

vertical (ACR OD line sizes).

3.41 Long Line Sets (50 ft or Longer)

For line sets where there are no vertical sections greater than 10 ft. and for lengths up to 150 ft. increase

the vapor line one size larger but leave the liquid line size as is. Also add 4 extra ounces of refrigerant oil

(3GS or Equivalent) to the system for every 50 ft. over 50 ft.

3.42 Vertical Line Sets

When the BKPOOLTM -AC remote condenser is installed either on a roof above the BKPOOLTM Unit, or on

the ground where the BKPOOLTM unit is on an upper floor or attic, special consideration needs to be taken

to insure that Oil will return to the compressor. Unlike a split system air conditioner, the compressor is in

the indoor unit.

If the remote condenser is above the indoor unit, special P-Traps need to be installed in the vapor line at

the bottom of the vertical section and every 10 ft. above that. Small particles of oil that circulate with the

Vapor will accumulate in the traps until they are large enough to be carried up the pipe by the velocity of

the refrigerant. Vertical sections of tubing should not be enlarged beyond that specified in table

BKPOOL01. Pre-manufactured traps are available at the air conditioning supply houses or traps can be

made up using long radius ells of the same size as the tubing.

If the remote condenser is below the indoor unit no special changes are necessary. The oil will travel

down hill with the vapor to the condenser and return with the liquid refrigerant to the indoor unit.

Fig 3.42 P-Traps must be added to vertical lines over 10 ft. where remote condenser is higher

than the indoor unit.

10ft.

BKPool

Indoor Unit

Remote

Condense

Vapor Line

uid Line

Trap

4. ELECTRICAL WIRING

CAUTION: Units with three phase compressors can be damaged by running backward. Verify

correct compressor rotation by observing refrigerant pressure gauges at startup. Little or no gauge

movement indicates reverse rotation. Reverse any two leads in the power junction box.

Note: Fan blower motor is single phase and not affected by lead connections.

4.1 Power Supply

Use properly sized wire. Install and connect unit in accordance with local codes. Unit must be grounded.

Size separate circuits to the BKPOOLTM and to the Remote Condenser.

4.2 24 VAC Control Wiring

Units Without Remote Condenser

A dehumidistat is supplied with the unit. It should be placed in the conditioned space away from heat

sources, entrance doors or any sources of humid air. Do not mount it directly on the side of the unit, as

the vibration may adversely affect it. Place the dehumidistat at a location where it could sense the

average relative humidity of the space.

The dehumidistat is of the 24 V type and should be wired with T-stat 18 gauge, 3 conductor low voltage

wire. (See wiring diagram in unit control panel.)

Units with Remote Condensers

For operation of units with a remote condenser, both temperature and humidity are controlled. A 24V

thermostat and a 24V dehumidistat are supplied with the BKPOOLTM AC. Wire the controls with

Thermostat 18 gauge low voltage wiring in accordance with the wiring diagrams.

NOTE: The operation of the remote condenser is by an internal pressure switch. No control wiring is

needed to the outdoor condenser.

5. CHARGING THE BKPOOLTM

The BKP™ is charged with refrigerant 22. The charge amount is listed on the nameplate. It is important to

have exactly the right charge in the unit or damage to the compressor or refrigerant components may

occur. Due to the wide range of operation of the BKP™ it is highly recommended that the charge be

weighed in to the ounce.

5.1 Standard Unit

Standard units (Non AC Models) are factory charged and ready to run after installation and wiring. If the

charge is in question, first, recover the refrigerant in the system and weigh in the proper charge. If it is

determined that the unit has a refrigerant leak, the leak must be repaired. Even though the unit appears to

operate, as the refrigerant level drops the compressor will over heat and be damaged before the condition

is recognized. Repair the leak and replace the liquid filter dryer. Evacuate the system using a Micron

Gauge down to 400 microns. Valve off the vacuum pump and insure the vacuum does not rise above 700

microns. Then weigh in the charge using a scale accurate to 1 once.

5.2 AC Units

The BKPoolTM AC model is shipped in two sections which must be piped together, evacuated and then

charged as a unit. Evacuate the refrigerant system to 400 microns or below. Valve off the vacuum pump

and insure the micron level does not increase above 700 microns. For BKPoolTM -AC units the system

must be evacuated from all three ports. This is due to the check valves used in the remote condenser. A

1/4 in. flair Tee and an extra refrigeration hose can be used to double up the discharge hose. Remove

the extra hose from the remote condenser tap after charging and before running the unit. Weigh in

the refrigerant charge using the suction and discharge ports. The proper charge of refrigerant 22 for the

unit and the remote condenser can be found on the nameplate. It is important to have the proper charge

of refrigerant. The preferred method of charging is to weigh in the charge from the nameplate with a

scale, which can be accurate to plus or minus one ounce. Additional refrigerant needs to be added for the

length of the line set. The liquid line (the smaller line) is full of liquid in both the heating and cooling

modes of operation. Measure the length of the line set one-way and add to the charge as follows:

3/8 in liquid line add 0.8 oz per foot

1/2 in liquid line add 1.5 oz per foot

5.3 Alternate Charging Method

NOTE: This method will only work if enough load can be maintained on the BKPTM that the suction

pressure does not fall below about 65 PSIG while charging. It will be necessary to fabricate a cover

out of cardboard the same size as the front cover (use the cover as a template) in which a small flap can

be cut for observing the sight glass. Do not run the unit without a cover in place. With the BKPTM

turned off, charge the unit with liquid until the unit can be run without shutting down on low pressure. Start

the unit in the heating mode and charge vapor into the low side port until the sight glass almost clears.

Run the unit for 15 minutes and then slowly add vapor until the sight glass just clears.

6. OPERATION

The dehumidistat controls the operation of the dehumidifier.

6.1 Units Without Remote Condenser

Set the dehumidistat at the desired level, the dehumidifier will run and remove humidity until the set

humidity is reached, at which time the dehumidifier will shut off. For normal operation, a range from 50%

to 60% will provide the best comfort. Settings below 50% will make the unit run longer and less

economical. Settings above 60% which may be required in certain situations will be more economical,

but may not provide adequate human comfort.

6.2 Units with Remote Condensers

The BKPOOLTM-AC with remote condenser is designed to control space temperature as well as humidity.

Therefore, they are controlled by both a dehumidistat and a thermostat. This design allows the

BKPOOLTM-AC to switch from normal operation to remote condenser operation automatically when extra

cooling is needed in the space. In the remote condenser mode, the BKPOOLTM-ACs dehumidify and

provide additional cooling to the space at the same time.

The thermostat should be set 2 to 3°F below the setting on the building thermostat so that the BKPOOLTM

operation will not interfere with the operation of the building A/C. The latter will continue to cycle on and

off to maintain the building temperature. When the building A/C cycles off, with the lower thermostat

setting, the BKPOOLTM continues to run in the thermostat cooling mode until the temperature drops to its

onset point. The BKPOOLTM then shifts to its normal mode, discharging dry warm air.

When the temperature rises to its thermostat set point, the BKPOOLTM again shifts to the additional

cooling mode. Therefore, it will cycle back and forth to maintain the inside temperature at its set point and

the building A/C will not cycle on unless the temperature has risen up to the building's higher thermostat

set point. In this manner, the building A/C cycles on only when the cooling by the BKPOOLTM is not

sufficient. When the relative humidity is down to the desired setting, the BKPOOLTM -AC will shut off and

the building will be back to its normal A/C operation.

During the wintertime when the space must be heated, the BKPOOLTM thermostat should be set 2 to 3

degrees above the main heating thermostat. This will use the BKPOOLTM normal dehumidifying operation

mode to provide additional heating to supplement the building's heating system. It will continue in this

mode until its dehumidistat is satisfied.

NOTE: The BKPOOLTM is not designed to cool when the outdoor temperature is below 50°F.

Refrigerant Migration will occur and the unit will shut down on low pressure.

7. MAINTENANCE

It is essential that the air filter on the inlet of the unit be kept clean in order to prevent excessive power

consumption and possible damage to the unit. Check the filters routinely to determine the frequency of

replacement.

Keep the outdoor remote condenser free of leaves and grass clippings which may impede air flow.

Check condensate drain regularly to ensure that the condensate is draining properly. If installed with an

auxiliary drain pan under the unit, check that it is dry.

It is recommended that the BKPOOLTM be serviced annually by an authorized HPT certified technician to

provide maximum efficiency and insure long life equipment.

8. SERVICE DIAGNOSIS

The BKPOOLTM is equipped with safety controls which will shut down the unit if a problem occurs. The

BKPOOLTM will remain locked out until it is reset.

If The Unit Locks Out:

1. Check the air filter in the inlet of the unit. A dirty air filter will cause an increase in power consumption

and in the long run may cause damage to the unit.

2. Check the remote condenser. If the air is blocked or the hot air discharge is not free to dissipate, a

high discharge pressure will result and may cause damage to the BKPOOLTM.

3. Check the power supply to the remote condenser. It will be on a separate breaker and if tripped will

cause the BKPOOLTM to shut down.

4. Check refrigerant charge as described above.

To reset the BKPOOLTM

Reset the BKPOOLTM by either turning the humidistat all the way up and then back down or turning the

power to the BKPOOLTM off and then on. Allow 5 minutes for the BKPOOLTM to restart. If it locks out

again after restart, have the unit serviced by a qualified service technician to determine the cause of the

shutdown and correct the problem. See Troubleshooting section below.

9. SEQUENCE OF OPERATION FOR STANDARD UNIT

The BKPOOLTM is controlled, on or off, by a dehumidistat which senses the relative humidity of the space.

The BKPOOLTM is shipped with a remote mounted De-Humidistat. The AC models also have a

Thermostat. Both are designed to be used with a duct system having a total external static of 0.5 in H2O

or less.

(SEE WIRING DIAGRAM) On a call for dehumidification the contact in the dehumidistat is made sending

control power through the safety shutdown switches, through the lockout relay and to the blower relay.

Control power is also sent through a recycle time delay to the compressor contactor.

The safety shutdowns consist of a high and low refrigerant pressure cutout. If either of these cut-outs

open, the current path from the dehumidistat to the contactor is shifted through the coil of the lock-out

relay. The normally closed contact in the lockout relay opens and the normally open contact closes,

essentially shorting across the coil of the compressor contactor and providing full control voltage to the

lockout relay coil.

The contactor will remain off as long as the lockout relay receives voltage from the dehumidistat. Turning

the dehumidistat up and then back down, mechanically opens the contact in the dehumidistat, dropping

the power from the lockout relay.

After reset, voltage can now go through the normally closed contact of the lockout relay to the

compressor contactor and blower relay, provided the safety shutdown has cleared. Control power to the

contactor will be resumed through the off-cycle time delay when the machine has been off for the

selected number of minutes (factory set to 5 minutes for single phase units 3 minutes for 3 phase units).

The refrigerant system is a R-22 (Chlorodifluoromethane) system consisting of a compressor, condenser

coil, sight glass, filter dryer, Thermal expansion valve, and an evaporator with dehumidifier heat pipes.

The coil section contains both the evaporator and condenser coils. The airflow enters through the precool

heat pipe then through the evaporator then the reheat heat pipe and the condenser.

9.1 Remote Condenser Units

The BKP-ACTM series operates similar to the standard unit except that it has a liquid receiver and

employs a separate outdoor condenser. Since the standard unit discharges air through the condenser

coil, the discharge air temperature will always be warmer than the inlet air and can reach temperatures

above 100F. The BKPool-ACTM unit, on the other hand has an outdoor condenser as well an indoor

condenser.

These units use a separate remote mounted thermostat along with the dehumidistat to control the BKP-

ACTM. The dehumidistat operates the unit on and off as described above. The thermostat controls a

reversing valve that diverts the refrigerant flow between the indoor and outdoor condensers. When the

temperature is below the set point, the valve sends the refrigerant through the indoor condenser. This

has the effect of warming the space temperature. When the temperature is above the set point the valve

sends the refrigerant through the outdoor condenser. The BKPool-ACTM then acts as an air conditioner,

bringing the space temperature back down. The BKPool-ACTM will switch back and forth between indoor

and outdoor condenser until the dehumidistat is satisfied.

The thermostat gets its control power from the red wire going to the dehumidistat. On a drop in

temperature, the thermostat contact sends control power directly to the reversing valve coil.

The outdoor condenser is powered from a separate power supply. No control voltage wiring is

connected. A head pressure switch inside the outdoor condenser controls the fan. The fan comes on

when the pressure in the outdoor coil reaches 240 psig and shuts off when it drops below 190 psig.

The refrigerant flows from the compressor to the reversing valve inlet. In the de-energized state the flow

is sent to the indoor condenser. The line going to the outdoor condenser is internally connected to the

reversing valve's center suction port, which is connected to the suction line coming out of the evaporator

by a 3/16" tube. This tube has a check valve installed in it. Any refrigerant in the outdoor condenser will

be pulled back through this 3/16" tube as the compressor runs. A check valve in the leaving liquid line of

the outdoor condenser prevents refrigerant from being pulled backward through the condenser coils.

When the reversing valve shifts to the outdoor condenser the indoor condenser is connected to the

suction by the 3/16" line. The indoor coil also has a check valve in the liquid line out.

The 3/16" line to the suction header provides a smoother transition when shifting. A hissing sound for 10

to 20 seconds is normal while the machine equalizes after shifting.

The BKP-ACTM also has a liquid receiver in the common liquid line.

If the BKPool-ACTM is installed in an application where it may need to run in the winter when outdoor

temperatures will be below freezing, special provisions need to be made in the installation. An outdoor

thermostat must be installed to prevent the BKPool-ACTM from shifting to the outdoor mode when

temperatures are below 50°F. If the unit is allowed to shift to the outdoor condenser when the

temperature is below that of the evaporator temperature, the compressor will not be able to pull the

refrigerant back when it shifts to the indoor coil and the unit will shut down on low pressure. A check

valve in the liquid line and in the small suction return line prevent refrigerant from migrating to the outdoor

coil during cold whether, while the unit operates in the Heating Mode.

9.2 OPTIONAL EQUIPMENT

9.21 Phase Loss Monitor for Three Phase Units

Units with a Phase loss monitor are provided with fuses which feed the phase loss monitor and the

control transformer. The monitor has an adjustable setting for operating voltage which determines the trip

settings. This voltage must be set at startup to the measured line voltage. This monitor samples the

voltage between all three phases and closes a set of normally open contacts when the voltage and phase

rotation is correct A red LED lights up to indicate the contact is closed. The contact will open if line

voltage on any phase drops by 10% of the adjusted line voltage setting or an unbalance of 4% occurs

between phases. The contact will open to drop the 24 V control power to the control system.

9.22 Cooling Priority Relay

Units with a cooling priority relay will energize the BKPoolTM in the cooling mode on a call for cooling from

the thermostat even if the dehumidistat is satisfied. Control voltage from the thermostat to the reversing

valve is used to energize the cooling relay. Normally open contacts 2 and 4 close to supply control power

directly from the transformer to the yellow wire coming from the dehumidistat. When the thermostat is

satisfied, the BKPoolTM will shut down again.

is used to energize the cooling relay. Normally open contacts 2 and 4 close to supply control power

directly from the transformer to the yellow wire coming from the dehumidistat. When the thermostat is

satisfied, the BKPool-ACTM will shut down again.

10. SPECIFICATIONS

BKPoolTM 300, 400, 500

Models 300 400 500

Capacity (lbs/day) at

85°F & 60% RH (AHAM) 302 422 532

Capacity (lbs/day) at

80°F & 50% RH (ASHRAE) 214 299 377

Air Flow Rate (cfm) 700 1000 1200

Operating Range All models can operate from 60°F/100% RH to 95°F/55% RH

Dimensions (WxHxD) (in.) 45 x 22 x 24 45 x 22 x 29 45 x 22 x 34

Net Weight (lbs) 250 300 350

Filter Size (WxHxD) (in.) 16 x 20 x 2 16 x 25 x 2 2 - 16 x 16 x 2

Electrical (60 Hz)*

Voltage/Phase 208/230 V/ 1 ph 208/230 V/ 1 ph 208/230 V/ 1 ph

Max. Fuse or HACR Circuit Breaker (A) 30 40 45

Min. Circuit Ampacity (A) 20 26 29

Normal Operating Power (W) 2500 W 3000 W 3500 W

Compressor Scroll Scroll Scroll

Blower Motor Power (hp) 1/3 1/2 3/4

Condensate Pumps Optional Optional Optional

BKPoolTM 300-AC, 400-AC, 500-AC

Models (Outdoor Unit) 300-AC 400-AC 500-AC

Dimensions (WxHxD) (in.) 24 x 25 x 20 24 x 25 x30 24 x 25 x 30

Net Weight (lbs) 65 95 95

Air Flow Rate (cfm) 800 1800 1800

Electrical (60 Hz)*

Voltage/Phase 208/230 V/1 ph 208/230 V/1 ph 208/230 V/1 ph

Fan Motor 1/4 1/4 1/4

Normal Operating Power (W) 350 W 350 W 350 W

*50 Hz models available on custom order.

265V and 460V also available on custom order

Specifications subject to change without notice.

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