ClimateMaster DC Series Unit installation

Ultra Classic (VT) Series
Residential Vertical
Two-Stage Geothermal
Heat Pumps
Installation, Operation &
Maintenance Instructions
69197343
Revision: 07/07/05D
TABLE OF CONTENTS
Model Nomenclature
2
ECM Fan Control
14
Storage
2
ECM Blower Data
16
Pre-Installation
3
Electrical - Low Voltage
16
Physical Data
3
Freeze Protection Selection
16
Physical Dimensions
4
Water Valve Wiring
17
Unit Installation
5
Thermostat Wiring
17
Duct System
5
Electrical Wiring Schematic
18
Water Connections
6
CXM Control Description
19
Condensate Drain
6
Troubleshooting Information
22
Ground Loop Application
7
Troubleshooting Analysis
23
Flushing
7
Major Replacement Components
24
Antifreeze
8
Unit Start-Up Procedure
26
Open Loop/Well Water Installation
9
Operating Limits
26
Water Quality Standards
10
Pressure Drop Table
28
Hybrid Loop/Well Applications
10
Operating Pressures 28
Hot Water Generator
11
Warranty
31
Electrical - Line Voltage
13
Preventive Maintenance
BC
Electrical Data
13
GENERAL INFORMATION
Model Nomenclature
1
2
3
4
5
6
7
8
9
10
11
12
13 14
15
V T 0 3 6 G S S S L T D A S J
SERIES:
VT=ULTRACLASSICVERTICAL
SIZE:
REVISIONCODE:
J=CURRENTREVISIONSIZE036
H=CURRENTREVISIONSIZES042-072
036
042
048
060
072
S=STANDARD
VOLTAGE:
HEATEXCHANGEROPTIONS:
G=208V,230V/1PH/60Hz
A=COPPERWATERCOIL,E-COATEDAIRCOIL
B=COPPERWATERCOIL,
W/HOTWATERGENERATOR,E-COATEDAIRCOIL
J=CUPRO-NICKELWATERCOIL,E-COATEDAIRCOIL
K=CUPRO-NICKELWATERCOIL,
W/HOTWATERGENERATOR,E-COATEDAIRCOIL
CONTROLS:
SSS=CXMw/ECM
AIRFLOWCONFIGURATION:
LT=LEFTRETURN,TOPDISCHARGE
RT=RIGHTRETURN,TOPDISCHARGE
CABINET:
D=RESIDENTIALCLASS
Inspection
Rev.:04/15/04D
Storage
Upon receipt of the equipment, carefully check the
shipment against the bill of lading. Make sure all units
have been received. Inspect the carton or crating of
each unit, and inspect each unit for damage. Assure
the carrier makes proper notation of any shortages or
damage on all copies of the freight bill and he completes
a common carrier inspection report. Concealed damage
not discovered during unloading must be reported to the
carrier within 15 days of receipt of shipment. If not filed
within 15 days, the freight company can deny the claim
without recourse. Note: It is the responsibility of the
purchaser to file all necessary claims with the carrier.
Notify the ClimateMaster Customer Service of all damage
within fifteen (15) days of shipment.
Introduction
ClimateMaster UltraClassic Geothermal Heat Pump units
are typically installed in a floor level closet, basement,
or in a small mechanical room. The installation site
chosen for these units must allow adequate clearance for
maintenance and servicing of the unit without its removal
from the installation location.
CAUTION: DO NOT store or install units in
corrosive environments or in locations subject to
temperature or humidity extremes (e.g., attics,
garages, rooftops, etc.). Corrosive conditions and
high temperature or humidity can significantly
reduce performance, reliability, and service life.
Always move units in an upright position. Tilting
units on their sides may cause equipment damage.
Equipment should be stored in its shipping carton in a
clean, dry area. Store units in an upright position at all
times. Stack vertical units a maximum of 2 units high. DO
NOT remove equipment from shipping cartons until
equipment is required for installation.
Unit Protection
Cover units on the job site with either shipping cartons,
vinyl film, or an equivalent protective covering. Cap the
open ends of pipes stored on the job site. In areas where
painting, plastering, or spraying has not been completed,
all due precautions must be taken to avoid physical
damage to the units and contamination by foreign material.
Physical damage and contamination may prevent proper
start-up and may result in costly equipment cleanup.
Examine all pipes, fittings, and valves before installing
any of the system components. Remove any dirt or trash
found in or on these components.
Page Ultra Classic (VT) Series
Pre-Installation
GENERAL INFORMATION
Installation, operation and maintenance instructions
are provided with each unit. Before unit start-up, read
all manuals and become familiar with the unit and its
operation. Thoroughly check the system before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate
with ordering and shipping information to verify the
correct unit has been shipped.
2. Keep the cabinet covered with the shipping carton
until installation is complete and all plastering,
painting, etc., is finished.
3. Verify refrigerant tubing is free of kinks or dents and
that it does not touch other unit components.
4. Inspect all electrical connections. Connections must
be clean and tight at the terminals.
Remove Fan Motor shipping bracket in rear of
Air Handler compartment.
To avoid equipment damage, DO NOT use these
units as a source of heating or cooling during the
construction process. The mechanical components
and filters used in these units will quickly become
clogged with construction dirt and debris which
may cause system damage.
To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit
must be serviced only by technicians who meet
local, state and federal proficiency requirements.
All refrigerant discharged from this unit must be
recovered WITHOUT EXCEPTION. Technicians
must follow industry accepted guidelines and all
local, state and federal statutes for the recovery
and disposal of refrigerants.
If a compressor is removed from this unit,
system refrigerant circuit oil will remain in the
compressor. To avoid leakage of compressor oil,
the refrigerant lines of the compressor must be
sealed after it is removed.
The installation of geothermal heat pump units and all
associated components, parts and accessories which
make up the installation shall be in accordance with
the regulations of ALL authorities having jurisdiction
and MUST conform to all applicable codes. It is the
responsibility of the Installing Contractor to determine and
comply with ALL applicable codes and regulations.
VTPhysicalData
Table 1: Physical Data
MODEL
FanWheel(Dia.XWidth),in.
036
9X7
FanMotor&HP
ECM-1/2
Compressors
2-Rotary
No.RefrigerantCircuits
No.CoaxialHeatExchangers
2
2
042
048
060
11X10
ECM-1/2
2
2
ECM-1
2-Scroll
072
11X10
2
2
2
2
ECM-1
2-Scroll
2
2
R-22Charge(SysA/SysB),oz
40/40
57/59
62/62
54/54
58/58
AirCoilLengthxHeight,in.
20X24
24X24
24X32
24X36
24X36
Filter-1"ElectroStatic(Std.)
24x24
27x31
27x31
27x35
27x35
235
285
315
395
WaterConnectionSize(fptswivel)
Weight-Operating(lbs.)
Weight-Packaged(lbs.)
1"
225
1"
275
1"
305
385
1"
450
460
Rev.:8/07/04D
Allunitshavetxvexpansiondevices,20gasheetmetal,
and7/8"&1-1/8"electricalknockouts.
Allunitshavedual1"Swivelwaterconnections(4total)
HWGutilizes1/2"fptwaterconnectionsandisavailableonlyoncircuitA.
Allunitshave3/4"fptcondensatedrainconnections.
Ultra Classic (VT) Series
Revision
1"
Page Date
INSTALLATION
Physical Dimensions
������
�
�
�
�
�
�
�
�
�
��
����������������������������������������������������
����������������������������������������������������
�����������������������������������������������������
�����������������������������������������������������
���������������������������������
��������������������������������������������������
���������������������������������������������������
�������������������������������������������������
���������������������������������������������
������������������������������������
���������������
�������������
���
���
���
���
��������������������
��������������������
������������������������
��������������������������
�����������������
��������������������
��������������������
�����������������������±��������
�����
�
�
�
�
�
�����
�����
������
������
�����
������
�����
��
�� ���
���
������
��
��
���
���
������ �� ���
���
������ �� ���
��
��
���
���
������ �� ���
��
���
���
���
������ �� ���
��
���
���
����
�� ���
�� ���
���
����
�� ���
�� ���
���
����
�� ���
�� ���
���
����
�� ���
�� ���
���
����
�������� ��������
���
���
�
���
���
���
���
�����
���
�����
��
�����
������
� ���
�
�
���
�����
������
���
����
���
�������
�� ���
�� ���
�
�
� ���
�
�
������
�����
������
������
� ���
�
�
��
���
��
���
��
���
���
���
���
���
��
��
���
���
� ���
� ���
� ���
� ���
� ���
�� ���
�� ���
� ���
�
�
� ���
�� ���
�� ���
���
�� ���
�� ���
���
���
��
���
��
���
��
���
���
���
���
��
��
���
���
�
� ���
�� ���
� ���
� ���
� ���
� ���
� ���
� ���
�� ���
�� ���
� ���
�
�
� ���
�� ���
�� ���
���
���
���
��
���
��
���
��
���
���
���
���
���
��
��
���
���
�� ���
�
� ���
�� ���
� ���
� ���
� ���
� ���
� ���
� ���
�� ���
�� ���
� ���
�
�
� ���
�� ���
���
���
���
��
���
��
���
��
���
���
���
���
���
��
��
���
���
�
� ���
�� ���
� ���
� ���
� ���
� ���
� ���
� ���
�� ���
�� ���
� ���
�
�
� ���
�� ���
�� ���
���
���
���
��
���
��
���
��
���
���
���
���
���
��
��
���
����
���
���
���
���
Page �
�
� ���
������������������������������������������������������������������������������������������������������������������������
������������������������������������
��������
����
�������������������
��������
������������������������������������������
�������
����������������������������������������������
������
����������������������������������������
��������
� ���
�����������������
������������������������������±��������
�
���
��
� ���
�
�� ���
��
� ���
�
���
���
� ���
�
� ���
��
��
�
�
�������� �������� � ���
���
�
���
�������� �������� � ���
���
�
� ���
��
�
�
�
�������� �������� � ���
���
�
��
�������� �������� � ���
���
�
��������������������
�������������������
Ultra Classic (VT) Series
���
����������������
General Unit Location
INSTALLATION
Figure 1a: Vertical unit mounting
Locate the unit in an indoor area that allows easy removal
of the filter and access panels, and has enough space
for service personnel to perform maintenance or repair.
Provide sufficient room to make water, electrical and duct
connection(s). If the unit is located in a confined space,
such as a closet, provisions must be made for return air to
freely enter the space by means of a louvered door, etc.
Any access panel screws that would be difficult to remove
after the unit is installed should be removed prior to
setting the unit. These units are not approved for outdoor
installation and, therefore, must be installed inside the
structure being conditioned. Do not locate in areas where
ambient conditions are not maintained with 40-100°F and
up to 75% relative humidity.
Vertical Units Location and Access
Vertical Units are typically installed in a floor level
closet, basement, or in a small mechanical room. Install
units with adequate clearance to allow maintenance and
servicing. Conform to the following guidelines when
selecting unit location:
1. Provide adequate clearance for filter replacement and
drain pan cleaning. Do not block filter access with
piping, conduit or other materials. Refer to the unit
catalog for Vertical Unit Dimensions.
2. Provide access for fan and fan motor maintenance
and for servicing the compressor and coils without
removing the unit. Note: UltraClassic compressor
and refrigerant circuit service requires that left
side access be provided.
3. Provide an unobstructed path to the unit within the
closet or mechanical room. Space should be sufficient
to allow removal of the unit, if necessary.
4. Provide access to water valves and fittings and
screwdriver access to the unit side panels, discharge
collar and all electrical connections.
Setting Vertical Units
Vertical units are available in left or right air return
configurations. Vertical units should be mounted level on
a vibration absorbing pad or extruded polystyrene slightly
larger than the base to provide isolation between the unit
and the floor. It is not necessary to anchor the unit to the
floor (see Figure 1a).
Duct System
A field installed air outlet bracket is provided on vertical
units to facilitate duct connection. A flexible connector
is recommended for both discharge and return air duct
connections on metal duct systems. Uninsulated duct
should be insulated with a minimum of one-inch duct
insulation. Application of the unit to uninsulated ductwork
in an unconditioned space is not recommended as the
unit’s performance will be adversely affected.
Air Pad or extruded
polystyrene
If the unit is connected to existing ductwork, a previous
check should have been made to assure the ducts have the
capacity to handle the air required for the unit. If ducting
is too small, as in the replacement of heating only systems,
larger ductwork should be installed. All existing ductwork
should be checked for leaks and repaired as necessary.
The duct system should be sized to handle the design
airflow quietly. To maximize sound attenuation of the unit
blower, the supply and return plenums should include
internal duct liner of glass fiber or be of ductboard
construction for the first few feet. If air noise or excessive
air flow is a problem, the airflow can be changed. See the
Blower Performance and Fan Speed sections for further
instruction (See Page 14).
Air Coil
To obtain maximum performance, the air coil should be
cleaned before start-up. A 10% solution of dishwasher
detergent and water is recommended for both sides of
coil, a thorough water rinse should follow.
Water Connections
The UltraClassic Heat Exchanger water connections are
swivel piping fittings that accept a 1" Male Pipe Thread
(MPT) connector. The swivel connector has a rubber
gasket seal similar to a garden hose gasket, which when
mated to the flush end of any 1" threaded pipe provides a
leak-free seal without the need for thread sealing tape or
compound. Check to insure that the rubber seal is in the
swivel connector prior to attempting any connection. (The
rubber seals are shipped attached the swivel connector.) DO
NOT OVERTIGHTEN or leaks may occur.
Never use flexible hoses smaller than 1" inside diameter
on the unit and limit hose length to 10 ft. per connection.
Check carefully for water leaks. Figure 3 shows a
manifold being used in an earth loop application. Flow
(pressure drop) and temperature measurements in the
configuration will represent the total flow going through
both coaxes regardless of which refrigerant circuits are
active. Figure 4 illustrates a well system using individual
connections. Flow and temperature measurements will
represent each refrigerant circuit.
Ultra Classic (VT) Series
Page INSTALLATION
Internallyinsulatesupply
ductforfirst4’[1.2m]each
waytoreducenoise
Useturningvanesin
supplytransition
Flexiblecanvasduct
connectortoreduce
noiseandvibration
Roundedreturn
transition
run. When some sagging in the condensate line may be
anticipated (as in a long line of plastic pipe) or when
“double trapping” may occur. Also vent when large units
are working against higher external static pressure that
other units connected to the same condensate main since
this may cause poor drainage for all units on the line.
Figure 3: Loop Piping using a manifold
P/TPlugs
Internallyinsulatereturn
transitionducttoreduce
noise
Rev3/27/00
To make the connection to a ground loop system, mate
the brass loop connection against the rubber gasket in
Internallyinsulatesupply
the swivel connector, and thread the femaleductforfirst4’eachway
locking
toreducenoise
ring onto the pipe threads, while maintaining the brass
Useturningvanesin
supplytransition
connector in the desired direction (see Figure
2). Tighten
the connectors by hand to provide a leak proof joint.
When connecting to an open loop (ground Flexiblecanvasduct
water) system,
connectortoreduce
thread any 1" MPT fitting (PVC or copper)noiseandvibration
into the swivel
connector and tighten in the same manner as noted above.
The open and closed loop piping system must
include
Roundedreturn
transition
pressure/temperature taps for serviceability.
����������
���������
����������
Internallyinsulatereturn
����
transitionducttoreduce
noise
Optional
Accessory
Manifold
Figure 4: Well Piping using a individual connections
������������
�����
������
�������������
Rev.:11/2/00
������
��������
Figure 5: Typical drain connection
�������������
Figure 2: The Female Locking Ring is threaded onto
the pipe threads which holds the male pipe end against
the gasket, and seals the joint. HAND TIGHTEN
ONLY! DO NOT OVERTIGHTEN!
Condensate Drain
Each unit utilizes a condensate hose inside the cabinet as
a trapping loop, therefore an external trap is not necessary.
Figure 5 shows typical condensate connections.
Each unit must be installed with means to flush or
blowout the condensate drain line. Do not install units
with a common trap and/or vent.
Install a vent in the condensate line of any application
which may allow dirt or air to collect in the line. Always
vent when the application requires a long, horizontal
Page Ultra Classic (VT) Series
Piping Installation
GROUND LOOP APPLICATION
Flushing the Earth Loop
The typical closed loop ground source system is shown
in Figure 10. All earth loop piping materials should be
limited to only polyethylene fusion in inground sections
of the loop and galvanized or steel fitting should not be
used at any time due to their tendency to corrode. All
plastic to metal threaded fittings should be avoided as well
due to their potential to leak in earth coupled applications
and a flanged fitting substituted. P/T plugs should be used
so that flow can be measured using the pressure drop of
the unit heat exchanger in lieu of other flow measurement
means. Earth loop temperatures can range between
25-110°F and 2.25 to 3 gpm of flow per ton of cooling
capacity is recommended in these applications. Upon
completion of the ground loop piping, pressure test the
loop to assure a leak free system.
Horizontal Systems: Test individual loops as installed.
Test entire system when all loops are assembled.
Vertical U-Bends and Pool Loop Systems: Test Vertical Ubends and pond loop assemblies prior to installation with
a test pressure of at least 100 psi.
Table 2: Approximate Fluid Volume (gal.) per 100' of Pipe
Pipe
Size
Volume
Copper
1"
4.1
1.25"
6.4
1.5"
9.2
Rubber Hose
1"
3.9
3/4" IPS SDR11
2.8
1" IPS SDR11
4.5
1 1/4" IPS SDR11
8.0
Polyethylene
1 1/2" IPS SDR11
10.9
2" IPS SDR11
18.0
1 1/4" IPS SCH40
8.3
1 1/2" IPS SCH40
10.9
2" IPS SCH40
17.0
Unit Heat Exchanger
Typical
1.0
Flush Cart Tank
10" diam x 3 ft
10.0
Once piping is completed between the unit, flow center
and the ground loop (Figure 10), final purging and
charging of the loop is needed. A flush cart (at least a 1.5
hp pump) is needed to achieve adequate flow velocity
in the loop to purge air and dirt particles from the loop
itself. Antifreeze solution is used in most areas to prevent
freezing. All air and debris must be removed from the
earth loop piping system before operation. Flush the loop
with a high volume of water at a high velocity (2 fps
in all piping), both directions. The steps below must be
followed for proper flushing. Fill loop with water from
a garden hose through flush cart before using flush cart
pump to ensure an even fill. Once full, do not allow the
water level in the flush cart tank to drop below the pump
inlet line or air can be pumped back out to the earth
loop. Try to maintain a fluid level in the tank above the
return tee so that air can not be continuously mixed back
into the fluid. 50 psi surges can be used to help purge
air pockets by simply shutting off the return valve going
into the flush cart reservoir. This "dead heads" the pump
to 50 psi. To purge, dead head the pump until maximum
pumping pressure is reached. Open the return valve and a
pressure surge will be sent through the loop to help purge
air pockets from the piping system. Notice the drop in
fluid level in the flush cart tank. Note: If air is purged
from the system, the level will drop only 1-2 inches in
a 10" diameter PVC flush tank (about a half gallon)
since liquids are incompressible. If the level drops
more than this, flushing should continue since air is still
being compressed in the loop fluid. Do this "dead head"
procedure a number of times.
When the fluid level is dropping less than 1-2" in a 10"
diameter tank the flow can be reversed. Finally the dead
head test should be checked again for an indication of
air in the loop. Note: This fluid level drop is your only
indication of air in the loop.
Table 3: Antifreeze Percentages by Volume
Methanol
Type
100% USP food grade Propylene Glycol
Minimum Temperature for Freeze Protection
10°F
25%
38%
15°F
20°F
30% 22%
21%
Ultra Classic (VT) Series
16%
25°F
10%
15%
Page GROUND LOOP APPLICATION
Antifreeze may be added before, during or after the
flushing procedure. However, depending upon which time
is chosen, antifreeze could be wasted when emptying the
flush cart tank. See antifreeze section for more details.
Loop static pressure will fluctuate with the seasons.
Pressures will be higher in the winter months than during
the cooling season. This fluctuation is normal and should
be considered when charging the system initially. Run the
unit in either heating or cooling for a number of minutes
to condition the loop to a homogenous temperature. This
is a good time for tool cleanup, piping insulation etc. Then
final flush and pressurize the loop to a static pressure of
40-50 psi (winter) 15-20 psi (summer).
loop temperature would be 25-22°F and freeze protection
should be at 15°F (30°F-15°F=15°F). All alcohols should
be premixed and pumped from a reservoir outside of the
building when possible or introduced under water level
to prevent fuming. Initially calculate the total volume
of fluid in the piping system using Table 2. Then use the
percentage by volume shown in Table 3 for the amount
of antifreeze. Antifreeze concentration should be checked
from a well mixed sample using a hydrometer to measure
specific gravity. See Flow Controller IOM for more
information.
After pressurization, be sure to remove the plug in the end
of the Grundfos loop pump motor(s) to allow trapped air
to be discharged and to insure the motor housing has been
flooded. This is not required for Taco circulators. Insure
the loop flow center provides adequate flow through the
unit by checking pressure drop across the heat exchanger
and comparing it to the figures shown in Table 12.
When an antifreeze is selected, the FP1 jumper (JW3)
should be clipped to select the low temperature
(Antifreeze 10°F) setpoint to avoid nuisance faults. See
Freeze Protection Selection. Valves should be included
in case of servicing. Boiler drains or other valves should
be "tee’d" in the line to allow acid flushing of just the
heat exchanger. Pressure temperature plugs should be
used so that flow and temperature can be measured. The
water freezestat should be wired. Piping materials should
be limited to PVC SCH80 or copper. Note: Due to the
pressure and temperature extremes, PVC SCH40 is
not recommended.
Antifreeze
In areas where minimum entering loop temperatures
drop below 40°F or where piping will be routed through
areas subject to freezing, anti-freeze is needed. Alcohols
and glycols are commonly used as antifreezes, however
your local territory manager should be consulted for the
antifreeze best suited to your area. Freeze protection
should be maintained to 15°F below the lowest expected
entering loop temperature. For example, if 30°F is the
minimum expected entering loop temperature, the leaving
Freeze Protection Setting
CXM or DXM Control:
Figure 10: Typical Closed Loop System.
Page Ultra Classic (VT) Series
Water Quality
OPEN LOOP - WELL WATER SYSTEMS
Water quality should be plentiful and of good quality.
Table 4 shows recommended water quality guidelines.
The unit can be ordered with either a copper or cupronickel water heat exchanger. Copper is recommended for
closed loop systems and open loop ground water systems
that are not high in mineral content or corrosiveness.
In conditions anticipating heavy scale formation or
in brackish water, a cupro-nickel heat exchanger is
recommended. In ground water situations where scaling
could be heavy or where biological growth such as
iron bacteria will be present, a closed loop system is
recommended. Heat exchanger coils may over time
lose heat exchange capabilities due to a build up of
mineral deposits inside. These can be cleaned only by a
qualified service mechanic as acid and special pumping
equipment are required. Note: Desuperheater coils can
likewise become scaled and possibly plugged. In areas
with extremely hard water, the home owner should
be informed that the heat exchanger may require
occasional acid flushing.
Expansion Tank
Use a closed, bladder-type expansion tank to minimize
mineral formation due to air exposure. The expansion
tank should be sized to handle at least one minute run
time of the pump to prevent premature pump failure using
its drawdown capacity rating. The pump should be sized
to the home’s domestic water load (5-9 gpm) plus the
heat pump water load. Discharge water from the unit is
not contaminated in any manner and can be disposed of
in various ways, depending on local building codes, i.e.
recharge well, storm sewer, drain field, adjacent stream
or pond, etc. Most local codes forbid the use of sanitary
sewer for disposal. Consult your local building and zoning
department to assure compliance in your area.
Figure 11: Typical Well Water/Open Loop System
Water Control Valve
Note the placement of the water control valve. Always
maintain water pressure in the heat exchanger by placing
water control valves at the outlet of the unit to prevent
mineral precipitation. Pilot operated slow closing valve’s
solenoid valves are recommended to reduce water
hammer. If water hammer persists, a mini-expansion tank
can be mounted on the piping to help absorb the excess
hammer shock. Insure that the total "VA" draw of the
valve can be supplied by the unit transformer. For instance
the slow closing valve can draw up to 35VA. This can
overload smaller 40 or 50 VA transformers depending
on the other controls employed. A typical pilot operated
solenoid valve draws approximately 15VA. Note the wiring
diagram in Figure 20.
Flow Regulation
Flow regulation can be accomplished by two methods.
Most water control valves have a flow adjustment built
in. By measuring the pressure drop through the unit heat
exchanger flow rate can be determined and compared
to Table 9. Since the pressure is constantly varying two
pressure gauges might be needed. Simply adjust the
water control valve until the desired flow of 1.5 to 2 gpm
per ton is achieved. Secondly a flow control device may
be installed. The devices are typically an orifice that is
designed to allow a specified flow rate. These are mounted
on the outlet of the water control valve. On occasion these
valves can produce a velocity noise that can be reduced
by applying some back pressure. This is accomplished
by slightly closing the leaving isolation valve of the well
water setup.
Freeze Protection Setting
CXM or DXM Control:
When well water is used, the FP1 jumper (JW3) should
NOT be clipped, but should be left in the factory position
of water setting (30°F). See Freeze Protection Selection.
Ultra Classic (VT) Series
Page Table 4: Water Quality Standards
����������
��������������
�����������
�������������
�������������
��������
��������������������������������������������������������������������
��������������������������������������������������������������������������������
���������������
������������������
������������������� ��������
���������������������������
�������
��
�����������������������������������
�������
��
����������������
�������
��
������������������
�������
����
�����������������������������������
��������������
�
���������������������������������������������������������������������������������
�����������������������������������������������������������������������������
����������������������������������������������������������������������������������������������
HYBRID GROUND LOOP/WELL WATER SYSTEMS
The UltraClassic dual refrigerant circuits with individual
water connections for each, allows each refrigerant
circuit to utilize a different ground source and benefit
from a dramatically shortened earth loop as illustrated in
Figure 12. For instance a 4 ton unit can utilize a 2.5 ton
earth loop on circuit 1 and well or city water on circuit 2.
The earth loop is used as first stage with the well or city
water source used as the second circuit. Using the well
as second stage greatly reduces the amount of earth loop
required and limits the well or city water usage.
Note: City water rates should be examined for feasibility
before installation. City water should not be used as a
source in areas where water temperatures fall below
45°F. ClimateMaster should be consulted when sizing
earth loops for this application because of the increased
runtime on the earthloop. Traditional loop sizing will
be inadequate and can result in poor performance and
possibly complete failure of the system.
Pete's plugs should be installed on both systems to
facilitate servicing. Standard water flows can be utilized
on each circuit 2.25 - 3 gpm /ton for earth loops and 1.52 per ton well/city water. Each circuit should have the
appropriate freezestat setting. Be sure circuit A is Earth
Loop and circuit B is Well setting or City. The Ground
Loop and Well System sections should be consulted for
further details.
Figure 12: Typical Hybrid Loop/Well system
Page 10
Ultra Classic (VT) Series
HOT WATER GENERATOR
The HWG (Hot Water Generator) or desuperheater option
provides considerable operating cost savings by utilizing
excess heat energy from the heat pump to help satisfy
domestic hot water requirements. The HWG is active
throughout the year, providing virtually free hot water
when the heat pump operates in the cooling mode or hot
water at the COP of the heat pump during operation in the
heating mode. Actual HWG water heating capacities are
provided in the appropriate heat pump performance data.
All Climate Master heat pumps equipped with the
HWG option include a built-in water to refrigerant heat
exchanger to eliminate the need to open and tie into the
heat pump’s refrigerant circuit in the field. The control
circuit is also built in. The concentric fitting is optional.
Figure 14 is a typical example of HWG water piping
connections on an UltraClassic unit with a built-in pump.
Using a concentric or coaxial hot water tank connection
fitting eliminates the need to tie into the hot water tank
cold water piping. (see Figure 16)
Typically a single tank of at least 52 gallons is used
to limit installation costs and space. However, a dual
tank, as shown in Figure 15, is the most efficient system
providing the maximum storage and temperate source
water to the desuperheater. Using a concentric hot water
tank connection fitting eliminates the need to tie into
the hot water tank water piping. In high liming areas
(hardness>100ppm or 6 grains per gallon) the alternative
piping scheme in Figure 16 may be used to eliminate the
Figure 14: Typical UltraClassic HWG Installation
possible scaling of the smaller cross-sectioned area of
the concentric fitting. It is always advisable to use water
softening equipment on domestic well water systems
to reduce the liming potential and lengthen equipment
life. In extreme water conditions, it may be wise to not
use the HWG option since the probable cost of frequent
maintenance may offset or exceed any savings.
Installation
The HWG aquastat is set at 125 °F and is located on the
HWG heat exchanger “Water In” line. If the HWG is
connected incorrectly or if circulation is reversed, the
aquastat will sense leaving water temperature and prevent
HWG operation. UNDER NO CIRCUMSTANCES
DISCONNECT OR REMOVE THE HWG AQUASTAT!
Full load conditions could drive hot water tank
temperatures far above desirable temperature levels if the
aquastat has been disconnected or removed.
The heat pump, water piping, pump, and hot water tank
should be located where the ambient temperature does not
fall below 50 °F. Keep water piping lengths at a minimum
– DO NOT use a one way length greater than 50 feet.
All installations must be made in accordance with local
codes. The installer is responsible for knowing the local
requirements, and for performing the installation accordingly.
ColdInlet
Domestic
ColdSupply HotOutlet
tohome
Shut-offValvewithWaste
Ventathighpoint
Upper
elementto
120 - 130°F
Shut-offValve
Powered
Water
Heater
Insulatedwaterlines5/8”OD50ftmaximum
Ultra Classic (VT) Series
Lower
elementto
100-110°F
Teeanddrain
Page 11
HOT WATER GENERATOR
Figure 15: UltraClassic HWG Double Tank Installation
Hot Outlet to
house
Shut Off Valves with Waste
Vent at high point
Hot Outlet
Cold Inlet
Cold Inlet from
Domestic supply
Upper element to 130°F
(or owner preference)
serve the most energy. On tanks with both upper and
lower elements and thermostats, the lower element
should be turned down to 100°F or lowest setting,
while the upper element should be adjusted to 120°F.
Depending upon the specific needs of the customer,
you may want to adjust the upper element differently.
On tanks with a single thermostat, lower the thermostat setting to 120°F or the “LOW” position.
6. Replace access cover(s) and restore power or fuel supply.
Powered
Lower element to 120°F
Water Heater
Unpowered
Water Heater
Initial Start-Up
1. Make sure all valves in the HWG water circuit are
full open.
2. Turn on the heat pump and allow it to run for 10-15 minutes.
Field Supplied 3/4” brass nipple and “T”
Insulated water lines - 5/8” OD
50 ft maximum
Water Tank Preparation
1. Turn off power or fuel supply to the hot water tank.
2. Connect a hose to the drain valve on the water tank.
3. Shut off the cold water supply to the water tank.
4. Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank.
5. In an existing tank, once drained the tank should be
flushed with cold water until the water leaving the
drain hose is clear and free of sediment.
6. Close all valves and remove the drain hose.
3. Turn the heat pump and heat pump power supply
“OFF” and CONNECT POWER TO THE HWG
PUMP as shown in Figure 17. On units with the internally mounted pump, connect the pump power lead
as instructed on the lead tag.
4. The HWG pump should not run if the compressor is
not running.
5. The temperature difference between the water entering and leaving the HWG coil should be approximately 10°F.
6. Allow the unit to operate for 20 to 30 minutes to
ensure it is functioning properly.
Figure 16: Alternate UltraClassic HWG Piping
7. Install HWG water piping.
HWG Water Piping
1. Using at least 5/8" O.D. copper, route and install the
water piping, valves and air vent as shown in Figures
14, 15, or 16. When used, the air vent MUST be at
the high point of the HWG water piping.
2. Insulate all HWG water piping with no less than 3/8"
wall closed cell installation.
3. Open both shut off valves and make sure the tank
drain valve is closed.
Water Tank Refill
1. Open the cold water supply to the tank.
2. Open a hot water faucet to vent air from the system
until water flows from the faucet, then close.
3. Depress the hot water tank pressure relief valve
handle to ensure there is no air remaining in the tank.
4. Inspect all work for leaks.
5. Before restoring the power or fuel supply to the water
heater, adjust the temperature setting on the tank
theremostat(s) to ensure maximum utilization of the
heat available from the refrigeration system and conPage 12
Ultra Classic (VT) Series
ELECTRICAL-LINE VOLTAGE
All field installed wiring, including electrical ground,
must comply with the National Electrical Code as well as
all applicable local codes.
WARNING
To avoid possible injury or death due to
electrical shock, open the power supply
disconnect switch and secure it in an open
position during installation.
Refer to the unit wiring diagrams for fuse sizes and a
schematic of the field connections which must be made by
the installing (or electrical) contractor.
WARNING
Consult the unit wiring diagram located on the inside of the
compressor access panel to ensure proper electrical hookup.
CAUTION: Use only copper conductors for field
installed electrical wiring. Unit terminals are not
designed to accept other types of conductors.
All final electrical connections must be made with a
length of flexible conduit to minimize vibration and sound
transmission to the building.
�������������
Table 5: Electrical Data
����������
�����
�����
���
�����
���
���
���
���
���
���
����
�����
�������
���
���
���
�����
�����
����
����
���
�������
����
����
����
�������
��
���
����
����
����
��������
���
���
���
����
������������
���
���
��
���
��
���
���
���
���
����
����
��
��
��
��
���
����
��
����
��
���
���
���
���
����
����
��
��
�
��
���
����
��
����
��
���
���
���
���
����
����
��
��
�
���
���
����
��
����
��
���
���
���
���
����
����
��
��
�
���
���
����
��
����
��
���
���
���
���
����
����
��
��
�
���
����������������������������������������
�������������������������������������
������������������������������������������������
�����������������������������������������������������������������������������������������°��������������������
���������������
General Line Voltage Wiring
Be sure the available power is the same voltage and
Figure
17: Line Voltage Field Wiring
��������
����
phase
as that shown on the unit serial plate. Line and
������������������������
��������
Pump
low
voltage wiring must be done in accordance with
�������������������������������������������������������������������������������
�������
Circt Brkr
local codes or the National Electric Code, whichever is
applicable.
Unit Power Connection
Transformer
Line voltage connection is made by connecting the
incoming line voltage wires to the “L” side of the
contactor as shown in Figure 16. Consult Table 5 for
correct wire and fuse size.
Compressor A
Contactor
with ground
(see Elect. Table for wire
and Brkr. size)
PR
External Loop Power Connection
Source Pump
L1
L2
Ground
HWG
Blk
Yellow
208 Volt Operation
ICM2
Controller
Install HWG Pump
Power after insuring
water is in HWG circuit
CXM Control - B
HWG Pumping Wiring
Low Voltage
Connector
All 208-230 Volt units are factory wired for 230 Volt.
The transformers may be switched to 208V operation as
illustrated on the wiring diagram.
CXM Control - A
External Loop Pump(s)
208-230/60/1
4 Amp Max.
Low Voltage
Connector
If the unit is to be used with an external loop pump, the
pump(s) will be connected to the loop pump terminals in
the unit electrical box as shown in Figure 17. The pumps
will automatically be cycled as required by the unit.
Compressor B
Contactor
Install HWG Pump power wires on HWG Pump power
block after insuring water is in HWG circuit.
Ultra Classic (VT) Series
Page 13
ECM Fan Motor
Fan speeds are selected with jumpers for version
I or via a nine position DIP switch for version II. To
take full advantage of the ECM motor features, a
multi-stage thermostat should be used (2-stage
heat/2-stage cool or 3-stage heat/2-stage cool).
Note: Power must be off to the unit for at least three
seconds before the ECM motor will recognize a
speed change. The motor will recognize a change
in the CFM Adjust or dehumidification mode
settings while the unit is powered.
There are four different airflow settings from lowest
airflow rate (speed tap 1) to the highest airflow rate
(speed tap 4). The charts below indicate settings for
both versions of the ECM interface board, followed
by detailed information for each setting.
Cooling settings: The cooling setting determines
the cooling (normal) CFM for all units with ECM
motor. Cooling (normal) setting is used when the
unit is not in dehumidification mode. This setting
also determines the heating CFM for Genesis (GS)
units. Tap 1 is the lowest CFM setting, while tap 4 is
the highest CFM setting. To avoid air coil freeze-up,
tap 1 may not be used if the dehumidification mode
is selected. Consult submittal data or specifications
catalog for the specific unit series and model to
correlate speed tap setting to airflow in CFM.
Heating settings: The heating setting determines
the heating CFM for Tranquility 27™ (TT) and
Tranquility 20™ (TS) units. This setting is not used
for Genesis (GS) units. Tap 1 is the lowest CFM
setting, while tap 4 is the highest CFM setting.
Consult submittal data or specifications catalog
for the specific unit series and model to correlate
speed tap setting to airflow in CFM.
Auxiliary/Emergency Heat settings: The auxiliary/
emergency heat setting determines the CFM when
the unit is in auxiliary heat or emergency heat
mode. This setting is used for residential units with
internal electric heat. When auxiliary electric heat
is energized (i.e. compressor and electric heat), the
greater of the auxiliary/emergency or heating setting
will be used. A “G” (fan) signal must be present from
the thermostat for electric heat to operate. Consult
the submittal data or specifications catalog for the
specific unit series and model to correlate speed tap
setting to airflow in CFM.
“fine tune” airflow adjustments. The TEST setting
runs the ECM motor at 70% torque, which causes
the motor to operate like a standard PSC motor, and
disables the CFM counter.
Dehumidification Mode settings: The
dehumidification mode setting provides field
selection of humidity control. When operating in
the normal mode, the cooling airflow settings are
determined by the cooling tap setting above. When
dehumidification is enabled there is a reduction in
airflow in cooling to increase the moisture removal
of the heat pump. Consult submittal data or
specifications catalog for the specific unit series and
model to correlate speed tap to airflow in CFM. The
dehumidification mode can be enabled in two ways.
1. Constant Dehumidification Mode: When the
dehumidification mode is selected (via DIP
switch or jumper setting), the ECM motor will
operate with a multiplier applied to the cooling
CFM settings (approx. 20-25% lower airflow).
Any time the unit is running in the cooling mode,
it will operate at the lower airflow to improve
latent capacity. The “DEHUM” LED will be
illuminated at all times. Heating airflow is not
affected. NOTE: Do not select dehumidification
mode if cooling setting is tap 1.
2. Automatic (Humidistat-controlled)
Dehumidification Mode: When the
dehumidification mode is selected (via DIP
switch or jumper setting) AND a humidistat
is connected to terminal DH (version II) or
HUM (version I), the cooling airflow will only
be reduced when the humidistat senses that
additional dehumidification is required. The DH
(or HUM) terminal is reverse logic. Therefore, a
humidistat (not dehumidistat) is required. The
“DEHUM” LED will be illuminated only when the
humidistat is calling for dehumidification mode.
Heating airflow is not affected. NOTE: Do not
select dehumidification mode if cooling setting is
tap 1.
CFM Adjust settings: The CFM adjust setting
allows four selections. The NORM setting is the
factory default position. The + or – settings adjust
the airflow by +/- 15%. The +/- settings are used to
Page 14
Ultra Classic (VT) Series
ECM Fan Motor
Table 6: ECM Board Tap Settings
Coolingsettings:TT,TS,GSunits*
VersionII
VersionI
17B0019N01
69243707
DIPSwitch
Tap
HP CFM
Setting
Jumper
SW1
SW2
1
1
ON
ON
2
2
ON
OFF
3
3
OFF
ON
4
4
OFF
OFF
Heatingsettings:TT,TSunits*
*GSunitsusethesamesettingsfor
bothcooling(normal)CFMandheatingCFM.
*ThistablenotusedforGSunits.
CFMAdjustsettings:TT,TS,GSunits
VersionII
VersionI
17B0019N01
69243707
DIPSwitch
Tap
CFM Adj
Setting
Jumper
SW7
SW8
TEST
1
ON
ON
2
ON
OFF
+
3
OFF
ON
NORM
4
OFF
OFF
DehumModesettings:TT,TS,GSunits
VersionII
VersionI
17B0019N01
69243707
DIPSwitch
Tap
Dehumid
SW9
Setting
Jumper
ON
NORM
pins1,2
Dehumid
pins2,3
OFF
Tap
Setting
1
2
3
4
Figure 18a: ECM Version II Interface Layout
Y2
O
W
G
G
G
R
Figure 18b: ECM Version I Interface Layout
Thermostat
InputLEDs
C
G
TB1
Y1 Y2
1/4"Spade
Connections
toCXMor
DXMBoard
A
L
O
W1 EM C
Thermostat
InputLEDs
R
CFMCounter
1flashper100CFM
LED's
CFM
J01
6
TB01
1 2 3 4 5
Y
ECMMotor
LowVoltage
Connector
Norm
(+)
(–)
Test
4
3
2
1
CFM
Adjust
Aux
CFM
Hum
7 8 9 10
Y2 Y1 G O W1 EM NC C R
CFM
CFMCounter
1flashper100CFM
ECMMotor
LowVoltage
Connector
Dehumidification
LED
4
3
2
1
4
3
2
Norm 1
1 2
HP
CFM
Delay
2 3
Dehumid
J1
DEHUM
AL1
S1
SW1
SW2
SW3
SW4
SW5
SW6
SW7
SW8
SW9
OFF ON
G
A
Dehumidification
LED
Y2 Y1 G O W C R DH AL1 A
Thermostat
Connections
Thermostat
Connections
A L
Y1
G
*Residentialunits
A L
G
R
1/4"Spade
Connections
toCXMor
DXMBoard
Aux/EmergHeat settings:TT,TS,GSunits*
VersionII
VersionI
17B0019N01
69243707
DIPSwitch
Tap
AUX CFM
Setting
Jumper
SW5
SW6
1
1
ON
ON
2
2
ON
OFF
3
3
OFF
ON
4
4
OFF
OFF
VersionII
17B0019N01
DIPSwitch
SW3
SW4
ON
ON
ON
OFF
OFF
ON
OFF
OFF
VersionI
69243707
DELAY
Jumper
1
2
3
4
FanSpeedSelectionJumpers
FanSpeedSelectionDIPSwitch
Ultra Classic (VT) Series
Page 15
ECM BLOWER DATA
Table 7: Blower performance table and fan speed selection
Model
Max
ESP
(inwg)
Fan
Motor
(hp)
036
0.5
1/2
042
0.5
1/2
048
0.75
1
Tap
Setting
4
3
2
1
4
3
2
1
4
3
2
1
NormalMode
DehumidMode
Htg&NormalClg
Stg2
Stg1
Fan
Stg2
Stg1
Fan
1290
1200
1110
1020
1450
1400
1300
1190
1720
1600
1480
1360
710
660
610
560
800
770
720
660
950
880
810
750
650
600
560
510
730
700
650
600
860
800
740
680
1010
940
870
550
520
480
650
600
560
1130
1090
1010
620
600
560
730
700
650
1340
1250
1150
740
690
630
860
800
740
4
2150
1180
1080
1680
920
1080
3
2000
1100
1000
1560
860
1000
2
1850
1020
930
1440
800
930
1
1700
940
850
4
2250
1280
1130
1760
1000
1130
072
0.75
1
3
2130
1210
1070
1660
940
1070
2
2000
1140
1000
1560
890
1000
1
1900
1080
950
Boldfiguresindicatefactorysettings,settingonallmodels.
These values represent Left return models. For right return units move the CFM adj from (norm) to the (+) setting.
DuringAuxiliaryoperationtheCFMwillrunatthehigheroftheHPorAUXsettings.
Airflowiscontrolledwithin±5%uptoMaxESPshownwithwetcoilandwith1"throwawayfilter.
Standard1"electrostaticfilterwilladd0.15inwgwhenclean.
WhenDehumidificationmodeisselected,HPCFMsettingmustbe4,3,or2only.
AllunitsARI/ISO/ASHRAE13256-1ratedatmaximumexternalstatic.
060
0.75
1
Aux
CFM
Setting
4
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
Aux
Emerg
Mode
1290
1200
1110
1020
1450
1400
1300
1190
1720
1600
1480
1360
2150
2000
1850
1700
2250
2130
2000
1900
Rev.:07/06/05D
Electrical - Low Voltage
Revision
Date
Thermostat
Connections
DatafromTomNorth9/00
10/31/04 RRB
NewdatafromT North added right return note adj. 072 numbers
3/31/05 RRB
The
thermostat should be wired directly to the ECM
Changed042w/AuxHeattomatchnormal2ndstagefromTNorth
5/12/05 RRB
control board as shown in Figure 19. Consult the
Thermostat section for specific wiring.
Figure 19: Low Voltage Field Wiring
Pump
Circt Brkr
Compressor A
Contactor
Compressor B
Contactor
with ground
(see Elect. Table for wire
and Brkr. size)
Source Pump
The CXM/DXM control allows the field selection of
source fluid freeze protection points. The factory setting
of FP1 is set for water (30°F). In earth loop applications
jumper JW3 (FP1- antifreeze 10°F) should be clipped as
shown in Figure 20 to change the setting to 10°F, a more
suitable temperature when using antifreezes in colder
earth loops.
Air Coil Freeze Protection - FP2
Transformer
PR
Water Freeze Protection - FP1
Figure 20: Changing FP1-Freeze Protection Setpoint
L1
L2
The Air coil freeze protection is factory set at 30°F and
should not need adjusting.
Ground
HWG
Blk
Yellow
CXM Control - A
Low Voltage
Connector
External Loop Pump(s)
208-230/60/1
4 Amp Max.
ICM2
Controller
Install HWG Pump
Power after insuring
water is in HWG circuit
CXM Control - B
Low Voltage
Connector
Clip this JW3-FP1
jumper for anti-freeze
systems
CXM PCB
Page 16
Ultra Classic (VT) Series
Electrical - Low Voltage
Accessory Connections
Thermostat Selection and Wiring
A terminal paralleling the compressor contactor coil
have been provided on the CXM/DXM control of the
UltraClassic line. "A" has been provided to control
accessory devices, such as water valves, electronic air
cleaners, humidifiers, etc. Note: This terminal should
be used only with 24 Volt signals and not line voltage
signals. This signal operates with the compressor contactor.
See Figure 21 or the wiring schematic for details.
ATA32H01 - Auto Changeover electronic 3 Heat / 2
Cool thermostat
Figure 21: Accessory Wiring
��������������
�
�����
�
�������
�����
�����
This electronic thermostat, Fig 23, is suited to all UltraClassic applications.
The UltraClassic also employs an ECM board that features:
• Thermostat terminal connections
• Thermostat signal diagnostic LED's
• Airflow selection
• Airflow LED (100 cfm per flash)
• Dehumidification Mode Jumper
Figure 23: ATA32H01 wiring
����������
Water Solenoid Valves
When using solenoid valves on ground water installations.
Figure 21 illustrates a typical well water control valve
wiring which will limit wasted water during a lockout
condition. A slow closing valve may be required to
prevent water hammer. When using an AVM -Taco
Slow Closing valves on UltraClassic Series equipment
Figure 20 wiring should be utilized. The valve takes
approximately 60 seconds to open (very little water will
flow before 45 seconds) and it activates the compressor
only after the valve is completely opened (by closing
its end switch). Only relay or triac based electronic
thermostats should be used with the AVM valve. When
wired as shown, the valve will operate properly with the
following notations:
��������
��
��
��
��
��
��
�
�
�
���
�
�
�
�
�
�
�
��
����
������������������������������
1 - The valve will remain open during a unit lockout.
2 - The valve will draw approximately 25-35 VA through the “Y” signal of the thermostat. Note: This can overheat the anticipators of electromechanical thermostats. Therefore only relay or triac based thermostats should be used.
Figure 22: Well Water AVM Valve Wiring
C
Y
UltraClassic
2
3
AVM
TacoValve
Y
Heater Switch
C
1
Thermostat
Ultra Classic (VT) Series
Page 17
Electrical Schematic
Page 18
Ultra Classic (VT) Series
CXM Control Description
Features
Retry Mode - If the control is attempting a retry of a fault,
the status LED will slow flash (slow flash = one flash
every 2 seconds) to indicate the control is in process of
retrying.
• Anti-short cycle protection
• High and Low pressure cutouts
• Water Coil freeze protection
Note: In the following field configuration options,
jumper wires should be clipped ONLY when power is
removed from the CXM control.
• Air Coil freeze protection
• Random Start
• Over/Under Voltage protection
Water Coil Freeze Protection Limit Setting - Jumper
2 (JW3-F12 Low Temp) provides field selection of
temperature limit setting for FP1 to be 30°F or 10°F.
• Diagnostic LED
Not Clipped = 30°F. Clipped = 10°F.
• Reset Lockout at unit or disconnect
• Condensate Overflow sensor
Air Coil Freeze Protection Limit Setting - Jumper
3 (JW2-FP2 Low Temp) provides field selection of
temperature limit setting for FP2 to be 30°F or 10°F.
• Test Mode
Not Clipped = 30°F. Clipped = 10°F.
• Electric Heat Outputs
Alarm Relay Setting - Jumper 1 (JW1-AL2 Dry) provides
field selection of Alarm Relay terminal AL2 to be
jumpered to 24Vac or to be dry (no connection).
• Unit Performance Sentinel
• Intelligent Reset
• Accessory Water Valve Connection
• Optional LonWorks Control
Not Clipped = AL2 connected to R. Clipped = AL2 dry
contacts (no connection).
Field Selectable Inputs
Test Mode - Test Mode allows the service personnel to
check the operation of the control in a timely manner. By
momentarily shorting the test terminals, the CXM control
enters a 20 minute Test Mode period in which all time
delays are sped up 15 times. Upon entering Test Mode, the
Status LED will flash a code representing the last fault.
For Diagnostic ease at the thermostat, the alarm relay will
also cycle during test mode. The Alarm relay will cycle
on and off similar to the status LED to indicate a code
representing the last fault, at the thermostat. Test mode can
be exited by shorting the test terminals for 3 seconds.
DIP Switches
Unit Performance Sentinel Disable - Dip Switch 1
provides field selection to disable The UPS Feature
On = Enabled. Off = Disabled.
Stage 2 - Dip Switch 2 provides selection of whether
compressor has an on delay. If set to stage 2, the
compressor will have a 3 second delay before energizing.
Also, if set for stage 2, the alarm relay will NOT cycle
during test mode.
On = Stage 1. Off = Stage 2.
Table 8: LED & Alarm Relay Operations
DescriptionofOperation
LED
AlarmRelay
NormalMode
NormalModewithUPSWarning
CXMisnon-functional
FaultRetry
Lockout
Over/UnderVoltageShutdown
On
On
Off
SlowFlash
FastFlash
SlowFlash
Open
Cycle(closed5sec.,Open25sec.)
Open
Open
Closed
Open(Closedafter15minutes)
TestMode-Nofaultinmemory
FlashingCode1
CyclingCode1
TestMode-HPFaultinmemory FlashingCode2
CyclingCode2
TestMode-LPFaultinmemory
FlashingCode3
CyclingCode3
TestMode-FP1Faultinmemory FlashingCode4
CyclingCode4
TestMode-FP2Faultinmemory FlashingCode5
CyclingCode5
TestMode-COFaultinmemory FlashingCode6
CyclingCode6
TestMode-Over/Under
shutdowninmemory
FlashingCode7
CyclingCode7
TestMode-UPSinmemory
FlashingCode8
CyclingCode8
TestMode-SwappedThermistor FlashingCode9
CyclingCode9
Special Notes and Examples:
-Slow Flash = 1 flash every 2 seconds
-Fast Flash = 2 flashes every 1 second
-Flash code 2 = 2 quick flashes, 10 sec.
pause, 2 quick flashes, 10 sec. pause, etc.
Ultra Classic (VT) Series
Page 19
Safety Features
CXM Control Description
The following safety features are provided to protect
the compressor, heat exchangers, wiring and other
components from damage caused by operation outside of
design conditions.
Anti-Short Cycle Protection- The control features a 5
minute anti-short cycle protection for the compressor.
Note: The 5 minute anti-short cycle also occurs at
power up.
Random Start - The control features a random start upon
power up of from 5-80 seconds.
Fault Retry - In Fault Retry mode, the Status LED begins
slow flashing to signal that the control is trying to recover
from a fault input. The CXM control will stage off the
outputs and then “try again” to satisfy the thermostat "Y"
input call. Once the thermostat input calls are satisfied,
the control will continue on as if no fault occured. If 3
consecutive faults occur without satisfying the thermostat
"Y" input call, then the control will go to Lockout mode.
The last fault causing the lockout will be stored in
memory and can be viewed by going into test mode.
Lockout - In Lockout mode, the Status LED will
begin fast flashing. The compressor relay is turned
off immediately. Lockout mode can be soft reset via
the thermostat “Y” input or can be hard reset via the
disconnect. The last fault causing the lockout will be
stored in memory and can be viewed by going into test
mode.
Lockout with Emergency Heat - While in Lockout mode,
if W becomes active, then Emergency Heat mode will
occur.
High Pressure Switch - When the High Pressure Switch
opens due to high refrigerant pressures, the Compressor
relay is de-energized immediately since the High Pressure
Switch is in series with the compressor contactor coil.
The High Pressure Fault recognition is immediate as well.
High Pressure Lockout Code = 2
Example: 2 quick flashes, 10 sec pause, 2 quick flashes,
10 sec. pause, etc.
Low Pressure Switch - The Low Pressure Switch must be
open and remain open for 30 continuous seconds during
"on" cycle to be recognized as a Low Pressure fault. If
the low pressure switch is open for 30 seconds prior to
compressor power up it will be considered a low pressure
(loss of charge) fault. The Low Pressure Switch input is
bypassed for the initial 60 seconds of a compressor run
cycle. Low Pressure Lockout Code = 3.
thermistor temperature must be below the selected freeze
Page 20
Water Coil Freeze Protection (FP1) - The FP1
protection limit setting for 30 continuous seconds during
a compressor run cycle to be recognized as a FP1 fault.
The FP1 input is bypassed for the initial 60 seconds of a
compressor run cycle. FP1 Lockout Code = 4.
Air Coil Freeze Protection (FP2) - The FP2 thermistor
temperature must be below the selected freeze protection
limit setting for 30 continuous seconds during a
compressor run cycle to be recognized as a FP2 fault.
The FP2 input is bypassed for the initial 60 seconds of a
compressor run cycle. FP2 Lockout Code = 5.
Condensate Overflow - The Condensate Overflow sensor
must sense overflow levels for 30 continuous seconds to
be recognized as a CO fault. Condensate Overflow will be
monitored at all times. CO Lockout Code = 6.
Over/Under Voltage Shutdown - An Over/Under Voltage
condition exists when the control voltage is outside the
range of 19Vac to 30Vac. Over/Under Voltage Shutdown
is self resetting in that if the voltage comes back within
range of 19Vac to 30Vac for at least 0.5 seconds, then
normal operation is restored. This is not considered a fault
or lockout. If the CXM is in over/under voltage shutdown
for 15 minutes, the alarm relay will close. Over/Under
Voltage Shutdown Code = 7.
Unit Performance Sentinel-UPS (patent pending) - The
UPS feature warns when the heat pump is operating
inefficiently. A UPS condition exists when:
a) in heating mode with compressor energized, if FP2 is greater than 125°F for 30 continuous seconds,
or
b) in cooling mode with compressor energized, if FP1 is greater than 125°F for 30 continuous seconds, or FP2 is less than 40°F for 30 continuous seconds.
If a UPS condition occurs, the control will immediately go
to UPS warning. The status LED will remain on as if the
control is on Normal mode. (see"LED and Alarm Relay
Operation Table" ). Outputs of the control, excluding LED
and Alarm Relay, will NOT be affected by UPS. The UPS
condition cannot occur during a compressor off cycle.
During UPS warning, the alarm relay will cycle on and
off. The cycle rate will be On for 5 seconds, Off for 25
seconds, On for 5 seconds, Off for 25 seconds, etc. Unit
Performance Sentinel Warning Code = 8.
Ultra Classic (VT) Series
Diagnostic Features
CXM Control Description
The Status LED on the CXM control advises the
serviceman of the current status of the CXM control. The
status LED can display either the current CXM mode or
the last fault memory if in test mode. See Table 8 for a
complete listing of codes.
Unit Operation Description
PowerUp - The unit will not operate until all the inputs
and safety controls are checked for normal conditions.
Note: The compressor will have a 5 minute anti-short
cycle delay at power-up.
Standby - In Standby mode, Y and W inputs are not active.
Inputs O and G may be active. Compressor will be off.
Cooling - To enter Cooling mode, Y and O become
active. The first time after power-up that there is a call for
compressor, the compressor will follow a 5 to 80 second
random start delay. There will also be a 5 min compressor
anti-short cycle protection time as well. After the random start
delay, the compressor relay is energized. On all subsequent
compressor calls, the random start delay is omitted.
Heating Stage 2 - To enter Heating Stage 2 mode, W
becomes active (Y already active). The Compressor
relay remains on. EH1 is turned on immediately. With
continuing Heating Stage 2 demand, EH2 will turn on
after 10 minutes. The EH2 will not turn on in heating (or
will turn off if already on) if loop temperature is above
approximately 50°F (FP1 >45°F).
Emergency Heat - In Emergency Heat mode, W
becomes active while Y is not active. EH1 is turned on
immediately. With continuing Emergency Heat demand,
EH2 will turn on after 5 minutes. The FP1 and FP2
temperatures do not effect emergency heat operation.
ECM Control Board
The UltraClassic also employs an ECM board that features:
• Thermostat terminal connections
• Thermostat signal diagnostic LED's
• Airflow selection
• Airflow LED (100 cfm per flash)
• Dehumidification Mode Jumper
Heating Stage 1 - To enter Heating Stage 1 mode, Y
becomes active. The first time after power-up that there
is a call for compressor, the compressor will follow a 5 to
80 second random start delay. There will also be a 5 min
compressor anti-short cycle protection time as well. After
the random start delay, the compressor relay is energized.
On all subsequent compressor calls, the random start
delay is omitted.
Table 9: Fault Description Table
�����
���������
����
���������������
��������������������
�
�����������������
��������������������������
�
�������������������������������������������
���������������������������������������������
����������������������������
�
���������������������������������������������
��������������������������������������������
��������������������������������
�
�������������������
�
���������������������������
���������������������������������������������
��������������������������������������������
������������������������������������������
�������
�������������
������������������������������������
Ultra Classic (VT) Series
Page 21
Troubleshooting Information
General
CXM board troubleshooting in general is best
summarized as simply varifying inputs and outputs.
After this process has been varified, confidence in board
operation is confirmed and the trouble must be else
where. Below are some general guidelines required
for developing training materials and procedures when
applying the CXM control.
The thermistor resistance should be measured with the
connector removed so that only the impedance of the
thermistor is measured. If desired this reading can be
compared to the chart shown in the thermistor section
of this manual based upon the actual termperature of
the thermistor clip. An ice bath can be used to check
calibration of a thermistor if needed.
Field Inputs
Outputs
All inputs are 24VAC from the thermostat.and can be
varified using a Volt meter between C and Y, G, O, W. See
the I/O Reference table below.
The compressor relay is 24VAC and can be varified using
a voltmeter. The fan signal is passed through the board
to the external fan relay. The alarm relay can either be
24VAC as shipped or dry contacts (measure continuity
during fault) for use with DDC by clipping the J1 jumper.
Electric heat outputs are 24VDC ground sinking and
require a voltmeter set for DC to varify operation. See the
I/O Reference table below.
Sensor Inputs
All sensor inputs are "paired wires" connecting each
component with the board. Therefore continuity on
pressure switches, and the condensate switch can be
checked at the board connector.
Test Mode
Test mode can be entered for 20 minutes by shorting the
test pins.
Table 10: CXM Input/Output Reference Table
����������
�
�
�
�
�
�
���
���
�
��
���
��
���
��
��
���
���
��
��
�����
��
��
��������
������
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�����������
������
������������������������
����������������������������������������������������
����������������������������������������������������������
����������������������������������������������������������������������
���������������������������������������������
������������������������������������������������������
������������������������
���������������������������������������������������������������������������
�������������������������������������������������
������������������������������
�����������������������������������
��������������������������������������
������������������������������������
�����������������������������������
���������������������������������������������
�������������������������������������������
����������������������������������������������������������
�����������������������������������
�������������������������������������
�����������������������������������������
�����������������������������������������
Page 22
Ultra Classic (VT) Series
TROUBLE ANALYSIS
Preliminary Trouble Inspection
After completing the preliminary checks described above,
be sure to inspect for other obvious problems such as
leaking connections, broken or disconnected wires, etc.
WARNING
HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING
REMOTE DISCONNECTS BEFORE
SERVICING. Failure to disconnect power before
servicing can cause severe personal injury or
death.
If everything appears to be in order, but the unit still fails to
operate properly, refer to the following Troubleshooting Chart.
Troubleshooting Chart
The Troubleshooting Chart that follows is provided to
serve as an aid for identifying malfunctions that may
occur. Within the chart are three columns:
If operational difficulties are encountered, be sure to
perform the preliminary checks before referring to the
Troubleshooting Chart.
1. The Problem column describes what the unit is doing.
•
Verify that the unit is receiving electrical supply power.
•
Make sure the fuses in the fused disconnect switches
are intact.
3. The Correction column describes what should be
done to correct the problem.
Start
CXM Functional
Troubleshooting Chart
DidUnit
Attemptto
Start?
No
DidUnit
Lockoutat
Start-up?
No
Yes
Yes
See“ Unit
short
cycles”
Yes
UnitShort
Cycles?
No
See“ Only Yes
FanRuns”
OnlyFan
Runs?
See“ Only Yes
Comp
Runs”
No
Only
Compressor
Runs?
See“ Does No
notOperate
inClg”
2. The Cause column identifies the most likely sources
of the problem.
CheckMain
power(seepower
problems)
Nofault
shown
CheckfaultLEDcode
oncontrolboard
SeeHP
Fault
See
LP/LOC
Fault
SeeFP2
Fault
SeeFP1
Fault
See
Condensate
Fault
Replace
CXM
SeeOver/
Under
Voltage
No
Didunitlockout Yes
afteraperiodof
operation?
No
Doesunit
operatein
cooling?
Yes
Unit is OK!
‘See Performance
Troubleshooting’ for
further help
Ultra Classic (VT) Series
Page 23
Functional Troubleshooting
Fault
MainpowerProblems
Htg Clg PossibleCause
X
HPFault-Code2
Highpressure
X
GreenStatusLEDOff
X
Reducedornowaterflow
incooling
X
X
Solution
CheckLineVoltagecircuitbreakeranddisconnect
CheckforlinevoltagebetweenL1andL2onthecontactor
Checkfor24VACbetweenRandConCXM/DXM
Checkprimary/secondaryvoltageontransformer
Checkpumpoperationorvalveoperation/setting
Check water flow adjust to proper flow rate
WaterTemperatureoutofrangein
Bringwatertempwithindesignparameters
cooling
ReducedornoAirflow
inheating
Checkfordirtyairfilterandcleanorreplace
Checkfanmotoroperationandairflowrestrictions
DirtyAirCoil-constructiondustetc.
Toohighofexternalstatic.Checkstaticvsblowertable
X
LP/LOCFault-Code3
X
X
X
X
X
X
AirTemperatureoutofrangein
heating
Bringreturnairtempwithindesignparameters
Overchargedwithrefrigerant
Checksuperheat/subcoolingvstypicaloperatingcondition
table
BadHPSwitch
Insufficientcharge
Checkswitchcontinuityandoperation.Replace
Checkforrefrigerantleaks
LowPressure/LossofCharge
X
Compressorpumpdownatstartup
FP1Fault-Code4
X
Reducedornowaterflow
Checkpumpoperationorwatervalveoperation/setting
inheating
Pluggedstrainerorfilter.Cleanorreplace.
X
Inadequateanti-freezelevel
Checkantifreezedensitywithhydrometer
X
Impropertemperaturelimitsetting
(30°Fvs10°F)
Clip JW3 jumper for antifreeze (10°F)use
X
WaterTemperatureoutofrange
Bringwatertempwithindesignparameters
X
X
Badthermistor
ReducedornoAirflow
incooling
Checktempandimpedancecorrelationperchart
Checkfordirtyairfilterandcleanorreplace
Checkfanmotoroperationandairflowrestrictions
Toohighofexternalstatic.Checkstaticvsblowertable
X
AirTemperatureoutofrange
Toomuchcoldventair?Bringenteringairtempwithin
designparameters
X
Impropertemperaturelimitsetting
(30°Fvs10°F)
Normalairsideapplicationswillrequire30°Fonly
X
X
Badthermistor
Checktempandimpedancecorrelationperchart
X
X
BlockedDrain
Checkforblockageandcleandrain
X
X
X
Impropertrap
PoorDrainage
X
Moistureonsensor
X
UnderVoltage
Checktrapdimensionsandlocationaheadofvent
Checkforpipingslopeawayfromunit
Checkslopeofunittowardoutlet
Poorventing.Checkventlocation
Checkformoistureshortingtoaircoil
Checkpowersupplyand24VACvoltagebeforeandduring
operation.
Checkpowersupplywiresize
Checkcompressorstarting.Needhardstartkit?
WaterCoillow
temperaturelimit
FP2fault-Code5
X
AirCoillow
temperaturelimit
CondensateFault-Code 6
Over/UnderVoltageCode7
(Autoresetting)
X
X
X
Checkchargeandstart-upwaterflow
Check water flow adjust to proper flow rate
Check24VACandunittransformertapforcorrectpower
supplyvoltage
OverVoltage
Checkpowersupplyvoltageand24VACbeforeandduring
operation.
Check24VACandunittransformertapforcorrectpower
supplyvoltage
UnitPerformance
Sentinel-Code8
NoFaultCodeShown
UnitShortCycles
OnlyFanRuns
X
HeatingmodeFP2>125°F
Checkforpoorairfloworoverchargedunit.
X
CoolingModeFP1>125°FOR
FP2<40°F
Checkforpoorwaterflow,orairflow
X
X
Nocompressoroperation
See"Onlyfanoperates"
X
X
CompressorOverload
CheckandReplaceifnecessary
X
X
X
X
X
X
Controlboard
DirtyAirFilter
Unitin"TestMode"
X
X
Unitselection
X
X
CompressorOverload
Resetpowerandcheckoperation
CheckandCleanairfilter
Resetpowerorwait20minutesforautoexit.
Unitmaybeoversizedforspace.Checksizingforactual
loadofspace.
CheckandReplaceifnecessary
X
X
Thermostatposition
Insurethermostatsetforheatingorcoolingoperation
X
X
Unitlockedout
Checkforlockoutcodes.Resetpower.
X
X
Thermostatwiring
Checkthermostatwiringatheatpump.JumperYandR
forcompressoroperationintestmode.
X
Page 24
X
CompressorOverload
Checkcompressoroverload.Replaceifnecessary.
Ultra Classic (VT) Series
Functional Troubleshooting
OnlyCompressorRuns
X
X
Thermostatwiring
CheckGwiringatheatpump.JumperGandRforfan
operation.
X
X
Fanmotorrelay
JumperGandRforfanoperation.CheckforLinevoltage
acrossBRcontacts.
X
X
Fanmotor
X
X
Thermostatwiring
X
ReversingValve
X
Thermostatsetup
X
Thermostatwiring
X
Thermostatwiring
UnitDoesn'tOperatein
Cooling
Checkfanpowerenablerelayoperation(ifpresent)
Checkforlinevoltageatmotor.Checkcapacitor
Checkthermostatwiringatheatpump.JumperYandRfor
compressoroperationintestmode.
Setforcoolingdemandandcheck24VAConRVcoilandat
CXM/DXMboard.
IfRVisstuck,runhighpressureupbyreducingwaterflow
andwhileoperatingengageanddisengageRVcoilvoltage
topushvalve.
Checkfor'O'RVsetupnot'B'
CheckOwiringatheatpump.JumperOandRforRVcoil
'Click'.
Putthermostatincoolingmode.Checkfor24VAConO
(checkbetweenCandO);checkfor24VAConW(check
betweenWandC).ThereshouldbevoltageonO,butnot
onW.IfvoltageispresentonW,thermostatmaybebad
orwiredincorrectly.
Performance Troubleshooting
Performance
Troubleshooting
Insufficientcapacity/
Notcoolingorheating
properly
HighHeadPressure
Htg Clg PossibleCause
X
X
X
Solution
DirtyFilter
Replaceorclean
inheating
Checkfanmotoroperationandairflowrestrictions
Toohighofexternalstatic.Checkstaticvsblowertable
Checkfordirtyairfilterandcleanorreplace
Checkfanmotoroperationandairflowrestrictions
Toohighofexternalstatic.Checkstaticvsblowertable
Checksupplyandreturnairtemperaturesattheunitandat
distantductregistersifsignificantlydifferent,ductleaks
arepresent
Checksuperheatandsubcoolingperchart
Checksuperheatandsubcoolingperchart.Replace.
PerformRVtouchtest
Checklocationandforairdraftsbehindstat
Recheckloads&sizingchecksensibleclgloadandheat
pumpcapacity
ReducedornoAirflow
Checkfordirtyairfilterandcleanorreplace
X
ReducedornoAirflow
incooling
X
X
Leakyductwork
X
X
X
X
X
X
X
Lowrefrigerantcharge
Restrictedmeteringdevice
DefectiveReversingValve
Thermostatimproperlylocated
X
X
Unitundersized
X
X
Scalinginwaterheatexchanger
PerformScalingcheckandcleanifnecessary
X
X
InletWatertooHotorCold
Checkload,loopsizing,loopbackfill,groundmoisture.
ReducedornoAirflow
inheating
Checkfordirtyairfilterandcleanorreplace
Checkfanmotoroperationandairflowrestrictions
X
Toohighofexternalstatic.Checkstaticvsblowertable
X
X
LowSuctionPressure
X
X
X
X
X
X
X
X
X
X
X
X
Lowdischargeair
temperatureinheating
Highhumidity
Checkpumpoperationorvalveoperation/setting
Check water flow adjust to proper flow rate
Checkload,loopsizing,loopbackfill,groundmoisture.
Bringreturnairtempwithindesignparameters
Scalinginwaterheatexchanger
UnitOvercharged
Non-condensablesinsystem
Restrictedmeteringdevice
Reducedwaterflow
inheating
PerformScalingcheckandcleanifnecessary
Checksuperheatandsubcooling.Reweighincharge
Vacuumsystemandreweighincharge
Checksuperheatandsubcoolingperchart.Replace.
Checkpumpoperationorwatervalveoperation/setting
Pluggedstrainerorfilter.Cleanorreplace.
Check water flow adjust to proper flow rate
WaterTemperatureoutofrange
Bringwatertempwithindesignparameters
ReducedAirflow
incooling
X
AirTemperatureoutofrange
X
Insufficientcharge
Checkfordirtyairfilterandcleanorreplace
Checkfanmotoroperationandairflowrestrictions
Toohighofexternalstatic.Checkstaticvsblowertable
Toomuchcoldventair?Bringenteringairtempwithin
designparameters
Checkforrefrigerantleaks
Toohighofairflow
Checkfanmotorspeedselectionandairflowchart
X
PoorPerformance
Toohighofairflow
X
Unitoversized
See'InsufficientCapacity'
Checkfanmotorspeedselectionandairflowchart
Recheckloads&sizingchecksensibleclgloadandheat
pumpcapacity
X
X
Reducedornowaterflow
incooling
InletWatertooHot
AirTemperatureoutofrangein
heating
Ultra Classic (VT) Series
Page 25
UNIT START UP
Operating Limits
Environment – This unit is designed for indoor
installation ONLY.
Power Supply – A voltage variation of +/– 10% of
nameplate utilization voltage is acceptable.
Starting Conditions
GT-X Units – Units start and operate in an ambient of
45°F with entering air at 45°F, entering water at 32°F
and both air and water at the stated flow rates of ISO/
ASHRAE/ARI 13256-1 for initial winter start-up.
Notes:
1. These are not normal or continuous operating
conditions. It is assumed that winter start-up
is to bring the building space up to occupancy
temperatures.
2. Voltage utilization range complies with ARI
Standard 110.
Determination of operating limits is dependent primarily
upon three factors: 1) return air temperature 2) water
temperature and 3) ambient temperature. When any one of
these factors is at minimum or maximum levels, the other
two factors should be at normal levels to ensure proper
unit operation.
Extreme variations in temperature and humidity
and corrosive water or air will adversely affect unit
performance, reliability and service life.
Table 11: Operating Limit
Air Limits
Ultra Classic
Cooling
Heating
Min. Ambient Air
Rated Ambient Air
Max. Ambient Air
Min. Entering Air
Rated Entering Air db/wb
Max. Entering Air db/wb
45°F
80°F
100°F
50°F
80/67°F
110/83°F
45°F
70°F
85°F
40°F
70°F
80°F
30°F
50-90°F
110°F
20°F
30-60°F
90°F
Water Limits
Min. Entering Water
Normal Entering Water
Max. Entering Water
Before powering unit, check the following:
High voltage is correct and matches nameplate
Fuses, breakers and wire size correct
Low voltage wiring complete
Piping completed and water system cleaned and flushed
Air is purged from closed loop system
Isolation valves are open, water control valves or loop pumps wired
q Condensate line open and correctly pitched
q Transformer switched to lower voltage tap if needed q Air coil cleaned
q
q
q
q
q
q
Page 26
q HWG pump disconnected unless piping is completed
and air has been purged
q Blower rotates freely – shipping support has been removed
q Blower speed correct (taps on correct pins)
q Air filter is clean and in position
q Service/access panels are in place
q Return air temperature is between 40-80°F in heating and 50-110°F in cooling
q CXM field selectable options such as thermistor settings are correct.
Ultra Classic (VT) Series
UNIT START UP
Start up Procedure
If Delta-T Water is outside the range shown in
table 12, check cooling refrigerant pressure in table 14. Verify correct water flow by comparing unit pressure drop across the heat exchanger versus the data in Table 12. Heat of rejection can be calculated and compared to specification catalog.
WARNING
When the disconnect switch is closed, high
voltage is present in some areas of the electrical
panel. Exercise caution when working with
energized equipment.
1. Turn thermostat fan position to “ON.” Blower should start.
f. Check air temperature drop across the coil when compressor is operating. Air temperature should drop between 15°F and 25°F.
g. Turn thermostat to “OFF” position. A hissing noise indicates proper functioning of the
reversing valve.
2. Balance air flow at registers.
3. Adjust all valves to their full open position. Turn on the
line power to all heat pump units.
4. Operate unit in cooling cycle. Room temperature should
be approximately 45-100°F DB. For Start-up check,
loop water temperature entering the heat pumps
should be between 40°F and 90°F.
5. Two factors determine the operating limits of a
ClimateMaster UltraClassic System– (a) return air
temperature, and (b) water temperature. When any
one of these factors is at a minimum or maximum
level, the other factor must be at normal levels to
ensure proper unit operation.
a. Adjust the unit thermostat to the coolest position. Slowly reduce thermostat setting until the compressor activates.
b. Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate.
Note: Units have a five minute time delay in the
control circuit that can be eliminated on the CXM
PCB as shown below in Figure 24. See controls
description for detailed features of the control.
c. Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger using the Pete’s plugs and comparing to Table 13.
d. Check the elevation and cleanliness of the
condensate lines. Dripping may be a sign of a
blocked line. Check that the condensate trap includes a water seal.
e. Refer to Table 12. Check the difference in temperature of supply and return water
temperature, usually referred to as Delta-T Water. Figure 24: Test Mode Pins
Short test pins
together to enter Test
Mode and speed-up
timing and delays for
20 minutes
6. Operate the heat pump in the heating cycle
immediately after checking cooling cycle operation.
Allow five (5) minutes between tests for pressure to
equalize or cycle the reversing valve to equalize.
a. Turn thermostat to lowest setting and set thermostat switch to “HEAT” position.
b. Slowly turn thermostat to a higher temperature until the compressor activates.
c. Check for warm air delivery at the unit grille within a few minutes after the unit has begun to operate.
d. Check the temperature of both supply and discharge water. Refer to Table 12. If temperature is within range, proceed with test. If temperature is outside operating range, check heating refrigerant pressures in Table 14.
e. Check air temperature rise across the coil when compressor is operating. Air temperature should rise between 20°F and 30°F. Heat of extraction can be
calculated and compared to specification catalog.
f. Check for vibration, noise, and water leaks.
7. If unit fails to operate, perform Troubleshooting
analysis. If the check described fails to reveal the
problem and the unit still does not operate, contact a
trained service technician to ensure proper diagnosis
and repair of the equipment.
8. When testing is complete, set system to maintain
desired comfort level.
9. BE CERTAIN TO FILL OUT AND FORWARD
ALL WARRANTY REGISTRATION PAPERS TO
CLIMATEMASTER.
Note: If performance during any mode appears
abnormal, refer to the troubleshooting section. To
obtain maximum performance the air coil should be
cleaned before start-up. A 10% solution of dishwasher
detergent and water is recommended.
CXM Board
Ultra Classic (VT) Series
Page 27
Table 12: Water Temperature Change Through Heat Exchanger
��������������������������������
���������������������������������
�������
����������
����������
�������
����������
��������
�������
����������
���������
�������
����������
��������
��������������
������������
��������
�������
�������
���������� ����������
���������
��������
����������������������������������
�����������������������������������
����������
��������
����������
����������
����������
���������������������
������������������
��������������������
����������
��������������
��������������
����������������
Table
13: Water Pressure Drop Table
��������������
�����
���
���
���
���
���
���
�������������
�������������������
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
��
�
�
�
��
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
�
�
�
��
�
�
��
��
�
�
��
��
�
��
��
��
�
��
��
��
��������������������������������
�������������������
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
�
�
�
��
�
�
��
��
�
�
��
��
�
��
��
��
�
��
��
��
�������������������
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
����
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
���
����
���������������
��������
��������
����
����
����
����
���������������������������������������
���
Table 14: Unit operating pressures and temperatures
������������������������������
��������
�����
�������
���������
�����
����
��������
��������
������
�������
�������
����
����
����
����������������������������
�����
���
�������
���������
����
����
�����
��������
��������
�������
�������
����������
����
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
������
������
���
�����
������
�����
�����
�����
�����
��
���
�����
�����
�����
�����
�����
�����
���
�����
�����
�����
�����
����
�����
���
�����
�������
�����
�����
�����
�����
��
���
�����
�������
�����
����
�����
�����
���
�����
�������
�����
����
����
�����
���
�����
�������
����
����
�����
�����
��
���
�����
�������
����
����
�����
�����
���
�����
�������
����
����
����
�����
���
�����
�������
����
����
�����
�����
��
���
�����
�������
����
����
�����
�����
���
�����
�������
����
����
����
�����
���
�����
�������
����
�����
�����
�����
���
���
�����
�������
����
�����
����
�����
���
�����
�������
����
�����
����
�����
�����������������������������������������������������
�����������������������������������������������������������������������������������
��������������������������������������������������������������������������
����������������������������������������������������������������������
Page 28
Ultra Classic (VT) Series
�����
���
������
����
����
�����
����
����
�������
����������
�������
�������
�������
�������
�������
�������
�������
�������
�������
�������
�������
�������
�������
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
���
���
���
���
���
���
���
���
���
���
���
���
�������
�������
�������
���������
�������
�������
���������
��������
�������
���������
���������
�������
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
�����
Notes
Ultra Classic (VT) Series
Page 29
Page 30
Ultra Classic (VT) Series
Ultra Classic (VT) Series
Page 31
Please refer to the CM Installation, Operation and Maintenance Manual for operating and maintenance instructions.
Rev.: 5/03
Part No.: RP404
NOTE: Some states or Canadian provinces do not allow limitations on how long an implied warranty lasts, or the limitation or exclusions of consequential or incidental damages, so the foregoing exclusions and limitations
may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state and from Canadian province to Canadian province.
Climate Master, Inc. • Customer Service • 7300 SW 44th Street • Oklahoma City, Oklahoma 73179 • (405) 745-6000 • e-service@climatemaster.com
OBTAINING WARRANTY PERFORMANCE
Normally, the dealer or service organization who installed the products will provide warranty performance for the owner. Should the installer be unavailable, contact any CM recognized distributor, dealer or service
organization. If assistance is required in obtaining warranty performance, write or call:
LIMITATION OF LIABILITY
CM shall have no liability for any damages if CM’s performance is delayed for any reason or is prevented to any extent by any event such as, but not limited to: any war, civil unrest, government restrictions or restraints,
strikes, or work stoppages, fire, flood, accident, shortages of transportation, fuel, material, or labor, acts of God or any other reason beyond the sole control of CM. CM EXPRESSLY DISCLAIMS AND EXCLUDES ANY
LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGE IN CONTRACT, FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, OR IN TORT, WHETHER FOR CM’s NEGLIGENCE
OR AS STRICT LIABILITY.
LIMITATION OF REMEDIES
In the event of a breach of the Limited Express Warranty, CM will only be obligated at CM’s option to repair the failed part or unit, or to furnish a new or rebuilt part or unit in exchange for the part or unit which has failed.
If after written notice to CM’s factory in Oklahoma City, Oklahoma of each defect, malfunction or other failure, and a reasonable number of attempts by CM to correct the defect, malfunction or other failure, and the remedy
fails of its essential purpose, CM shall refund the purchase price paid to CM in exchange for the return of the sold good(s). Said refund shall be the maximum liability of CM. THIS REMEDY IS THE SOLE AND
EXCLUSIVE REMEDY OF THE BUYER OR PURCHASER AGAINST CM FOR BREACH OF CONTRACT, FOR THE BREACH OF ANY WARRANTY OR FOR CM’S NEGLIGENCE OR IN STRICT
LIABILITY.
Limitation: This Limited Express Warranty is given in lieu of all other warranties. If, notwithstanding the disclaimers contained herein, it is determined that other warranties exist, any such express warranty, including
without limitation any express warranties or any implied warranties of fitness for particular purpose and merchantability, shall be limited to the duration of the Limited Express Warranty.
This Limited Express Warranty applies to CM Residential Class products manufactured on or after June 9, 2003 (CM Units with serial numbers beginning with E124 and higher), and is not retroactive to any products
produced prior to June 9, 2003 (CM Units with serial numbers beginning with E123 and lower).
CM is not responsible for: (1) The costs of any fluids, refrigerant or system components supplied by others, or associated labor to repair or replace the same, which is incurred as a result of a defective part covered by CM’s
Limited Express Warranty; (2) The costs of labor, refrigerant, materials or service incurred in diagnosis and removal of the defective part, or in obtaining and replacing the new or repaired part; (3) Transportation costs of the
defective part from the installation site to CM, or of the return of that part if not covered by CM’s Limited Express Warranty; or (4) The costs of normal maintenance.
This warranty does not cover and does not apply to: (1) Air filters, fuses, refrigerant, fluids, oil; (2) Products relocated after initial installation; (3) Any portion or component of any system that is not supplied by CM,
regardless of the cause of the failure of such portion or component; (4) Products on which the unit identification tags or labels have been removed or defaced; (5) Products on which payment to CM, or to the owner’s seller, is
in default; (6) Products subjected to improper or inadequate installation, maintenance, repair, wiring or voltage conditions; (7) Products subjected to accident, misuse, negligence, abuse, fire, flood, lightning, unauthorized
alteration, misapplication, contaminated or corrosive air or liquid supply, operation at abnormal air or liquid temperatures or flow rates, or opening of the refrigerant circuit by unqualified personnel; (8) Mold, fungus or
bacteria damages; (9) Corrosion or abrasion of the product; (10) Products supplied by others; (11) Products which have been operated in a manner contrary to CM’s printed instructions; (12) Products which have insufficient
performance as a result of improper system design or improper application, installation, or use of CM’s products; or (13) Electricity or fuel costs, or any increases or unrealized savings in same, for any reason whatsoever.
To make a claim under this warranty, parts must be returned to CM in Oklahoma City, Oklahoma, freight prepaid, no later than ninety (90) days after the date of the failure of the part; if CM determines the part to be
defective and within CM’s Limited Express Warranty, CM shall, when such part has been either replaced or repaired, return such to a factory recognized distributor, dealer or service organization, F.O.B. CM, Oklahoma City,
Oklahoma, freight prepaid. The warranty on any part repaired or replaced under warranty expires at the end of the original warranty period.
GRANT OF LIMITED EXPRESS WARRANTY
CM warrants its Residential Class products, purchased and retained in the United States of America and Canada, to be free from defects in material and workmanship under normal use and maintenance as follows: (1) Air
conditioning, heating and/or heat pump units built or sold by CM (“CM Units”) for five (5) years from the Warranty Inception Date (as defined below); (2) Thermostats, auxiliary electric heaters and geothermal pumping
modules built or sold by CM, when installed with CM Units, for five (5) years from the Warranty Inception Date (as defined below); (3) Sealed refrigerant circuit components of CM Units (which components only include
the compressor, refrigerant to air/water heat exchangers, reversing valve body and refrigerant metering device) for ten (10) years from the Warranty Inception Date (as defined below); and (4) Other accessories and parts built
or sold by CM, which are not supplied under warranty, for one (1) year from the date of shipment from CM. The “Warranty Inception Date” shall be the date of original unit installation, or six (6) months from date of unit
shipment from CM, whichever comes first.
It is expressly understood that unless a statement is specifically identified as a warranty, statements made by Climate Master, Inc. a Delaware corporation, (“CM”) or its representatives, relating to CM’s products, whether
oral, written or contained in any sales literature, catalog or agreement, are not express warranties and do not form a part of the basis of the bargain, but are merely CM’s opinion or commendation of CM’s products.
EXCEPT AS SPECIFICALLY SET FORTH HEREIN, THERE IS NO EXPRESS WARRANTY AS TO ANY OF CM’S PRODUCTS. CM MAKES NO WARRANTY AGAINST LATENT DEFECTS. CM MAKES
NO WARRANTY OF MERCHANTABILITY OF THE GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PARTICULAR PURPOSE.
CLIMATE MASTER, INC.
LIMITED EXPRESS WARRANTY/LIMITATION OF REMEDIES AND LIABILITY FOR
RESIDENTIAL CLASS PRODUCTS
PREVENTIVE MAINTENANCE
Water Coil Maintenance –
(Direct Ground Water Applications Only)
If the installation is performed in an area with a known
high mineral content (125 P.P.M. or greater) in the
water, it is best to establish with the owner a periodic
maintenance schedule so the coil can be checked
regularly. Consult the well water applications section
of this manual for a more detailed water coil material
selection. Should periodic coil cleaning be necessary, use
standard coil cleaning procedures which are compatible
with either the heat exchanger material or copper water
lines. Generally, the more water flowing through the unit
the less chance for scaling therefore 1.5 gpm per ton is
recommended as a minimum flow.
Water Coil Maintenance –
(Other Water Loop Applications)
Generally water coil maintenance is not needed however,
if the installation is located in a system with a known
high dirt or debris content, it is best to establish with
the owner a periodic maintenance schedule so the coil
can be checked regularly. These dirty installations are a
result of the deterioration of iron or galvanized piping
or components in the system or open cooling towers
requiring heavy chemical treatment and mineral buildup
through water use. Should periodic coil cleaning be
necessary, use standard coil cleaning procedures which
are compatible with both the heat exchanger material and
copper water lines. Generally, the more water flowing
through the unit, the less chance for scaling, however flow
rates over 3 gpm per ton can produce water (or debris)
velocities that can erode the heat exchanger wall and
ultimately produce leaks.
Filters – Filters must be clean to obtain maximum
performance. They should be inspected every month
under normal operating conditions and be replaced when
necessary. Units should never be operated without a filter.
Washable high efficiency electrostatic filters, when dirty,
can exhibit a very high pressure drop for the fan motor
and reduce air flow resulting in poor performance. With
ECM fan motors, excessive fan watts will be used as well.
It is especially important to provide consistent washing of
these filters (in opposite direction of the normal air flow)
once per month using a high pressure wash similar to that
found at self-serve car washes.
Condensate Drain – In areas where airborne bacteria
produce a slime in the drain pan, it may be necessary to
treat chemically with an algaecide every three months
or so to minimize the problem. The condensate pan may
also need to be cleaned periodically to assure indoor air
quality. The condensate drain can pick up lint and dirt,
especially with dirty filters. Inspect the drain twice a year
to avoid the possibility of overflow.
Fan Motors - All units have lubricated fan motors. Fan
motors should never be lubricated unless
obvious, dry operation is suspected. Periodic
maintenance oiling is not recommended because it
will result in dirt accumulating on excess oil and cause
eventual motor failure.
Air Coil – The air coil must be cleaned to obtain
maximum performance. Check once a year under normal
operating conditions and, if dirty, brush or vacuum clean.
Care must be taken not to damage the aluminum fins
while cleaning. CAUTION: Fin edges are sharp.
Hot Water Generator Coils – See water coil maintenance
for ground water units. If the domestic water is hard or
not chemically softened the high temperatures of the
desuperheater will tend to "lime up" even quicker than the
water coil and may need more frequent inspections.
Cabinet - Do not allow water to stay in contact with the
cabinet for long periods of time to prevent corrosion of
the cabinet sheet metal. Generally the cabinet is set up
from the floor a few inches for prevention. The cabinet
can be cleaned using a mild detergent.
Refrigerant System - To maintain sealed circuit integrity,
do not install service gauges unless unit operation appears
abnormal. Reference the operating chart for pressure and
temperatures. Verify that air and water flow rates are at
proper levels before servicing the refrigerant circuit.
7300 S.W. 44th Street
Oklahoma City, OK 73179
Phone: 405-745-6000
FAX: 405-745-6045
www.climatemaster.com
*69197343*
Part # 69197343
ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time for order may be changed
without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the basis of
any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products.
© ClimateMaster 2000
Rev.: 7/07/05D