WaterFurnace Premier2 Installation manual

Geothermal/Water Source Heat Pumps

• 3/4 thru 6 Ton

Installation Information

Water Piping Connections

Desuperheater Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

IM1555 11/06

PREMIER INSTALLATION MANUAL

Model Nomenclature

P 040 T L 3 2 0 C A D S S A

Family

P = Premier

Unit Capacity

MBTUH

Discharge Air Configuration

T = Top Discharge Vertical

E = End Discharge Horizontal

S = Side Discharge Horizontal

Return Air Configuration

L = Left

R= Right

Voltage

0 = 208-230/60/1 (Commercial)

1 = 208-230/60/1 (Residential)

2 = 265-277/60/1

3 = 208-230/60/3

4 = 460/60/3

Hot Water Option

0 = None

1 = Hot Water Generation

With Factory Installed Pump (Residential)

2 = Hot Water Generation

Without Pump (Commercial 022-066, 230 VAC only)

Note: * FX10 available only on units with PSC blowers without desuperheaters.

Vintage

A = All Others

B = P028(Single Phase),

P056(All Voltages)

Non-Standard Option Details

Non-Standard Options

S = Standard

4 = FX10*

5 = FX10 w/Open N2 Com. Card*

6 = FX10 w/LonWorks Com. Card*

7 = FX10 w/BacNet Com. Card*

Filter Options

D = 1" Pleated Disposable

Sound Kit

A = None

B = Blanket

Coax Options

C = Copper

N = Cupronickel

Blower Options

0 = PSC Blower

1 = ECM Blower

2 = Oversized ECM Blower Option

(040-046 Only)

2

Table of Contents


Closed Loop Ground Source Systems 8

Open Loop Ground Water Systems 9

Boiler/Cooling Tower Closed Loop Systems 10

System Cleaning & Flushing 11

Desuperheater Connection & Startup 12-13

15

Electronic Thermostat Installation 15

Standard Microprocessor Control Operation 30-31

Description of Unit Operation 36-37

Troubleshooting 38

3


General Installation Information

WARNING: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch.

Electrical shock could cause personal injury.

Safety Considerations

Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualifi ed service personnel should install, repair or service heating and air conditioning equipment.

Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing fi lters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fi re extinguisher available.

Moving and Storage

Move units in the normal “up” orientation as indicated by the arrows on each carton. Horizontal units may be moved and stored per the information on the carton. Do not stack more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. Do not attempt to move units while stacked.

When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the cartons if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage. Units are to be stored in clean, dry location to prevent damage.

Unit Location

Locate the unit in an indoor area that allows for easy removal of the fi lter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide suffi cient room to make water, electrical and duct connection(s). If the unit is located in a confi ned 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 diffi cult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. Care should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components.

Installing Vertical Units

Vertical units are available in left or right air return confi gurations. Vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the fl oor. It is not necessary to anchor the unit to the fl oor (see right). If access to the left side of the unit will be limited after installation, remove the two mounting screws on the left side of the control box before setting the unit (leave the two front mounting screws intact).

This will allow the control box to be removed with only the two front mounting screws for future service.

Figure 1: Vertical Unit Mounting

Vibration

Absorbing

Mesh or

Air

Pad

4


Installing Horizontal Units

Horizontal units are available with side or end discharge and may be fi eld converted from one to the other by replacing the discharge panel with a new panel which must be ordered separately. Horizontal units are normally suspended from a ceiling by four or six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit.

Lay out the threaded rods per the dimensions in Figure 3. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow fi lter access, one bracket on the fi lter side should be installed 180° from the position shown in the

Figure 2: Typical Horizontal Unit Installation fi gure below. The unit should be pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit. The use of longer bolts could damage internal parts.

Some residential applications require the installation of hori-

Electric heat assembly

(optional)

Flexible Duct

Collar

Insulate supply plenum and use at least a 90° elbow to reduce noise

3/8”

Threaded rods (6)

To Line

Power

To Thermostat

P/T Plugs

Hose Kits zontal units on an attic fl oor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing mesh. The secondary drain pan prevents possible condensate overfl ow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the

Disconnects

Line Voltage

Hanging

Brackets

(included)

Ball V alves

Building Water

Loop

CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling.

Figure 3: Hanger Location and Assembly

E

3/8”

Threaded Rod

(not supplied)

Vibration Isolator

W asher

A C

Compressor

Section

Air Handler

Section

B

D

P010-034, 4 hangers included

P040-066, 6 hangers included

Bolt and

Lockwasher

MODEL

P010, 013

P019

P022, 028, 034

P040, 046

P056

P066

A

24.8

24.8

24.8

27.8

27.8

27.8

Hex Nuts

(not supplied)

B

42.5

51.5

61.5

70.5

75.5

80.5

C

22.5

22.5

22.5

25.5

25.5

25.5

D

44.0

53.0

63.0

72.0

77.0

82.0

–

–

E

–

29.9

29.9

29.9

5


Duct System

An air outlet collar is provided on vertical top fl ow units and all horizontal units to facilitate a duct connection. A fl exible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-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.

If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct 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 if necessary.

The duct system should be sized to handle the design airfl ow quietly and effi ciently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fi berglass or constructed of ductboard for the fi rst 10 feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airfl ow is a problem, the blower speed can be changed (refer to pages 16-17).

CAUTION: Be sure to remove the shipping material from the blower discharge before connecting ductwork.

Water Piping

The proper water fl ow must be provided to each unit whenever the unit operates. To assure proper fl ow, use pressure/ temperature ports to determine the fl ow rate. These ports should be located adjacent to the supply and return water connections on the unit. The proper fl ow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger.

All source water connections on residential units are swivel fi ttings that accept a 1-inch male pipe thread (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the fl ush end of any 1-inch threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4L and CK3L connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fi tting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fi tting (SCH80

PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability.

All source water connections on commercial units are standard female pipe thread.

Never use fl exible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection.

Check carefully for water leaks.

Freeze Protection

Set the freeze protection switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solution to “LOOP”. On applications using an open loop/groundwater system (or closed loop no antifreeze), set this dip switch to

“WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 20.)

6


Water Quality

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. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualifi ed service mechanic, as special solutions and pumping equipment are required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional fl ushing.

Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning.

Material pH

Scaling

Corrosion

Acidity/Alkalinity

Calcium and Magnesium Carbonate

Hydrogen Sulfide

Sulfates

Chlorine

Chlorides

Carbon Dioxide

Ammonia

Ammonia Chloride

Ammonia Nitrate

Ammonia Hydroxide

Ammonia Sulfate

Total Dissolved Solids (TDS)

Iron, Fe 2 + (Ferrous)

Bacterial Iron Potential

Copper

7- 9

(Total Hardness) less than 350 ppm

Less than .5 ppm

(rotten egg smell appears at 0.5 PPM)

Less than 125 ppm

Less than .5 ppm

Less than 20 ppm

Less than 50 ppm

Less than 2 ppm

Less than .5 ppm

Less than .5 ppm

Less than .5 ppm

Less than .5 ppm

Less than 1000 ppm

None

Iron Fouling

(Biological Growth)

Erosion

Iron Oxide

Suspended Solids

Threshold Velocity (Fresh Water)

Less than 1 ppm. Above this level deposition will occur.

Less than 10 ppm and filtered for max of 600 micron size

5-8 ft/sec

Note: Grains = PPM divided by 17 • mg/l is equivalent to PPM

90/10 Cupro-Nickel

5 - 9

(Total Hardness) less than 350 ppm

10 - 50 ppm

Less than 125 ppm

Less than .5 ppm

Less than125 ppm

10 - 50 ppm

Less than 2 ppm

Less than .5 ppm

Less than .5 ppm

Less than .5 ppm

Less than .5 ppm

1000-1500 ppm

None

Less than 1 ppm. Above this level deposition will occur.

Less than 10 ppm and filtered for max of 600 micron size

8-12 ft/sec

Condensate Drain

On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a

3/4-inch PVC female adapter and a fl exible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the fi eld-installed PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary.

On horizontal units, a copper stub is provided for condensate drain piping connection. An external trap is required (see

Figures 4 and 5 below). If a vent is necessary, an open stand pipe may be applied to a tee in the fi eld-installed condensate piping.

Figure 4: Horizontal Drain Connection

Figure 5: Unit Pitch for Drain

Copper tube stub

Plastic Hose Clamps

(Included with unit)

Clear PVC hose

3/4" barb to glue adapter

Vent (if needed)

3/4" PVC

1/8" per foot

1.5"

1.5"

1/4'' Pitch

Drain

7


Closed Loop Ground Source Systems

Note: For closed loop systems with antifreeze protection, set SW2-2 to the “loop” position (see table on page 32).

Once piping is completed between the unit, fl ow center and the ground loop (see fi gure below), fi nal purging and charging of the loop is required. A fl ush cart (or a 1.5 HP pump minimum) is needed to achieve adequate fl ow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 PSI (summer) or 50-75 PSI (winter). This is normally adequate for good system operation. Loop static pressure will fl uctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fl uctuation is normal and should be considered when initially charging the system.

After pressurization, be sure to remove the plug in the end of the loop pump motor(s), if applicable, to allow trapped air to be discharged and to ensure that the motor housing has been fl ooded. Ensure that the loop fl ow center provides adequate fl ow through the unit by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in the specifi cation catalog. Usually 2.5 to 3 GPM of fl ow per ton of cooling capacity is recommended in earth loop applications. (See wiring diagram attached to the inside of the unit for pump wiring details.)

Figure 6: Closed Loop, Ground Source Application - Single unit with Flow Center

Unit Supply

Auxiliary Heat

Supply

GeoLink ®

Polyethylene w/

Armaflex ®

Insulation

TO

LOOP

Flexible Duct

Collar

Auxiliary

Heater

Knockout

Unit Power

Desuperheater

Connections

GeoLink

Flow

Center

®

Disconnects

(If Applicable)

Drain

External

Pump Power

Low

Voltage to

Thermostat

P/T Plugs

Vibration Absorbing Pad

Multiple Units on One Flow Center

When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the SL terminals on connector P2 in both units with 2-wire thermostat wire. These terminals are polarity dependant. The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one fl ow center is generally limited to a total of 20 GPM capacity.

GroundLoop Connector

Kits withArmaflex ®

(CK4S or CK4L)

Figure 7: Primary/Secondary Hook-up

Premier to Premier

Microprocessor Units

Premier Unit #1

Shut

Down

C C

SL1

In

SL1

Out

SL2

In

SL2

Out

With pump wired to Unit 1

With pump wired to

Unit 2

Premier to

Electromechanical Unit

Premier Unit #1

Shut

Down

C C

SL1

In

SL1

Out

SL2

In

SL2

Out

Shut

Down

C C

SL1

In

Premier Unit #2

SL1

Out

SL2

In

SL2

Out

C S

To Electromechanical Unit

8


Open Loop Ground Water Systems

Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensure proper water fl ow through the unit by checking pressure drop across the heat exchanger and comparing it to the fi gures in

Capacity Tables in the Specifi cation Catalog. Normally, about 2 GPM fl ow rate per ton of cooling capacity (1.5 GPM per ton minimum at 50°F) is needed in open loop systems.

Note: For open loop/ground water systems or systems that do not contain an antifreeze solution, set SW2-Switch #2 to the

“WELL” position.

Figure 8: Open System - Groundwater Application

Unit Supply

Aux. Heat Supply

Flexible

Duct Collar

Rubber Bladder

Expansion Tank

Auxiliary

Heater

Knockout

Desuperheater

Connections

Flow Control

Valve

(on outlet of

Solenoid Valve)

Solenoid

Valve

Water Out

Water In

Drain

Disconnects

(If Applicable)

Shut Off Valves

Shut Off Valves

(to isolate solenoid valve while acid flushing)

Compressor

Line Voltage

Low Voltage to Thermostat and Valve

P/T Plugs

Vibration

Absorbing Pad

Strainer

Boiler Drains

For HX Flushing

Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain fi eld, adjacent stream or pond, etc.). Most local codes forbid using the sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

The water control solenoid is wired between the common pin

#2 connector P1 and pin #3 connector P3, and a jumper wire is connected between R and pin #1 connector P3 (refer to Figure

9). Notice that DIP switch 2-3, located on the PCB, must be switched to the “Comp” position so the valve will operate with the compressor.

Figure 9: Typical single-stage external 24V water solenoid valves (type PPV100 or BPV100) wiring

P1

C

R

2

1

Solenoid

Valve

ACC Com

1

ACC NC 2

ACC NO 3

Note: Switch SW2 - 3 to comp position.

9


Boiler/Cooling Tower Closed Loop Systems

Boiler/Cooling Tower

The water loop is usually maintained between 60°F and 90°F. Premier units allow 25°F to 110°F EWT for proper heating and cooling operation.

To reject excess heat from the water loop, the use of a closed circuit evaporative cooler or an open type cooling tower with a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower is used without a secondary heat, continuous chemical treatment and fi ltering of the water must be performed to ensure the water is free from damaging materials.

Water Piping Connections

Units should not be connected to the supply and return piping until the water system has been cleaned and fl ushed completely. Supply and return water connections are standard female pipe thread on commercial units (1-inch swivel on residential units). Never use fl exible hoses with an inside pipe diameter that is smaller than the water connections on the unit and limit the hose length to 10 feet or less per connection. High-pressure fl exible hoses provide sound attenuation for both normal unit operating noise and hydraulic pumping noise. Hard piping can also be brought directly to the unit although it is not recommended since no vibration or noise attenuation can be accomplished.

10


System Cleaning and Flushing

Prior to start up of any heat pump, the water circulating system must be cleaned and fl ushed of all dirt and debris. If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location to prevent the introduction of dirt into the unit, (see Figure 10). The system should be fi lled at the water makeup connection with all air vents open. After fi lling, vents should be closed.

The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air and to verify circulation through all components of the system.

As water cirulates through the system, the contractor should check and repair any leaks found in the piping system.

Drain(s) at the lowest point(s) in the system should be opened for the initial fl ush and blowdown, making sure water fi ll valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the makeup water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, unil drain water is clean and clear.

The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short circuited supply and return runouts should now be connected to the unit supply and return connections.

Refi ll the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5). The specifi ed percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Environol™ brand antifreeze is recommended.

Once the system has been fi lled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, fl ow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure. In boiler/tower applications, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full fl ow has been established through all components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the units will be ready for check, test and start up and for air and water balancing.

Note: For closed loop systems with antifreeze protection, set SW2-2 to the “LOOP” position.

Figure 10: Flushing with Water Shutoff Valve Equipped Systems

Return Runout

Supply Runout

Rubber Hose

Runouts initially connected together

Mains

11


Desuperheater Connections

Water Tank Preparation

Electric water heaters are recommended for use with the desuperheater in potable water systems. A tank with a 50-gallon minimum capacity should be installed. Multiple tanks may be piped in series to create larger buffer tanks.

Figure 11: Water Heater Connection Kit

Brass Nipple

Boiler Drain

Male Adapter

Brass Tee

Figure 12: Desuperheater Installation In Preheat Tank

Venting Waste Valve or Vent Coupling

3/4” x 3/4” x 1/2” tee Cold

Water In

Hot

Water Out

Figure 13: Typical Desuperheater Installation

Venting Waste Valve or Vent Coupling

3/4” x 3/4” x 1/2” tee Cold

Water In

Hot

Water Out

DHW

Water In

DHW

Water Out P/T Relief

Valve

In

P/T Relief

Valve

Drain Valve Drain Valve

DHW

Water In

Note: Desuperheater pump mounted externally with commercial units; internally in residential units.

DHW

Water Out

P/T Relief

Valve

In

Drain Valve

12


Initial Desuperheater Startup

Plumbing Installation

1.

Remove drain valve and fi tting from water heater.

6.

7.

8.

9.

2.

3.

4.

5.

10.

11.

Thread the 3/4-inch NPT x 3 1/2-inch brass nipple into the water heater drain port.

Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.

Attach the 1/2-inch SWT x 3/4-inch NPT copper adapter to the side of the tee closest to the unit.

Install the drain valve on the tee opposite the adapter.

Run interconnecting tubing from the tee to DHW “WATER OUT” at the unit.

Cut the cold water “IN” line going to the water heater.

Insert the 3/4-inch x 3/4-inch x 1/2-inch reducing solder tee “IN” line with cold water line as shown.

Run interconnecting copper tubing between the unit DHW “WATER IN” and the tee (1/2-inch nominal) using (2) 1/2-inch sweat x 1-inch MPT adapters. The recommended maximum distance is 50 ft.

To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.

Insulate all exposed surfaces of both connection water lines with 3/8-inch wall closed cell insulation.

Note: All plumbing and piping connections must comply with local plumbing codes .

Desuperheater Startup

1. Close the drain valve to the water heater.

2. Open the cold water supply to the tank.

3. Open the hot water faucet in the house to bleed air from the system. Close when full.

4. Depress the handle on the pressure relief valve to bleed any remaining air from the tank then close.

5. If so equipped, unscrew the indicator plug on the motor end of the pump until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines.

6. Carefully inspect all plumbing for water leaks and correct as required.

7. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank.

• On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to 130°F. Depending upon the specifi c needs of the customer, you may want to adjust the upper element differently.

• On tanks with a single element, lower the thermostat setting to 120°F.

8. After thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater.

9. Make sure that any valves in the desuperheater water circulating circuit are open.

10. Turn on the Premier unit to fi rst stage heating.

11. The DHW pump should be running. Be sure the disable switch for the DHW pump (SW4) is ON. The DHW OFF

LED on the unit should not be illuminated.

12. The temperature difference between the water entering and leaving the desuperheater should be 5°F to 15°F. The

13. Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal.

14. When the pump is fi rst started, open the inspection port (if equipped) until water dribbles out, then replace. Allow the pump to run for at least fi ve minutes to ensure that water has fi lled the circulator properly.

CAUTION: Never operate the DHW circulating pump while dry. If the unit is placed in operation before the desuperheater piping is connected, be sure that the pump switch is set to the OFF position.

Desuperheater Notes: When servicing a unit’s refrigeration circuit, it is always good practice to disable the desuperheater pump. This can be accomplished by using the DHW pump disable switch located on the front of the unit cabinet near the LED annunciator panel. The red DHW OFF LED will illuminate, indicating the DHW pump is disabled.

13


Electrical Connections

General

Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Unit Power Connection

Connect the incoming line voltage wires to L1 and L2 or L1, L2, and L3 of the contactor as shown in Figures 14 and 15.

(For more information, refer to the Unit Electrical Data section in the Specifi cation Catalog SP1555.)

External Loop Pump Power Connection

If the unit is to be used with an external loop pump (FC1 or FC2 fl ow center), the pump(s) will be connected to the terminals on PB1 in the unit electrical box as shown in Figures 14 and 15. The pumps will automatically be cycled as required by the unit or by an SL signal from another Premier unit sharing the fl ow center.

Accessory Relay

A set of “dry” contacts has been provided to control accessory devices, such as 2-wire water solenoid valves on open loop installations, electronic air cleaners, humidifi ers, etc. This relay contact should be used only with 24 volt signals and not line voltage power. The relay has both normally open and normally closed contacts and can operate with either the fan or the compressor. Use DIP switch SW2-3 to cycle the relay with fan or compressor. The relay contacts are available on terminals #2 and #3 of P3. The default value of the switch is set to operate with fan. For use with electronic air fi lter.

208 Volt Operation

All Premier units are factory wired for 230 volt operation. There is a switch located on the control box which allows the installer to select 208 volt unit operation. Refer to Figures 14 and 15 below for switch location.

Figure 14: Line Voltage 208-230/60/1 Control Box

Compressor

Capacitor

Transformer

Compressor

Contactor

Ground

Lugs

208-230/60/1

Service with

Ground

L2

L1

Figure 15: Line Voltage 208-230/60/3 Control Box

Compressor

Contactor

208-230/60/3

Service with

Ground

Transformer

Ground

Lugs

L3

L2

L1

Voltage

Selection

Rocker Switch

PB1 PB1

Voltage

Selection

Rocker Switch

A

PS

C D A

PS

C D

Unit Control

Board

External Loop Pump(s)

208-230/60/1

1/2 HP Max

14

Unit Control

Board

External Loop Pump(s)

208-230/60/1

1/2 HPMax


Electronic Thermostat Installation

Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors and secure base to the wall. Thermostat wire must be 8-conductor 18 AWG wire. Strip the wires back 1/4-inch (longer strip lengths may cause shorts) and insert the thermostat wires into the connector as shown. Tighten the screws to insure tight connections. The thermostat has the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for detailed installation and operation information.

Figure 16: Thermostat Wiring

R

C

Y1

Y2

W

O

G

L

24VAC (Hot)

24VAC (Common)

Compressor (1st Stage)

Compressor (2nd Stage)

Aux. Heat

Reversing Valve

Blower Relay

System Monitor

Figure 17: Logic Board Physical Layout

F1 F1

N.O.

CR1- DHW

Pump

N.O.

CR2- Loop

Pump

N.C.

N.O.

Com

CR3-

N.O.

CR4-

Com

P4

1 2 3

CC-GND

CC

CCLO

CCHI

Microprocessor

C

C

R

R

P1

1 2 3 4 5 6

Off

SW1

On

7

8

5

6

3

4

1

2

9

10

11

12

7 8

R C Y1 Y2 W O G L

Off

SW2

On

7

8

5

6

3

4

1

2

SW3

Off On

1

Shut

Down

P2

2 3 4 5 6 7

C C

SL1

IN

SL1

Out

SL2

IN

SL2

Out

3

4

1

2

5

8

1

2

3

4

5

6

7

P3

1 2 3

8

9

10

11

12

13

14

9

10

11

12

13

14

15

16

5

6

3

4

7

2

1

ACC

NO

ACC

NC

ACC

COM

P6

P5

Notes: DIP switch SW2-#8 is required to be in the “OFF” position for the control to recognize the 24VAC thermostat inputs.

The second stage compressor wire must be installed between the unit and the thermostat for proper control operation. SW3-

2 “OFF” to be used with zoned systems. SW3-2 “ON” to be used for unzoned systems. SW3-4 “OFF” is used with ECM and

17P501A01 Electric Heat board. SW3-4 “ON” is used with ECM2 and 17P514A01 Electric Heat board.

15


Wiring Schematics

P Series/E Series - Single Speed Wiring Schematic - 208-230/60/1, ECM Blower

97P618-19 10/13/05

Compressor

Note 11

S C

Optional Factory

Intstalled Internal Pump

208-230/60/1

Pump

Note 12

PTCR

Blu

Cap

Tan

Red

R

Blk

Black

Black

Current Switch

CS

Ext Pump

1/2 hp Total

208-230/60/1

Unit Power

208-230/60/1

L2

T2

CC

T1

L1

Pump Pump

2

PB1

2

1

1

G

NOTE 4

PS1

D

C

G

Blk/Wh

Gray/Wh

A

Blk Blk/Wh

Blu

Blu

NOTE 6

DHW

Pump

Pink

Yel

Gray

Or Brn

3A

FUSE

Blu

Fused L2 Fused L2

240V L2

240V L2

F1-10A 240V

240V L1

208V 240V

Transformer

Switch

NOTE 1

Red

208V

Blu

240V

NO NO NO NC NO NC

CR1 COM CR2 COM CR3 COM CR4 COM

Transformer

Yel

24V

Blk/Wh

CC

W

O

G

L1

Thermostat

R

C

Y1

Y2

Violet

Violet

NOTE 9

NOTE 2

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 10

Optional

Electronic

Air-Filter

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

NOTE 3

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

7

8

5

6

3

4

1

2

1 2 3

P4

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

NOTE 7

SW1 On

7

8

5

6

9

3

4

1

2

10

11

12

SW2 On SW3

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12 (24 VDC)

On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 13)

No RPM / RPM

ECM, EH (See Note 8)

Must be ON

Main Logic PCB

R

4

5

14

13

7

8

P6

C

12

6

0

9

2

1

3

11

6

5

13

6

1

12

3

8

7

14

9

2

P5

11

4

10

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

Pink

Yellow

Yellow

Blue

Blue

Black

Black

LP

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

T

T

CS

CO

RV

HWL

FP

HP

SW4

Y

R

R

G

R

R

R

R LED Normal Display Mode

Drain

Water Flow

High Press

Low Press

Air Flow

Status

DHW Limit

DHW off

Field Selection Dips - #1 On, #6 On, #7 On

Drain pan overflow Lockout

FP thermistor (loop<15°F,well<30°F) Lockout

High Pressure > 380 PSI Lockout **

Low Pressure < 15 PSI Lockout **

ECM2 RPM < 100 rpm Lockout

Microprocessor malfunction*

HWL thermistor > 130°F

DHW pump switch off

*Green LED not flashing

** E Series units High Pressure > 600 PSI, Low Pressure < 40 PSI

Current Fault Status

#1 Off, #6 On, #7 On

Drain pan overflow

FP thermistor (loop<15°F, well<30°F)

High Pressure > 380 PSI

Low Pressure < 15 PSI

ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

16


Brn

Or

Grn

1 2 3 4 5 P11

ECM2

Fan Motor

3 15 16 10 8 P12

With optional ' EA' Series

Auxiliary ElectricHeat

Typical schematic shown

Brn

Or

Blu

Violet

Grn

1 2 3 4 5 P11

ECM2

Fan Motor

3 15 16 10 8 P12

Grn

P9

1

2

3

5

4

Auxiliary Electric Heat Power

208-230/60/1

L2 NOTE 5 L1

G L4 L2 L1 L3 G

F2

Brn

Or

Pink

Yel

Blk

Gray

PB2

Pink

Yel

Blk

Gray

ER1

2

1

4

3

P8

NO

Gray

ER2

NO

ER3

NO

Blk

Yel

2

3

1

P7

4

Gray

Blk

Yel

Pink

Pink

Yel

Blk

Gray

HE1

HE2

HE3

P2 1

ER4

NO

Pink

HE4

Gray

TS1

Blk

TS2

Yel

Pink

TS3

TS4

P10

1 2 3 4 5 6 EA Series PCB

17P514A01

P10

1

2

5

6

3

4

Black

Violet

Yellow

Blue

Gray

Orange

Blue

Pink

White

Tan

Red

L1

Legend

Factory Low voltage wiring

Factory Line voltage wiring

Field low voltage wiring

Field line voltage wiring

Optional block

DC Voltage PCB traces

Internal junction

Quick connect terminal

Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

T

G

P

1 2 3

Thermistor

Light emitting diode - Green

Relay coil

Capacitor w/ bleed resistor

Switch - Condensate overflow

Switch - High pressure

Switch - Low pressure

Switch -Hot Water On/Off

Polarized connector

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

Current Switch

Compressor Contactor

Condensate overflow sensor

DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses

Freeze protection sensor

HE -

HP -

Heater element

High pressure switch

ER1 to ER4 Aux heat stage relays

LP -

PB1, PB2 -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

TS -

HWL -

Low pressure switch

Power blocks

Power strip

Reversing Valve coil

DIP package 12 position



Hot water pump enable switch

Thermal limit switch

Hot water limit sensor

Logic Board Physical Layout

CSA installed units only

Local codes may require a single source of power supply

Single Disconnect Power

208-230/60/1

Breaker box furnished by installer

L1 L2

F1 F1

N.O.

N.O.

N.C.

N.O.

N.O.

CR1- DHW

Pump

CC-GND

CC

CCLO

CCHI

P4

1 2 3

C

C

R

R

SW1

Off On

7

8

5

6

3

4

1

2

9

10

11

12

P1

1 2 3 4 5 6 7 8

R C Y1 Y2 W O G L

CR2- Loop

Pump

SW2

Off On

7

8

5

6

3

4

1

2

CR3-

Microprocessor

Com

SeriesLogic Board

SW3

Off On

3

4

1

2

5

1

Shut

Down

2 3

P2

C C

4

SL1

IN

5

SL1

Out

6

SL2

IN

7

SL2

Out

Com

CR4-

1

9

1

10

11

12

13

14

15

2

3

4

5

6

7

16

8

8

9

1

2

10

11

12

13

14

3

4

5

6

P3

2

7

ACC

NO

ACC

NC

3

ACC

COM

P6

P5

L1

Circuit Breakers

L2 L1 L2

Aux Elect Power

208-230/60/1

Unit Power

208-230/60/1

Notes:

1 - Place switch to 208V position to operate unit at 208V.

2 - Connection of remote unit that does not have a loop pump for slave operation

3 - 24V Accessory relay (see SW2 - 3 for description of operation)

4 - The blk/wh and gray/wh wires are removed when Aux Heat is installed

5 - Buss lugs L1 and L2 can be removed and dual power wire sets connected directly to box

box lugs L1, L2, and L3, L4.

6 - DHW pump only in models with hot water generation option.

7 - Air Flow Configuration Example: SW1 configured for dip 3 as low, dip 5 as medium, and dip 7 as high speed ECM2 fan.

8 - SW3 - 4 should be in the OFF position when using ECM motor and 17P501A01 electric heat board and should be ON when using ECM2 with 17P514A01 electric heat board.

9 - When using thermostat TA32E12, SW2 -8 should be in the ON position.

When using 24VAC thermostats, SW2-8 should be in the OFF position.

10- When optional electronic air-filter is installed, power for the electronic air-filter is provided by P2-2 and 24 VAC.

11- Optional pumping systems available on residential models only. Internal pump only available on P Series units.

12- Only on 024 and 035 E series models.

13- SW3-2 should be OFF to operate with zone control system and ON to operate with unzoned system.

17


Wiring Schematics

P Series - Single Speed Wiring Schematic - 208-230/60/1, PSC Blower

97P619-36 10/13/05

NOTE 10

Grn

P010-013

PSC

Fan Motor

Wh

Brn

Cap

Grn

P019-066

PSC

Fan Motor

Wh

Brn

Cap

Compressor

Cap

Blu

Tan

S

Red

R

C

Blk

Black

Black

Current Switch

CS

3 Air Flow Settings

3 Air Flow Settings

H M L

P13

Wh

Unit Power

208-230/60/1

L2

T2 T1

CC

L1

Ext Pump

1/2 hp Total

208-230/60/1

Pump Pump

G

H M L C

P13

Wh

Blk

2

PB1

2

1

1

Gray

Yel

Blk

Blk

G

Wh

Or Brn

NOTE 4

NOTE 6

DHW

Pump

Blk/Wh

Gray/Wh

PS1

D

C

A

Blk Blk/Wh

Pink

Blu

Blu

3A

FUSE

208V 240V

Transformer

Switch

NOTE 1

240V L2

240V L2

Fused L2 Fused L2

240V L1

Blu

F1-10A 240V

Red

208V

Blu

240V

NO NO NO NC NO NC

AR

B

Transformer

COM COM

CR1 CR2 CR3 COM CR4 COM

Black

R

Yel

24V

Blk/Wh

S

C

R

Blk

Red

Brown

CC

Violet

Thermostat

R

C

Y1

Y2

L

1

G

W

O

Violet

NOTE 8

NOTE 2

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 9

Optional

Electronic

Air-Filter

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

5

6

7

8

3

4

1

2

NOTE 3

P3

Acc Com

Acc NC

Acc NO

1

2

3

1 2 3

P4

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

NOTE 7

SW1 On

6

7

4

5

1

2

3

10

11

8

9

12

SW2 On

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 11)

No RPM / RPM

EH (See Note 7)

Must be ON

Main Logic PCB

9

2

P5

11

4

10

5

13

6

7

14

1

12

3

8

14

12

6

15

10

9

2

1

3

13

7

4

5

8

P6

C

11

16

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

Pink

Yellow

Yellow

Blue

Blue

Black

Black

Not Used

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

LP

T

T

CS

CO

RV

HWL

FP

HP

SW4

G

Y

R

R

R

R

R

R

LED Normal Display Mode

Drain

Water Flow

High Press

Low Press

Air Flow

Status

DHW Limit

DHW off




High Pressure > 380 PSI Lockout

Low Pressure < 15 PSI Lockout




DHW pump switch off



#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

Diagnostic Modes

Inputs Outputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

18






208-230/60/1

L2 NOTE 5 L1

G L4 L2 L1 L3 G

F2

Brn

Or

3

2

5

4

1

3

2

5

4

1

Blu

Violet

Pink

Yel

P2

Blk

Gray

1

PB2

Pink

Yel

Blk

Gray

ER1

4

3

2

1

P8

NO

ER2

Gray

NO

ER3

NO

Blk

Yel

2

3

1

P7

4

Gray

Blk

Yel

Pink

Pink

Yel

Blk

Gray

HE1

HE2

HE3

ER4

NO

Pink

HE4

Gray

TS1

Blk

TS2

Yel

Pink

TS3

TS4

P10

1 2 3 4 5 6

EA Series PCB

17P514A01

P12

3

15

16

10

8

P10

1

2

5

6

3

4

Orange

Blue

Pink

White

Tan

Red

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

T

G

P

1 2 3

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HE -

HP -

ER1 to ER4 -

Current Sensor



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses


Heater element


Aux heat stage relays

Thermistor


Relay coil






Polarized connector

LP -

PB1, PB2 -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

TS -

HWL -

Low pressure switch

Power blocks

Power strip









CSA installed units only

Local codes may require a single source of power supply

Single Disconnect Power

208-230/60/1

Breaker box furnished by installer

L1 L2

F1 F1

N.O.

N.O.

N.C.

N.O.

N.O.

CR1- DHW

Pump

CC-GND

CC

CCLO

CCHI

P4

1 2 3

C

C

R

R

SW1

Off On

7

8

5

6

3

4

1

2

9

10

11

12

P1

1 2 3 4 5 6 7 8

R C Y1 Y2 W O G L

CR2- Loop

Pump

CR3-

Logic Board

17P513A02

Com Com

Microprocessor

SW2

Off On

7

8

5

6

3

4

1

2

SW3

Off On

3

4

1

2

5

1

Shut

Down

2 3

P2

C C

4

SL1

IN

5

SL1

Out

6

SL2

IN

7

SL2

Out

CR4-

1

ACC

NO

9

10

11

12

13

14

15

2

3

4

5

6

7

16

8

8

9

1

2

10

11

12

13

14

3

4

5

6

2

P3

7

1

ACC

NC

3

ACC

COM

P6

P5

L1

Circuit Breakers

L2 L1 L2

Aux Elect Power

208-230/60/1

AT Unit Power

208-230/60/1

Notes:


2 - Connection of remote unit that does not have a loop pump for slave operation.



5 - Buss lugs L1 and L2 can be removed and dual power wire sets connected directly to box lugs L1, L2, and L3, L4.

6 - DHW pump only in models with hot water generation option.

7 - SW3-4 should be in the ON position when using Premier 2 Electric Heat control 17P514A01, and it should be in the OFF position when using Premier Electric Heat control 17P501A01.

8 - When using thermostat TA32E12, SW2 -8 should be in the ON position. When using

24VAC thermostats, SW2-8 should be in the OFF position.

9 - When optional electronic air-filter is installed, power for the electronic air-filter is provided by

P2-2 and 24 VAC.

10- Unit may be wired with either example shown. Consult installation manual for blower speed wiring instructions.

11- SW3-2 should be OFF to operate with zone control system and ON to operate with unzoned system.

19


Wiring Schematics

P Series - Single Speed Wiring Schematic - 208-230/60/3, ECM Blower

97P618-20 10/13/05

Compressor

T3 T1

CS

Black

T2

Black

Red Blue

Current Switch

Blk

Ext Pump

1/2 hp Total

208-230/60/1

Pump Pump

G

2

PB1

2

1

1 G

Unit Power

208-230/60/3

L3

T3

L2

T2

CC

T1

L1

Blk/Wh

Gray/Wh

NOTE 4

C

A

PS1

D

Blk Blk/Wh

NO

Fused L2

NO

Yel Gray

Fused L2

NO NC NO NC

240V L2

F1-10A 240V

Or Brn

240V L1

208V 240V

Transformer

Switch

NOTE 1

Blu

240V

Red

208V

Transformer

24V

Yel Blk/Wh

NOTE 2

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 8

Optional

Electronic

Air-Filter

CC

W

O

G

L1

Thermostat

R

C

Y1

Y2

Violet

Violet

NOTE 7

SW4

R

R

G

Y

R

R

R

R

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

NOTE 3

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

1

2

3

4

7

8

5

6

CR1

COM

1 2 3

P4

CR2

COM

CR3 COM CR4 COM

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

NOTE 5

SW1 On

6

7

4

5

8

9

1

2

3

10

11

12

SW2 On

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 9)

No RPM / RPM


Must be ON

Main Logic PCB

R

10

3

8

P5

11

4

9

2

13

6

7

14

1

12

5

15

10

9

2

1

3

14

12

6

7

4

5

8

P6

C

13

11

16

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Pink

Yellow

Yellow

Blue

Blue

Black

Black

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

LP

LED

Drain

Water Flow

High Press

Low Press

Air Flow

Status

DHW Limit

DHW off

Normal Display Mode









DHW pump switch off



#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

T

T

CS

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

CO

RV

HWL

FP

HP

20


Brn

Or

Grn

1 2 3 4 5 P11

ECM2

Fan Motor

NOTE 9

3 15 16 10 8 P12

P10

1

2

3

4

5

6

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

P

T

G

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HE -

HP -

ER1 to ER4 -

Current Switch



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses


Heater element



Thermistor


Relay coil






Polarized connector

LP -

PB1, PB2 -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

TS -

HWL -

Low pressure switch

Power blocks

Power strip











Brn

Or

Blu

Violet

Orange

Blue

Pink

White

Tan

Red

Black

Violet

Yellow

Blue

Gray

Grn

1 2 3 4 5 P11

ECM2

Fan Motor

NOTE 9

3 15 16 10 8 P12

Logic Board (Single-Speed Configuration) Physical Layout


208-230/60/3

Grn

P9

1

2

3

5

4

Yel

Blk

P2

L1 L2 L3

F2

Brn

Or

PB2

Gray

1

G

Yel

Blk

Gray

2

1

4

3

P8

ER1

NO

ER2

Gray

NO Blk

ER3

Yel

NO

ER4

NO

2

3

4

1

P7

Gray

Blk

Yel

Yel

Blk

Gray

HE1

HE2

HE3

Gray

TS1

Blk

TS2

Yel

TS3

P10


17P514A01

P4

1 2 3

F1 F1

N.O.

N.O.

N.C.

N.O.

N.O.

Com Com

CR1- DHW

Pump

CC-GND

CC

CCLO

CCHI

CR2- Loop

Pump

C

C

R

R

SW1

Off On

7

8

6

5

3

4

1

2

9

10

11

12

P1

1 2 3 4 5 6 7 8

R C Y1 Y2 W O G L

SeriesLogic Board

17P513A02

Microprocessor

SW2

Off On

7

8

5

6

3

4

1

2

CR3-

SW3

Off On

3

4

1

2

5

1

Shut

Down

2 3

P2

C C

4

SL1

IN

5

SL1

Out

6

SL2

IN

7

SL2

Out

CR4-

1

ACC

NO

9

1

10

11

12

13

14

15

2

3

4

5

6

7

16

8

8

9

11

1

2

10

12

13

14

P3

2

5

6

7

3

4

ACC

NC

3

ACC

COM

P6

P5

Notes:





(ECM2 only).


6 - SW3-4 should be in the OFF position when using ECM motor and 17P501A01 electric heat board and should be ON when using ECM2 with 17P514A01 electric heat board.



8 - When optional electronic air-filter is installed, power for the electronic air-filter is provided by P2-2 and 24 VAC.

9 - SW3-2 should be OFF to operate with zone control system and ON to operate with un-zoned system.

21


Wiring Schematics


97P619-33 10/13/05

Compressor

PSC

Fan Motor

T3 T1

Brn

CS

Cap T2 Black

Grn

Wh

Black

Red Blue

Current Switch

Blk

3 Air Flow Settings

T3 T2 T1

H M L

P13

Unit Power

208-230/60/3

L3 L2

CC

L1

PS1 NOTE 4

Ext Pump

1/2 hp Total

208-230/60/1

Pump Pump

2

PB1

2

1

1

Black

White

G

Blk/Wh

Gray/Wh

D

C

Blk

Blk/Wh

G

A

208V 240V

Transformer

Switch

NOTE 1

Yel

Or Brn

Gray

Red

208V

Blu

240V

Fused L2

NO

Fused L2

NO NO NC NO

CR1

COM

CR2

COM

CR3 COM CR4 COM

NC

240V L2

F1-10A 240V

Black

240V L1

Transformer

24V

Yel Blk/Wh

NOTE 2

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 8

Optional

Electronic

Air-Filter

CC

Thermostat

R

C

Y1

Y2

W

O

G

L1

Violet

Violet

NOTE 7 P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

NOTE 3

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

1

2

3

4

7

8

5

6

1 2 3

P4

SW4

R

R

G

Y

R

R

R

R

ECM2

Air Flow

Settings

NOTE 5

SW1 On

6

7

4

5

1

2

3

8

9

10

11

12

SW2 On

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 9)

No RPM / RPM

EH (See Note 6)

Must be ON

Main Logic PCB


Drain

Water Flow

High Press





Low Press

Air Flow



Status

DHW Limit

DHW off




DHW pump switch off

Microprocessor

Logic Control

(DC Voltage)


#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

R

P5

11

4

9

2

10

3

8

13

6

7

1

12

5

14

15

10

9

2

1

3

14

12

6

7

4

5

8

P6

C

13

11

16

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Pink

Yellow

Yellow

Blue

Blue

Black

Black

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

LP

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

T

T

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

CS

CO

RV

HWL

FP

HP

22


Br n r

O

5

4

3

2

1




Brn

Or


208-230/60/3

Grn

P9

1

2

3

5

4

Yel

Blk

P2

L1 L2

F2

L3

Brn

Or

PB2

Gray

1

G

Blk

Gray

2

1

4

3

P8

Yel

Blk

Gray

ER1

NO

ER2

Gray

NO

Blk

ER3

Yel

NO

2

3

4

1

P7

Gray

Blk

Yel

ER4

NO

HE1

HE2

HE3

Gray

TS1

Blk

TS2

Yel

TS3

P10


17P514A01

P12

3

15

16

10

8

P10

1

2

3

4

5

6

Orange

Blue

Pink

White

Tan

Red


L1

Legend

Factory Blower voltage wiring





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

P

T

G

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HE -

HP -

ER1 to ER4 -

Current Switch



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses


Heater element



Thermistor


Relay coil






Polarized connector

LP -

PB1, PB2 -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

TS -

HWL -

Low pressure switch

Power blocks

Power strip







Hot water limit sensor P4

1 2 3

F1 F1

N.O.

N.O.

N.C.

N.O.

N.O.

CR1- DHW

Pump

CC-GND

CC

CCLO

CCHI

C

C

R

R

SW1

Off On

7

8

6

5

3

4

1

2

9

10

11

12

P1

1 2 3 4 5 6 7 8

R C Y1 Y2 W O G L

CR2- Loop

Pump

CR3-

SeriesLogic Board

17P513A02

Com Com

Microprocessor

SW2

Off On

7

8

5

6

3

4

1

2

SW3

Off On

3

4

1

2

5

1

Shut

Down

2 3

P2

C C

4

SL1

IN

5

SL1

Out

6

SL2

IN

7

SL2

Out

CR4-

1

ACC

NO

9

1

10

11

12

13

14

15

2

3

4

5

6

7

16

8

8

9

1

2

10

11

12

13

14

P3

2

3

4

5

6

7

ACC

NC

3

ACC

COM

P6

P5

Notes:





(ECM2 only).


6 - SW3-4 should be in the ON position when using Electric Heat control

17P514A01, and it should be in the OFF position when using Electric

Heat control 17P501A01.



8 - When optional electronic air-filter is installed, power for the electronic airfilter is provided by P2-2 and 24 VAC.


23


Wiring Schematics

P Series - Single Speed Wiring Schematic - 265/60/1, ECM Blower

97P618-15 10/13/05

Compressor Current Switch

S C

Blu

CS

Black

R

Black Cap

Red

Tan

Blk

Notes:









G

Unit Power

265/60/1

L2

T2 T1

CC

L1

Brn

Or

Grn

1 2 3 4 5 P11

240V L2

Fused L2 Fused L2

240V L2

F1-10A 240V

240V L1

Blk

Blu

265V

ECM2

Fan Motor

NO NO NO NC NO NC

CR1

COM

CR2

COM

CR3 COM CR4 COM

Transformer

Yel

24V

Blk/Wh

NOTE 1

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 5

Optional

Electronic

Air-Filter

CC

Thermostat

R

C

Y1

Y2

W

O

G

L1

Violet

Violet

NOTE 4

SW4

Y

R

R

G

R

R

R

R

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

NOTE 2

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

3

4

5

1

2

6

7

8

1 2 3

P4

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

NOTE 3

SW1 On

7

8

5

6

3

4

1

2

9

10

11

12

SW2 On

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3

On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 7)

No RPM / RPM


Must be ON

Main Logic PCB


Drain

Water Flow

High Press

Low Press

Air Flow

Status








DHW Limit

DHW off


DHW pump switch off



#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

R

10

9

2

1

3

12

6

15

7

4

5

14

8

13

P6

C

11

16

12

5

13

6

7

3

8

1

14

11

P5

4

9

2

10

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

Pink

Yellow

Yellow

Blue

Blue

Black

Black

LP

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

T

T

3 15 16 10 8 P12

CS

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

CO

P10

1

2

5

6

3

4

RV

HWL

FP

HP

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HP -

LP -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

Current Switch



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses



Low pressure switch

Power strip






P

T

G

Thermistor


Relay coil






Polarized connector

24


Wiring Schematics

P Series - Single Speed Wiring Schematic - 265/60/1, PSC Blower

97P619-21 10/13/05

Compressor Current Switch

NOTE 5

S C

Grn

P010-013

PSC

Fan Motor

Wh

Brn

Cap

3 Air Flow Settings

4 3 2 1 C

P13

4 Air Flow Settings

Grn

P019-034

PSC

Fan Motor

Wh

Brn

Cap

H M L

P13

Cap

Blu

Unit Power

265/60/1

Tan

L2

Red

R

T2 T1

CC

L1

Blk

Black

Black

CS

Notes:



3 - When using thermostat TA32E12, SW2 - 8 should be in the ON position.

When using 24VAC thermostats, SW2 - 8 should be in the OFF position.


5 - Unit may be wired with either example shown. Consult installation manual for blower speed wiring instructions.

6 - SW3-4 should be in the OFF position when using the 17P501A01 electric heat board and should be ON when using the 17P514A01 electric heat board.


Blk

Blk Wh

Wh G

Wh

Blk

RB

Blk

RB

Yellow

Black

Blk

Blu

265V

Fused L2 Fused L2

240V L2

240V L2

F1-10A 240V

240V L1

NO NO NO NC NO NC

NOTE 1

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 4

Optional

Electronic

Air-Filter

CC

Thermostat

R

C

Y1

Y2

W

O

G

L1

Violet

Violet

NOTE 3

CR1

COM

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

4

5

6

7

NOTE 2

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

6

7

4

5

8

1

2

3

1 2 3

P4

SW4

R

R

R

R

R

G

Y

R

CR2

COM

CR3 COM CR4 COM

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

SW1 On

7

8

5

6

3

4

1

2

9

10

11

12

SW2 On

1

2

3

4

Test / Norm

Loop / Well

Fan / Comp

Dehum / Norm

5 No Htg3 / Htg3

6 Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

4

5

2

3

2 Speed / 1 Speed

Zone (See Note 7)

No RPM / RPM

EH (See Note 6)

Must be ON

Main Logic PCB


Drain

Water Flow

High Press

Low Press

Air Flow







Status

DHW Limit

DHW off



DHW pump switch off


Yellow


#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

Transformer

Yel

24V

Blk/Wh R

15

10

9

2

1

3

14

12

6

7

4

5

8

P6

C

13

11

16

12

5

13

3

8

1

6

7

14

9

2

10

P5

11

4

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Pink

Pink

Yellow

Yellow

Blue

Blue

Black

Black

LP

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

T

T

CS

CO

P12

3

15

16

10

8

P10

1

2

3

4

5

6

RV

HWL

FP

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

HP -

LP -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

Current Switch



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses



Low pressure switch

Power strip






HP

P

T

G

Thermistor


Relay coil






Polarized connector

25


Wiring Schematics

P Series - Single Speed Wiring Schematic - 460/60/3, ECM Blower

97P618-16 10/13/05

Notes:

Compressor

Current Switch


T3 T1



T2

Black

CS

Unit Power

460/60/3

With Neutral

T3

Red

T2

Blue

Black

T1

Black




6 - 460 Volt units use a 265 volt, single phase ECM motor and require a dedicated neutral from the service panel.

G N L1 L2 L3 CC


L3 L2 L1

8- SW3-2 should be OFF to operate with zone control system and ON to operate with un-zoned system.

Note 6

Red

Brn

Violet

Or

White

CC Violet

Violet

Thermostat

R

C

Y1

Y2

W

O

G

L1

NOTE 4

NOTE 3

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 5

Optional

Electronic

Air-Filter

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

6

7

4

5

NOTE 1

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

3

4

5

1

2

6

7

8

NO

Fused L2

NO

Fused L2

NO NC NO

CR1

COM

CR2

COM

CR3 COM CR4 COM

NC

240V L2

F1-10A 240V

1 2 3

P4

SW4

Y

R

R

G

R

R

R

R

Microprocessor

Logic Control

(DC Voltage)

ECM2

Air Flow

Settings

NOTE 2

SW1 On

7

8

5

6

9

3

4

1

2

10

11

12

NOTE 3

SW2 On

1 Test / Norm

2

3

Loop / Well

Fan / Comp

4 Dehum / Norm

5 No Htg3 / Htg3

6 Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 8)

No RPM / RPM


Must be ON

Main Logic PCB


Drain

Water Flow

High Press

Low Press






Air Flow

Status

DHW Limit

DHW off





DHW pump switch off


#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

Blk

Blu

460V

240V L1

Transformer

24V

Yel Blk/Wh

Grn

1 2 3 4 5 P11

ECM2

Fan Motor

3 15 16 10 8 P12

R

4

9

2

P5

11

10

13

6

7

14

1

12

3

8

5

2

1

3

10

9

12

6

15

7

4

5

14

8

13

P6

C

11

16

Not Used

Not Used

Orange

Orange

Not Used

Not Used

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Yellow

Yellow

Blue

Blue

Black

Black

LP

T

CO

P10

1

2

5

6

3

4

RV

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HP -

LP -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

Current Sensor



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses



Low pressure switch

Power strip






FP

CS

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

HP

P

T

G

Thermistor


Relay coil






Polarized connector

26


NOTE 2

C

SL1 In

SL1 Out

Optional

Remote Unit

Without

Loop Pump

NOTE 5

Optional

Electronic

Air-Filter

CC Violet

Violet

Thermostat

R

C

Y1

Y2

W

O

G

L1

NOTE 3

Wiring Schematics


97P619-22 10/13/05

Current Switch

Green

PSC

Fan Motor

White

Brown

NOTE 4

Grn

PSC

Fan Motor

Brn

Wh

Cap

Refer to instructions below to change speeds.

- High - L1 to white side of capacitor, L2 to H on motor.

- Med - L1 to white side of capacitor, L2 to M on motor, orange wire to M1 on motor.

- Low - L1 to white side fo capacitor, L2 to L on motor,

Yellow wire to L1 on motor, Orange to M1 on motor.

Compressor

Red

T3

Blue

T2

T1

Black

Black

Black

CS

T3 T2 T1

3 Air flow

Settings

H M L Capacitor Unit Power

460/60/3

L3 L2

CC

L1

Ora Yel

Black

White

3 Air flow

Settings

H M L LI MI

MI LI

G

RB

Black

Blu

460V

Blk

Yellow

RB Black

1 2 3

P4

SW4

Y

R

R

G

R

R

R

R

NO

CR1

COM

P2

Shut

Down

C

C

SL1 In

SL1 Out

Not

Used

4

5

6

7

NOTE 1

P3

Acc Com

Acc NC

Acc NO

1

2

3

P1

R

C

Y1

Y2

W

O

G

LO

CC

CC-GND

7

8

5

6

3

4

1

2

Fused L2

NO

CR2

COM

Fused L2

NO

CR3 COM

NC NO

CR4 COM

Microprocessor

Logic Control

(DC Voltage)

NC

240V L2

F1-10A 240V

ECM2

Air Flow

Settings

SW1 On

6

7

4

5

1

2

3

10

11

8

9

12

SW2 On

1 Test / Norm

2

3

Loop / Well

Fan / Comp

4 Dehum / Norm

5

6

No Htg3 / Htg3

Inputs / Norm

7 Outputs / Norm

8 24 VAC / TA32E12

SW3 On

1

2

3

4

5

2 Speed / 1 Speed

Zone (See Note 6)

No RPM / RPM

EH (See Note 7)

Must be ON

Main Logic PCB


Drain

Water Flow

High Press

Low Press

Air Flow

Status








DHW Limit

DHW off



DHW pump switch off

Yellow


#1 Off, #6 On, #7 On

Drain pan overflow




ECM2 RPM < 100 rpm

Not Used


DHW pump switch off

12

5

13

3

8

1

6

7

14

9

2

10

P5

11

4

11

16

2

1

3

6

15

10

9

5

14

7

4

12

8

13

P6

C

240V L1

R

Yellow

Yellow

Blue

Blue

Black

Black

Not Used

Black

Violet

Yellow

Blue

Gray

Brown

Not Used

Not Used

Orange

Blue

Pink

White

Tan

Red

Not Used

Transformer

P10

1

2

3

4

5

6

16

10

8

P12

3

15

24V

Yel Blk/Wh

L1

Legend





Optional block


Internal junction


Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

CO

CS -

CC -

CO -

CR1 -

CR2-

CR3 -

CR4 -

F1 and F2 -

FP -

HP -

LP -

PS -

RV -

SW1 -

SW2 -

SW3 -

SW4 -

Current Switch



DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Fuses



Low pressure switch

Power strip






Not Used

Not Used

Orange

Orange

Not Used

Not Used

LP

T

CS

RV

FP

P

T

G

Thermistor


Relay coil






Polarized connector

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1

Y2

O

G

W

SL1

Not Used

--

Outputs

#6 On, #7 Off

Compressor

Not Used

RV

FAN

DHW Pump

Loop Pump

Not Used

--

Outputs2

#6 Off, #7 Off

Blower Lo

Blower Med

Blower Hi

Aux Heat #1

Aux Heat #2

AuxHeat #3

Aux Heat #4

--

HP

Notes:



3 - When using thermostat TA32E12, SW2 - 8 should be in the ON position. When using 24VAC thermostats, SW2 - 8 should be in the OFF position.

4 - Some fan motors may be terminated and wired with either example shown. Refer to instructions on motor to change speeds.

5 - When optional electronic air-filter is installed, power for the electronic air-filter is provided by

P2-2 and 24 VAC.

6 - SW3 - 2 should be OFF to operate with zone control system and ON to operate with un-zoned system.

7 - SW3-4 should be in the OFF position when using the 17P501A01 electric heat board and should be

ON when using the 17P514A01 electric heat board.

27


Fan Performance Data

ECM2 Motor

MODEL

P019

P022

P028

MAX

ESP

0.5

0.5

0.5

1

300

–

–

2

400

L

400

400

3

500

M

500

L

500

L

4

600

AIRFLOW DIP SWITCH SETTINGS

5

700

6

800

7

–

8

–

H

600

M

600

700

H

700

M

800

800

900

900

H

–

1000

9

–

–

1100

P034

P040

P046

P040 w/1hp*

P046 w/1hp*

P056

P066

0.5

0.5

0.5

0.75

0.75

0.75

0.75

–

650

650

800

L

800

750

750

10

–

–

–

11

–

–

–

12

–

–

–

–

750

–

850

L

850

600

950

700

L

M

800 900

M

1000

H

1100

H

1150

1050 1150 1250 1325 1375 1475

1225

–

1300

–

750

1000

M

1100

950

1300

H

1050 1150 1250 1325 1375 1475 1550 1600

L M H

1500 – – – – – – –

1000 1100 1300 1500 1600 1800

L M H

900 1000 1200

L

1400

M

1600 1700

–

1850

H

–

2000

–

2200

–

2300 2400

900 1000 1200 1400 1600 1700 1850 2000 2200 2300 2400

L M H

Notes: Factory settings are at recommended L-M-H DIP switch locations.

Factory L setting is minimum allowed for cooling.

M-H settings must be located within shaded CFM range.

CFM is controlled within 5% up to the maximum ESP.

Max ESP includes allowance for wet coil and standard fi lter.

* With optional 1 HP fan motor.

•

•

A 12-position DIP switch package on the control allows the airfl ow levels to be set for low, medium, and high speed when using the ECM2 blower motor. Only three of the DIP switches

• can be in the "on" position.

The fi rst "on" switch (the lowest position number) determines the low speed fan setting.

The second "on" switch determines the medium speed fan setting.

The third "on" switch determines the high speed fan setting.

The example to the right shows SW1 on the control board confi gured for the following P028 airfl ow settings.

Low Speed Fan: 500 CFM

Medium Speed Fan: 700 CFM

High Speed Fan: 900 CFM

Off

SW1

8

9

6

7

10

11

12

On

1

2

3

4

5

28


Fan Performance Data

PSC Motor

P028

P034

P040

P046

P056

L

H

M

L

H

M

L

H

M

L

H

M

L

H

M

MODEL

FAN

SPEED

MOTOR

HP

P010

H

MH

ML*

1/10

AIRFLOW (CFM) AT EXTERNAL STATIC PRESSURE (IN. WG)

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.60

0.70

0.80

0.90

1.00

450 440 420 410 380 360 340 330 310 300

410 400 380 370 350 330 310 300 280 270

–

–

–

–

–

–

–

–

–

–

P013

P019

P022

L

H

MH*

ML

L

H

M

L

H

M

1/10

1/6

1/5

370 360 340 330 310 290 280 270 250 240

310 300 280 270 250 240 230 220 210 200

450 440 420 410 390 370 350 340 320 310

400 390 380 370 350 340 320 310 290 280

370

330

790

1020

860

360

320

780

990

840

340

310

775

960

820

330

300

770

930

800

310

290

765

900

780

300

280

760

870

760

290

260

740

850

740

280

250

720

830

720

260

230

690

800

690

250

220

670

720 690 685 680 670 660 650 640 620 600

590 570 560 550 545 540 530 520 510 500

770

670

–

–

–

–

–

–

610

–

–

690

–

720 700 680 650 640 620 600 580 570 550 –

1120 1100 1070 1050 1040 1030 1020 1010 1000 980 830

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

1/3 1020 1000 980 960 920 880 860 840 820 790

1/2

1/2

1/2

860 850 840 830 810 800 780 760 740 710

1360 1340 1300 1270 1230 1200 1170 1150 1120 1090 990 870

1190 1170 1140 1120 1090 1060 1030 1010 970 930 – –

1010 990 970 950 940 920 900 880 860 840

– –

– –

1730 1700 1670 1650 1620 1580 1540 1490 1400 1290

–

–

1510 1500 1490 1480 1450 1430 1400 1380 1350 1320

1170 1160 1150 1140 1130 1120 1100 1080 1050 1030

– –

1710 1660 1630 1590 1560 1530 1490 1460 1410 1370

–

–

–

–

–

–

–

–

–

–

1870 1820 1780 1750 1720 1680 1630 1580 1450 1330 1190

–

1280 1250 1230 1220 1200 1180 1150 1120 1090 1050 –

– – – –

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

2180 2160 2130 2100 2070 2040 1990 1910 1810 1690

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

P066

L

H

M

L

3/4 2030 2010 1990 1970 1950 1930 1910 1880 1850 1830 1780 –

1790 1770 1760 1750 1730 1720 1700 1690 1670 1640 – –

1

–

–

–

–

–

–

– – – – 2540 2520 2490 2460 2430 2410 2320 2230 2130 1980 1820

2430 2390 2360 2340 2310 2290 2270 2250 2220 2190 2120 2050 – – –

2000 1980 1970 1950 1930 1920 1900 1860 1830 1780 – – – – –

Notes: Includes allowance for wet coil and clean factory installed fi lter.

A “ – “ in the table indicates operating range is not recommended.

Factory settings indicated in bold print.

* At 265V, the P010 is shipped on ML and the P013 on MH.

29


Standard Microprocessor Control Operation

The Premier control system is a microprocessor-based printed circuit board conveniently located in the unit control box for easy accessibility. The microprocessor provides control of the entire unit as well as outputs for status modes, faults, and diagnostics. Low voltage terminal strips provide all necessary terminals for fi eld connections. LEDs are located on the front of the unit for quick inspection without removing any access panels. The control offers optimal space conditioning. The board accepts traditional 24VAC thermostat inputs.

Startup

The unit will not operate until all the inputs and safety controls are checked for normal conditions. At fi rst power-up, a four-minute delay is employed before the compressor is energized.

Component Sequencing Delays

Components are sequenced and delayed for optimum space conditioning performance.

Accessory Relay

An accessory relay on the control board allows for fi eld connection of solenoid valves, electronic air cleaners, etc. The accessory relay has a normally open output and a normally closed output. The accessory relay is factory set to control the optional electronic air-cleaner.

Short Cycle Protection

The control employs a minimum “off” time of four minutes and a minimum “on” time of two minutes to provide for short cycle protection of the compressor.

Loop Pump SL Signals

A signal between multiple Premier control boards at the SL inputs and outputs (SL1-In and Out) will provide for remote control of the loop pump on any unit.

Condensate Overfl ow Protection

The Premier control board incorporates an impedance sensing liquid sensor at the top of the drain pan. Upon a continuous 30-second sensing of the condensate, compressor operation is suspended (see fault retry), the condensate overfl ow lockout LED begins fl ashing, and an output signal (LO) is made available for conneciton to a “fault” LED at the thermostat.

Shutdown Input

A simple grounded signal to the “shutdown” input on the control board puts the unit into shutdown mode. Compressor, hot water pump and fan operaiotn are suspended

Safety Controls

The Premier control receives separate signals for a high pressure switch for safety, a low pressure switch to prevent loss of charge damage, and a low suction temperature thermistor for freeze protection. Upon a continuous 30-second measurement of the fault (immediate for high pressure), compressor operation is suspended (see fault retry), the appropriate lockout

LED begins fl ashing, and an output signal (LO) is made available for connection to a “fault” LED at the thermostat.

Testing

The Premier control allows service personnel to shorten most timing delays for faster diagnostics (see fi eld selection DIP switch #1).

30


Standard Microprocessor Control Operation

Fault Retry

All faults (except for low RPM fault with the ECM2 fan motor) are retried twice before fi nally locking the unit out. The

“fault retry” feature is designed to prevent nuisance calls.

Diagnostics

The Premier control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board diagnosis (see fi eld selection DIP switches #6 and #7).

Resistance Heat Control

For units equipped with internal electric heaters, the electric heat control module contains the appropriate high-voltage control relays. Control signals energize the relays in the proper sequence, and the LED display board indicates which stages are energized.

Fan Speed Control

A DIP switch on the Premier control allows fi eld selection of low and medium fan speeds for cooling in the dehumidifi cation mode or medium and high fan speeds for cooling in the normal mode (ECM2 version only).

Hot Water High Limit

This mode occurs when the hot water thermistor temperature is at or above 130°F for 30 continuous seconds. The DHW limit status LED on the unit illuminates, and the hot water pump de-energizes. Hot water pump operations resume on the next compressor cycle or after 30 minutes of continuous compressor operation during the current thermostat demand cycle.

Hot Water Pump Switch

When the pump switch is engaged, hot water pump operation is disabled, and the pump status LED on the unit illuminates.

ECM2 Airfl ow Selection DIP Switches (SW1)

A 12-position DIP switch package on the Premier control allows the airfl ow levels to be set for low, medium and high speed when using the ECM2 blower motor (refer to the Blower table on page 28).

Only three of the DIP switches can be in the “on” position. The fi rst “on” switch (the lowest position number) determines the “low speed fan” setting. The second “on” switch determines the “medium speed fan” setting, and the third “on” switch determines the “high speed fan” setting.

31


DIP Switch Settings

Field Selection DIP Switches (SW2)

An eight-position DIP switch package on the control allows the fi eld selectable options shown in the table below.

FIELD SELECTION DIP SWITCHES (SW2)

DIP SWITCH

NUMBER

SW 2-

DESCRIPTION

1 Service Test Mode

Allows fi eld selection of “normal” or “test” operational modes. Test mode accelerates most timing functions 16 times to allow faster troubleshooting. Test mode also allows viewing the current status of the fault inputs on the LED display.

SW 2-

SW 2-

2 Freeze Protection Setting

Allows fi eld selection of freeze thermistor fault sensing temperatures for well water (30°F) or antifreeze-protected (15°F) earth loops.

3 Accessory Relay

Allows fi eld selection of the accessory relay to operate with the compressor or fan.

SW 2-

SW 2-

4 Fan Speed Control

Allows fi eld selection of reduced fan speed (85% of selected medium and high speed - ECM only) for cooling in the dehumidifi cation mode.

5 Auxiliary Off

Disables third-stage heating. Full emergency heat would still be available if needed.

SW 2-

SW 2-

SW 2-

Loop Water

Freeze Protection

15°F

Fan

OFF POSITION

Test Mode

Acc Relay Tracks

Dehumidifi cation

Fan Speeds

Disable Heating

Stage 3

6 Diagnostics-Inputs

Allows viewing the inputs from the thermostat to the control board such as Y1, Y2, O, G, W, and SL1-In on the LED display.

7 Diagnostics-Outputs

Allows viewing the outputs from the control board such as compressor, reversing valve, blower, hot water pump, and loop pump on the LED display

Diagnostic

Inputs/Output

Viewed at LEDs

Diagnostic

Outputs Viewed at LEDs

8 Thermostat Selection

Allows fi eld seleciton of the type of thermostat being connected to the Premier control. The DIP switch should be in the “off” position for 24VAC thermostats.

24 VAC

Thermostats

ON POSITION

Normal Timing

Operation

Well Water

Freeze Protection

30°F

Acc Relay Tracks

Compressor

Normal Fan

Speeds

Enable Heating

Stage 3

Normal Display

Viewd at LEDs

Normal Display

Viewed at LEDs

N/A

32


DIP Switch Settings

Factory Setup DIP Switches (SW3)

A fi ve-position DIP switch package on the control allows the fi eld selectable options shown in the table below.

FACTORY SETUP DIP SWITCHES (SW3)

DIP SWITCH

NUMBER

SW 3-

DESCRIPTION

1 Single-Speed

Confi gures the control for single-speed compressor operation and should always be left in the “ON” position.

SW 3-

SW 3-

OFF POSITION

Two-Speed Operation Single-Speed

Operation

2 Zoned/Finish on Second Stage

Confi gures control to operate with zoned or un-zoned systems

Zoned Systems

3 No RPM/RPM

Confi gures the control to monitor the RPM output of an

ECM/ECM2 blower motor. When using IntelliZone with a

PSC fan motor, the control should be confi gured for “NO

RPM” sensing.

PSC Fan/RPM

Monitoring

Disabled

ON POSITION

Un-Zoned Systems

ECM2 Fan/RPM

Monitoring

Enabled

SW 34 AT EH Board and ECM/Premier2 EH Board and ECM2

Confi gures the control to operate with electric heat control board (17P501A01) and ECM motor or with electric heat board (17P514A01) and ECM2

Electric Heat Control -

17P501A01

Electric Heat Control -

17P514A01

SW 35 Must be on Future Use Normal

33


FX10 Control Operation

(Optional Microprocessor)

•

•

•

•

•

•

•

•

FX10 Advanced Control

The Johnson Controls FX10 board is specifi cally designed for commercial heat pumps and provides control of the entire unit as well as input ports for Open N2, LonTalk,

BacNet communication protocols as well as an input port for a user interface. The user interface is an accessory item that can be used to aid in diagnostics and unit setup.

A 16-pin low voltage terminal board provides terminals for common fi eld connections. The FX10 Control provides:

Operational sequencing

High and low-pressure switch monitoring

General lockout

Freeze protection

Condensate overfl ow sensing

Lockout mode control

Emergency shutdown mode

Random start and short cycle protection

Main FX10 Board

(Shown with optional communication card)

User Interface

4 x 20 backlit LCD.

Short Cycle Protection

Allows a minimum compressor “off” time of four minutes and a minimum “on” time of two minutes.

•

•

•

Optional Plug-in Communication Modules -

(compatible with standard BAS protocols)

Open N2

LonTalk

BacNet

Random Start

A delay of 1 to 120 seconds is generated after each power-up to prevent simultaneous startup of all units within a building after the release from an unoccupied cycle or power loss.

Emergency Shutdown

A fi eld-applied dry contact can be used to place the control into emergency shutdown mode. During this mode, all outputs on the board are disabled.

Display

Requires DLI Card/Kit. Up to 2 displays, either 1 local and 1 remote, or 2 remote. (A 2-display confi guration requires identical displays.) Local display can be up to 3 meters from the controller, power supply, and data communication. Remote display can be up to 300 meters from the controller. Remote display must be independently powered with data communication done via 3 pole shielded cable.

Freeze Protection

Field selectable for 15° or 30°F (-9° or -1°C)

•

•

•

Installation Options

Stand-alone controlled by standard room thermostat

Stand-alone with a Zone Temperature Sensor (must have user interface to change set points beyond the allowed +/- 5°F)

Integrated into BAS by adding communication module

•

•

•

Inputs/Outputs

6 Analog Inputs

12 Digital Inputs

9 Digital Output Relays (or 7 relays & 2 triacs)

Control Timing & Fault Recognition Delays

Lead compressor “ON” delay 30 seconds

Lag compressor “ON” delay 60 seconds

(not applicable for single compressor models)

Minimum compressor “ON” time 2 minutes

(except for fault condition)

Short cycle delay

Random start delay

High pressure fault

Low pressure fault

4 minutes

0-120 seconds

<1 second

30 seconds

Freeze protection fault

Condensate overfl ow fault

Low pressure fault bypass

Freeze protection fault bypass

30 seconds

30 seconds

2 minutes

2 minutes

Accessory Outputs

Quantity 2. One cycled with fan, other with compressor.

Note: Refer to Submittal Data SD1981, Application Guide

AGFX10, or BACnet Protocol Implementation Conformance

Statement for more information.

34


Startup Procedures

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

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 fl ushed.

Air is purged from closed loop system.

Isolation valves are open, water control valves or loop pumps wired.

Condensate line open and correctly pitched.

Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been installed in models

019-066.

Dip switches are set correctly.

DHW pump switch is “OFF” unless piping is completed and air has been purged.

Blower rotates freely – foam shipping support has been removed.

Blower speed correct (DIP switch setting ECM blowers only).

Air fi lter/cleaner is clean and in position.

Service/access panels are in place.

Return air temperature is between 50-80ºF heating and 60-95ºF cooling.

Air coil is clean.

Startup Steps

Note: Complete the Equipment Startup/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure.

1. Initiate a control signal to energize the blower motor. Check blower operation. Desuperheater pump should be de-

energized.

2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.

3. First stage cooling will energize after a time delay.

4. Be sure that the compressor and water control valve or loop pump(s) are activated.

5. Verify that the water fl ow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and comparing to unit capacity data in specifi cation catalog.

6. Check the temperature of both the supply and discharge water. (Refer to the table on page 37.)

7. Check for an air temperature drop of 15°F to 20°F across the air coil, depending on the fan speed and entering water

temperature.

8. Decrease the cooling set point several degrees and verify high-speed blower operation.

9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps

deactivate.

10. Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set above room temperature.

11. First stage heating will energize after a time delay.

12. Check the temperature of both the supply and discharge water. (Refer to the table on page 37.)

13. Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the fan speed and entering water

temperature.

15. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.

16. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps

deactivate.

17. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.

18. Set system to desired normal operating mode and set temperature to maintain desired comfort level.

19. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.

35


Description of Unit Operation

Note: Fan speed operation below applies only to units equiped with ECM blower motors.

Heating Operation

Heat, 1st Stage (Y1)

The fan motor is started on low speed immediately, the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the “Y1” input. The fan is switched to medium speed 15 seconds after “Y1” input. The hot water pump is cycled 30 seconds after the “Y1” input.

Heat, 2nd Stage (Y1, Y2)

The hot water pump is de-energized, which directs all heat to satisfying the thermostat, and the fan changes to high speed 15 seconds after the “Y2”input.

Heat, 3rd Stage (Y1, Y2, W) additional stages of resistance heat engage sequentially every 5 minutes.

Emergency Heat

The fan is started on high speed, and the fi rst stage of resistance heat is energized 10 seconds after the “W” input.

Continuing demand will engage the additional stages of resistance heat sequentially every 2 minutes.

Cooling Operation

In all cooling operations, the reversing valve directly tracks the “O” input. Thus, anytime the “O” input is present, the reversing valve will be energized.

Cool, 1st Stage (Y1,O)

The fan motor is started on low speed immediately, the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized 10 seconds after the “Y1” input. In the ECM2 version, the fan is switched to medium speed 15 seconds after “Y1” input (remains in low speed if in dehumidifi cation mode). The hot water pump is cycled

30 seconds after the “Y1” input.

Cool, 2nd Stage (Y1, Y2, O)

The fan changes to high speed (85% of high speed if in dehumidifi cation mode) 15 seconds after the “Y2” input.

Fan (G only)

The fan starts on low speed. Regardless of fan input “G” from thermostat, the fan will remain on low speed for 30 seconds at the end of each heating, cooling or emergency heat cycle.

Lockout Conditions

During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The compressor, loop pump, hot water pump, and accessory outputs are de-energized. Unless the lockout is caused by an ECM2 low RPM fault, the fan will continue to run on low speed. If the thermostat calls for heating, emergency heat operation will occur.

Lockout modes of any kind can be reset at the thermostat after a 5-second waitinng perioud, which restores normal operation but keeeps the unit lockout LED illuminated. Interruption of power to the unit will reset a lockout without a waiting period and clear all lockout LEDs.

High Pressure

This lockout mode occurs when the normally closed safety switch is opened momentarily.

Low Pressure

This lockout mode occurs when the normally closed low pressure switch is opened for 30 continuous seconds.

Freeze Protection (Water Flow)

This lockout mode occurs when the freeze thermistor temperature is at or below the selected freeze protection point

(well 30°F or loop 15°F) for 30 continuous seconds.

Condensate Overfl ow

This lockout mode occurs when the condensate overfl ow level has been reached for 30 continuous seconds.

Fan RPM

When equipped with an ECM2 fan motor, the Premier control board monitors fan RPM to sense operation. This lockout mode occurs if the fan RPM falls below the low RPM limit (100 RPM) for 30 continuous seconds.

36


Operation Logic

OPERATION LOGIC

DATA

Compressor

ECM2 Normal

ECM2 Dehumidify

PSC

Rev Valve

Loop Pump

DHW Pump

Aux Heater

SL 1- Out

Emerg LED

T-Stat Signal

STG1

On

Med

Med

Low

Off

On

On

Off

On

On

Y1

HEATING

STG2

On

STG3

On

High

High

High

Off

On

Off

High

High

High

Off

On

Off

Off

On

Off

Y1, Y2

Staged

On

Off

Y1, Y2, W

EMERG

Off

High

High

High

Off

Off

Off

Staged

Off

On

W

COOLING

STG1

On

STG2

On

Med

Low

Low

On

On

On

High

Med

High

On

On

On

Off

On

Off

Y1, O

Off

On

Off

Y1, Y2, O

FAN ON SL1 - IN ON

–

Low

Low

–

–

–

–

–

–

Off

G

–

–

–

–

–

On

–

–

–

–

–

Typical Water and Air Temperature Changes

WATER

FLOW RATE

3 GPM/TON

1.5 GPM/TON

WATER TEMPERATURE CHANGE

RISE (CLG) DROP (HTG)

9-12

20-26

4-8

10-17

Water Pressure Drop

UNIT

P010

P013

P019

P022

P028

P034

P040

P046

P056

P066

GPM

4.0

5.5

7.0

5.0

7.0

9.0

3.0

4.0

5.0

3.0

4.5

6.0

5.0

8.0

11.0

6.0

9.0

12.0

1.5

2.0

2.5

1.5

2.5

3.5

8.0

11.0

14.0

10.0

13.0

16.0

30° EWT

1.2

2.1

3.2

2.4

3.9

6.2

1.2

2.1

3.5

1.5

3.2

6.0

1.7

3.5

6.2

2.2

4.5

7.2

2.1

3.4

5.2

2.0

4.6

8.1

2.6

4.8

7.5

3.7

6.1

9.3

AIR TEMPERATURE CHANGE

DROP (CLG) RISE (HTG)

15-20 20-35

50° EWT

1.2

2.0

3.1

2.2

3.7

5.9

1.2

2.0

3.3

1.4

3.1

5.8

1.6

3.3

5.9

2.1

4.3

6.8

2.0

3.2

4.9

1.9

4.4

7.7

2.5

4.6

7.2

3.5

5.8

8.9

PRESSURE DROP (PSI)

70° EWT

1.1

2.0

3.0

2.2

3.6

5.7

1.1

2.0

3.2

1.3

3.0

5.6

1.5

3.2

5.7

2.1

4.1

6.6

2.0

3.1

4.7

1.9

4.2

7.4

2.4

4.4

6.9

3.4

5.6

8.6

90° EWT

1.1

1.9

2.9

2.1

3.5

5.5

1.1

1.9

3.1

1.3

2.9

5.4

1.5

3.1

5.5

2.0

4.0

6.4

1.9

3.0

4.6

1.8

4.1

7.2

2.4

4.3

6.7

3.3

5.5

8.3

37

110° EWT

1.1

1.8

2.8

2.0

3.4

5.3

1.1

1.8

3.0

1.3

2.8

5.2

1.5

3.0

5.3

1.9

3.9

6.2

1.8

2.9

4.5

1.7

4.0

7.0

2.3

4.1

6.5

3.2

5.3

8.1


Troubleshooting

To check the unit control board for proper operation:

1.

Disconnect thermostat wires at the control board.

2.

Jumper the desired test input (Y1, Y2, W, O, or G) to the R terminal with the SW2-8 in the “OFF” position to simulate a thermostat signal.

3.

If control functions properly:

- Check for thermostat and fi eld control wiring (use the diagnostic inputs mode).

4. If control responds improperly:

- Ensure that component being controlled is functioning (Compressor, Blower, Reversing Valve, etc.)

- Ensure that wiring from control to the component is functioning (use the diagnostic outputs mode).

- If steps above check properly, replace unit control.

Note: Verify that air and water fl ow rates are at proper levels before servicing the refrigerant circuit.

LED Defi nition

LED

NORMAL DISPLAY

MODE

CURRENT FAULT

STATUS

Drain

Field Selection DIPs:

1-On, 6-On, 7-On

Drain Pan Overfl ow

Lockout

1-Off, 6-On, 7-On

Drain Pan Overfl ow

Water

Flow

High

Pressure

Low

Pressure

Airfl ow

Status

FP Thermistor

(Loop <15°F Well<30°F)

Lockout

High Pressure >380 PSI

Lockout

Low Pressure <15 PSI

Lockout

ECM2 RPM<100 RPM

Lockout

Microprocessor

Malfunction

FP Thermistor

(Loop<15°F, Well<30°F)

High Pressure >380 PSI

Low Pressure <15 PSI

ECM2 RPM <100 RPM

Not Used

DHW Limit HWL Thermistor >130°F HWL Thermistor >130°F

DHW Off DHW Pump Switch Off DHW Pump Switch Off

DIAGNOSTIC MODES

INPUTS OUTPUTS 1

1-N/A, 6-Off,

7-On

Y1

1-N/A, 6-On,

7-Off

Compressor

Y2

O

G

W

SL1

Not Used

–

Not Used

RV

Fan

DHW Pump

Loop Pump

Not Used

–

OUTPUTS 2

1-N/A, 6-Off,

7-Off

Blower Low

Blower Med

Blower High

Aux Heat #1

Aux Heat #2

Aux Heat #3

Aux Heat #4

–

Typical Superheat/Subcooling

ENTERING WATER

TEMPERATURE

30

50

70

90

HEATING COOLING

SUPERHEAT SUBCOOLING SUPERHEAT SUBCOOLING

9 - 14 5 - 9 25 - 35 15 - 25

10 - 14

12 - 16

N/A

5 - 9

5 - 8

N/A

10 - 18

9 - 14

8 - 13

15 - 25

13 - 18

13 - 18

Typical Suction & Discharge Pressures

ENTERING WATER

TEMPERATURE

HEATING

SUCTION DISCHARGE

30

50

70

90

35 - 45

55 - 65

70 - 90

90 - 110

170 - 200

185 - 220

200 - 240

220 - 260

COOLING

SUCTION DISCHARGE

62 - 77

70 - 83

73 - 86

75 - 88

95 - 125

125 - 165

170 - 210

220 - 260

38


Preventive Maintenance

Water Coil Maintenance

1.

Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to

2.

infi ltrate the water line. Lines should always be airtight.

Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure.

Note: On open loop systems, if the installation is in an area with a known high mineral content (125 PPM or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water fl owing through the unit the less chance for scaling.

Other Maintenance

Air Coil

To obtain maximum performance, the air coil should be cleaned before startup. A 10% solution of dishwasher detergent and water is recommended for both sides of coil; a thorough water rinse should follow.

CAUTION: Fin edges are sharp.

Fan Motors (ECM & PSC)

Blower Motors are equipped with sealed ball bearings and require no periodic oiling.

Desuperheater Coils

See Water Coil Maintenance section.

Filters

Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a fi lter.

Condensate Drain

In areas where airborne bacteria produce a sludge in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty fi lters. Inspect twice a year to avoid the possibility of overfl ow.

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 fi ns while cleaning.

Replacement Procedures

Obtaining Parts

When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

In-warranty Material Return

Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance.

39

Manufactured by WFI

9000 Conservation Way

Fort Wayne, IN 46809

WFI has a policy of continuous product research and development and reserves the right to change design and specifi cations without notice.

©2006 WFI.

Product:

Type:

Size:

Premier

Geothermal/Water Source Heat Pumps

3/4 thru 6 Tons

Document Type: Installation Manual

Part Number: IM1555

Release Date:

Supercedes:

11/06

IM1555 10/05

WaterFurnace Premier2 Installation manual

Geothermal/Water Source Heat Pumps

• 3/4 thru 6 Ton

Model Nomenclature

Table of Contents

Closed Loop Ground Source Systems 8

Open Loop Ground Water Systems 9

Boiler/Cooling Tower Closed Loop Systems 10

System Cleaning & Flushing 11

Desuperheater Connection & Startup 12-13

15

Electronic Thermostat Installation 15

Standard Microprocessor Control Operation 30-31

Description of Unit Operation 36-37

Troubleshooting 38

General Installation Information

Safety Considerations

Moving and Storage

Unit Location

Installing Vertical Units

Installing Horizontal Units

Duct System

Water Piping

Freeze Protection

Water Quality

Condensate Drain

Closed Loop Ground Source Systems

Multiple Units on One Flow Center

Open Loop Ground Water Systems

Boiler/Cooling Tower Closed Loop Systems

Boiler/Cooling Tower

Water Piping Connections

System Cleaning and Flushing

Desuperheater Connections

Water Tank Preparation

Initial Desuperheater Startup

Plumbing Installation

Desuperheater Startup

Electrical Connections

General

Unit Power Connection

External Loop Pump Power Connection

Accessory Relay

208 Volt Operation

Electronic Thermostat Installation

Wiring Schematics

P Series/E Series - Single Speed Wiring Schematic - 208-230/60/1, ECM Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 208-230/60/1, PSC Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 208-230/60/3, ECM Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 208-230/60/3, PSC Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 265/60/1, ECM Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 265/60/1, PSC Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 460/60/3, ECM Blower

Wiring Schematics

P Series - Single Speed Wiring Schematic - 460-575/60/3, PSC Blower

Fan Performance Data

ECM2 Motor

Fan Performance Data

PSC Motor

Standard Microprocessor Control Operation

Startup

Component Sequencing Delays

Accessory Relay

Short Cycle Protection

Loop Pump SL Signals

Condensate Overfl ow Protection

Shutdown Input

Safety Controls

Testing

Standard Microprocessor Control Operation

Fault Retry

Diagnostics

Resistance Heat Control

Fan Speed Control