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Installation and Service Manual
DXS-Series
Single-Stage R410a
Model Sizes 25-65
Direct Expansion Heat Pumps -
Split Systems
Maritime Geothermal Ltd.
P.O. Box 2555
Petitcodiac, N.B. E4Z 6H4
Ph. (506) 756-8135
DATE: 12 NOV 2012 Page 1
DATE: 12 NOV 2012
Email: [email protected]
Web: www.nordicghp.com
Document Number: 001570MAN-03
001570MAN-03
!
WARNING:
Ensure all access panels are in place and properly secured before applying power to the unit.
Failure to do so may cause risk of electrical shock.
WARNING:
Before performing service or maintenance on the heat pump system, ensure all power sources
are DISCONNECTED. Electrical shock can cause serious personal injury or death.
WARNING:
Heat pump systems contain refrigerant under high pressure and as such can be hazardous to
work on. Only qualified service personnel should install, repair, or service the heat pump.
CAUTION:
Safety glasses and work gloves should be worn at all times whenever a heat pump is serviced. A
fire extinguisher and proper ventilation should be present whenever brazing is performed.
CAUTION:
Venting refrigerant to atmosphere is illegal. A proper refrigerant recovery system must be
employed whenever repairs require removal of refrigerant from the heat pump.
Series:
DXS = Split Direct Expansion
Nominal Size:
25 = 2 Ton*
45 = 3 Ton
55 = 4 Ton
65 = 5 Ton
*Not available in 575-3-60
Functions:
H = Heating
AC = Active Cooling
W = Domestic Hot Water
Refrigerant:
P = R410a
MODEL NOMENCLATURE
DXS—65—HACW—P—1S—L—xx
Revision:
01, 02 etc.
Extra Loop:
= No
L = Yes
Compressor
Stages*:
S = 1 Stage
Voltage Code:
1 = 230-1-60 VAC
2 = 208-3-60 VAC
6 = 220-1-50 VAC
7 = 380-3-50 VAC
001570MAN-03 Page 2 DATE: 12 NOV 2012
SIZE FUNCTION
APPLICATION TABLE
REFRIGERANT VOLTAGE STAGES
25
45
55
HACW
HACW
HACW
P
P
P
REVISIONS
65 HACW P
This manual applies only to the models and revisions listed in this table
DATE: 12 NOV 2012 Page 3 001570MAN-03
Table of Contents
TABLES, DIAGRAMS & DRAWINGS: ……..……...………….……………………………………………………………… PAGE 5
INSTALLATION INFORMATION: …………………...………….……………………………………………………………… PAGE 6
Unit description: …………………………………………………………………………………………………..…... Page 6
Unpacking the unit: …………………………………………………………………………………………………... Page 6
Optimum Placement: …………………………………………………………………………………………………. Page 6
Electrical Connections: ……………………………………………………………………………………………… Page 6
Thermostat Requirements: ………………………………………………………………………………………….. Page 6
Air Handler Connections: …………………………………………………………………………………………… Page 6
Control Transformer: …………………………………………………………………………………………………. Page 6
Safety Controls: ………………………………………………………………………………………………………. Page 7
Domestic Hot Water Connections: …………………………………....…………………………………………… Page 7
DIRECT EXPANSION UNIT OPERATION: …………………....……………………………………………………………… PAGE 9
Refrigeration: ………………….…………………………………………………………………………………..…... Page 9
Control Board: …………...………………………………………………….………………………………………... Page 9
SIZING AND DUCTWORK: ………………...…………………………………………………………………………………… PAGE 12
Heat Pump Sizing: ……………………………………………………………………………………………………. Page 12
Air Handler Selection and Sizing: …………………………………………………………………………………. Page 12
Duct Systems - General: …………………………………………………………………………………………….. Page 12
Duct Systems - Grill Layout: ………………………………………………………………………………………… Page 13
Thermostat Location: ………………………………………………………………………………………………… Page 13
Plenum Heater (Optional): …………………………………………………………………………………………… Page 13
Condensate Drain: …………………………………………………………………………………………………….. Page 13
Duct Sizing Guide: ……………………………………………………………………………………………………. Page 15
DIRECT EXPANSION LOOP CONNECTION AND CHARGING: ………..……….………………………………………… PAGE 16
Line Set Interconnect Tubing: …….………………...……………………………………………………………… Page 16
Pipe Insulation: ………………………………………………………………………………………………………… Page 16
Silver Soldering Line Sets: ……..……………………………………………………………………………………. Page 16
Pressure Testing: ……………………………………………………………………………………………………… Page 16
Vacuuming the System: ……...………………………………………………………………………………………. Page 16
Charging the System: ………...………………………………………………………………………………………. Page 16
STARTUP PROCEDURE: ………………………………………………………………………………………………………. Page 18
Pre-start Inspection: …………………………………………………………………………………………………. Page 18
Unit Startup: …………..………………………………………………………………………………………………. Page 19
Startup Record: ……………….………………………………………………………………………………………. Page 20
HEATING TXV ADJUSTMENT: ………..…………….…………………………………………………………………………. Page 21
Adjustment Procedure: ……...………………………………………………………………………………………. Page 21
GENERAL MAINTENANCE: ……………………...…………….……………………………………………………………… PAGE 23
TROUBLESHOOTING GUIDE: ………………………………….……………………………………………………………… PAGE 24
Repair Procedures: …………………………………………………………………………………………………… Page 34
Refrigeration Diagrams: ……………………………………………………………………………………. Page 35
MODEL SPECIFIC INFORMATION: …………………..………………………………………………………………………. PAGE 37
Standard Capacity Ratings: ………………………..………………………………………………………………. Page 37
Capacity Ratings: ………………………………….…………………………………………………………………. Page 38
Electrical Tables: ……………………………………………………………………………………………………… Page 42
Electrical Diabrams—HACW (230-1-60): …………………………………………………………………………. Page 43
Case Details: ………………………...………………………………………………………………………………… Page 45
WARRANTY INFORMATION: ………………………………………………………………………………………………….. PAGE 48
001570MAN-03 Page 4 DATE: 12 NOV 2012
Tables, Diagrams and Drawings
TABLES
Table 1 - Control Signal Description: …….………………………………………………………………..…….... Page 6
Table 2 - Air Handler Control Signals: …..………………………………………………………………………... Page 6
Table 3 - Control Board Fault Codes: ……..……………………………………………………………………... Page 7
Table 4 - Cooling Mode Loop Sequences: ………………………………………………………………………... Page 9
Table 5 - Cooling Loop Configuration: ………………………………………….………………………………... Page 9
Table 6 - RS232 Port Configuration: ……………....……………………………………………….……………... Page 10
Table 7 - Control Board Commands: …………………..………………………..………………………………... Page 10
Table 8 - Control Board Default Settings: …..………….…………………………….…………………………... Page 10
Table 9 - Heat Pump Size vs. Heated Area: …………………………………….………………………………... Page 12
Table 10 - Air Flow and Air Coil Volume: …….....…..…………………………….……………………………... Page 12
Table 11 - Heat Pump Size vs. Hot Air Grills: …..…………………………….….……………………………... Page 13
Table 12 - Plenum Heater Sizing: …..…………..…………………………………..……………………………... Page 13
Table 13 - Duct Sizing Guide: ………………………..…………………………...………………………………... Page 15
Table 14 - DXS Charge Chart: …….…………………………………………………...…………………………... Page 16
Table 15 - Heating TXV Adjustment Record Column Descriptions: …….…………………………………... Page 21
Table 16 - Standard Capacity Ratings - Heating 60Hz: ………………………..…..…………………………... Page 37
Table 17 - Standard Capacity Ratings - Cooling 60Hz: …………….…………………………...……………... Page 37
Table 18 - Heat Pump Electrical Information (230-1-60): …..…………………….….………………………... Page 42
Table 19 - Heat Pump Electrical Information (208-3-60): …..…………………….….………………………... Page 42
Table 20 - Heat Pump Electrical Information (220-1-50): …..…………………….….………………………... Page 42
Table 21 - Heat Pump Electrical Information (380-3-50): …..…………………….….………………………... Page 42
DRAWINGS
000970PDG - Single Unit Connection to DHW Pre-Heat Tank (Brass FPT): ……………………………….. Page 8
000301CDG - NCB Laptop Communication Cable: ………………………….………………………………….. Page 11
000644CDG - Typical DXS Split System Duct and Condensate Connections: …...……….………………. Page 14
000769PDG - DX Line Set Interconnect Tubing Installation (R410a): ………..……………………………… Page 17
001568SCH - DXS-**-HAC*-P-1S Schematic Diagram: …………..….……….………….……..………….……. Page 43
001569ELB - DXS-**-HAC*-P-1S Electrical Box Diagram: ………..…...……..……..…………..……………... Page 44
DATE: 12 NOV 2012 Page 5 001570MAN-03
Installation Information
THERMOSTAT REQUIREMENTS
UNIT DESCRIPTION
The DXS-Series unit is a high efficiency single-stage split direct expansion (DX) heat pump with R410a refrigerant. It extracts and rejects heat from the earth via direct contact with copper loops, eliminating the need for a secondary heat exchanger and associated components. It must be connected to an air handler to complete the system.
Direct expansion units require less “loop” per ton and are more efficient than conventional ground loop systems. The reduced thermal resistance between the earth and the refrigerant circuit provides better heat transfer, resulting in a higher suction pressure and increased output.
The unit has several key features that are described in the specifications document for the particular heat pump. Please request a copy if desired or visit www.nordicghp.com
The DXS-Series unit requires a two-stage heating and one stage cooling thermostat with relay outputs for proper operation.
Triac output thermostats are incompatible with the control
board in the heat pump. The stages are S1 = Stage 1 compressor, S2 = electric auxiliary (heating only). One can be purchased with the unit, or other thermostats with the same number of stages can be used. The electrical box diagram (ELB) on the electrical box cover and
TABLE 1
provide a description of the signals.
TABLE 1 - Control Signal Description
Signal
G
Y
1
Description
Fan low speed (for air circulation)
Heat Pump Stage 1 (Compressor Stage 1)
UNPACKING THE UNIT
R
H
When the heat pump reaches its destination it should be unpacked to determine if any damage has occurred during shipment. Any visible damage should be noted on the carrier's freight bill and a suitable claim filed at once.
The heat pump is well constructed and every effort has been made to ensure that it will arrive intact, however it is in the customer's best interest to examine the unit thoroughly when it arrives.
L
W
2
Fault (24VAC when fault condition)
Heat Pump Stage 3 (auxiliary heat) /
Emergency Heat
O/B/W
1
Cooling Mode (reversing valve)
Y
2
Not Applicable
I
1
Plenum Heater dry contact
Plenum Heater dry contact
OPTIMUM PLACEMENT
NOTE: Some models are not available in two-stage at the present time (see Electrical Tables ). The Y2 signal is not used for these units.
The placement of the unit has negligible effects on the operation of the system. The unit can be placed wherever it can most easily be connected to.
If possible the access panels should remain clear of obstruction for a distance of two feet to facilitate servicing and general maintenance.
Raising the heat pump off the floor a few inches is generally a good practice since this will prevent rusting of the bottom panel of the unit. We recommend that the heat pump be placed on a piece of 2'' thick styrofoam. The styrofoam will smooth out any irregularities in the cement floor and deaden any compressor noise emitted from the bottom of the cabinet.
AIR HANDLER CONNECTIONS
The DXS unit is the master and is connected to the thermostat. It must provide control signals to the slave air handler as required for proper system operation. The available connections are shown in
TABLE 2
. These are all dry contact connections, meaning the control transformers for the DXS unit and the air handler remain separated.
For multi-speed or ECM fan motors all of the signals may be required. For single speed fan motors only F
G
is required.
Refer to the electrical box diagram and schematic for more information. The air handler power supply is separate from the
DXS unit power supply and should be on it’s own breaker.
ELECTRICAL CONNECTIONS
TABLE 2 - Air Handler Control Signals
The heat pump has a concentric 1.093” / 0.875” knockout for power supply connection to the electrical box. There is also a 0.875” knockout. There are two 1/2” openings with plastic grommets (grommet hole is 3/8”) in the upper section of the electrical box, one for the thermostat connections, and one for the optional plenum heater connections.
A schematic diagram and electrical box layout diagram
(ELB) can be found inside the electrical box cover of the unit as well as in the Model Specific section of this manual. The Electrical Tables in the Model Specific section and the ELB diagram contain information about the size of wire for the connections, as well as the recommended breaker size.
A properly qualified electrician should be retained to
make the connections to the heat pump and associated controls. The connections to the heat pump MUST CON-
FORM TO LOCAL CODES.
Signal
F
G
Description
Fan low speed (for air circulation)
F
Y2
F
W2
Fan high speed
Fan auxiliary / emergency heat speed
Use F
G
only if the air handler has a single speed fan.
CONTROL TRANSFORMER
The low voltage controls for all models are powered by a
100VA transformer with either primary and secondary fuses or a
100VA transformer with a secondary resettable breaker for circuit protection. Should a fuse blow, determine the problem and rectify it before replacing the fuse or resetting the breaker.
NOTE: For 208/230VAC-1-60 units, if connecting to 208VAC
001570MAN-03 Page 6 DATE: 12 NOV 2012
power supply move the red wire connected to the 240 terminal of the transformer to the 208 terminal of the transformer.
SAFETY CONTROLS
The heat pump has two built in safety controls which are designed to protect the unit from situations which could damage it should the operation of the refrigeration circuit fall outside the allowable operating range.
A. Low Pressure Control
The low pressure control monitors the compressor suction pressure and will shut the compressor down if the refrigerant evaporating pressure becomes too low.
B. High Pressure Control
The high pressure safety control monitors the compressor discharge pressure and will shut the compressor down if the condensing pressure becomes too high.
Each of the controls are auto-reset controls. There is also a manual reset high pressure control (HACW only) should the control board be faulty and fail to disengage the compressor. It can be reset by pressing the rubber button on the end of it. It is electrically located between the Y output of the control board and the compressor contactor coil.
HW units contain a control board that monitors the safety controls and operates the compressor accordingly. Refer to
APPENDIX A
for control board specifications. The low pressure control is connected to LP1 and LP2. The high pressure control is connected to HP1 and HP2.
The HW control board has an on-board LED and a
FAULT pin with a 24VAC output. An external indicator or relay can be connected across the FAULT pin and ground if external signaling is desired. Should a fault occur, the LED will flash the code of the fault condition while the safety control in question is open The codes are shown in
TABLE 3.
The control board will lock out the compressor for five minutes when a fault occurs.
Three retries per fault condition are allowed within a 60 minute period.
If the fault condition occurs a fourth time the control board will permanently lock out the compressor and energize the
FAULT pin. This can only be reset by powering down the unit.
The LED will flash the fault code until the unit is reset.
TABLE 3 - Control Board Fault Codes
Fault
High Pressure
Low Pressure
Code (HW)
1
2
LED (HACW)
HI (red)
LOW (green)
If the control board enters permanent lockout mode there is a serious problem with the system and it must be rectified if the unit is to maintain good service.
HACW units contain a control board that monitors the safety controls and operates the compressor accordingly. The
HACW control board also controls loop switching in cooling mode. Refer to the
Direct Expansion
section for more information.
The HACW control board monitors the pressure controls and shuts the compressor off immediately for a set period of time (adjustable) should there be a fault. Refer to
TABLE 3
for
DATE: 12 NOV 2012 Page 7 the LED indicators. The counter for the safety control in question will be increased by 1. The LED indicator for the control will flash until the control is reset as the pressures equalize in the unit. The unit may restart after the timer period has expired.
Should the unit trip on the safety control again , the compressor will once again shut down and the counter will be incremented by one again. Each time this occurs the count is incremented until the counter reaches the max value (default is 3) at which point a permanent lockout will occur if this occurred within a set period of time (default 6 hours) and the compressor cannot be started again until the control board is reset by shorting the reset pins together or turning the power off and on again. The lockout count is decreased after a set period of time (default 6 hours) if there are no more occurrences.
If the control board enters permanent lockout mode there is a serious problem with the system and it must be rectified if the unit is to maintain good service.
DOMESTIC HOT WATER
CONNECTIONS
A typical piping diagram for a pre-heat tank configuration can be found in
drawing 000970PDG
at the end of this section.
Be sure to note the position of the check valve and the direction of water flow. Other configurations are possible, and there may be multiple units tied together in larger buildings.
!
WARNING: USE ONLY COPPER LINES TO CONNECT
THE DESUPERHEATER. TEMPERATURES COULD
REACH 200F SHOULD THE DHW CUTOUT SWITCH
FAIL, POTENTIALLY RUPTURING PEX PIPING.
Ensure the tank is filled with water and under pressure before activating the heat pump. Slightly loosen the boiler drain on the DHW Out pipe to allow air to escape from the system before the unit is started. This step will make certain that the domestic hot water circulator in the unit is flooded with water when it is started.
CAUTION: the domestic hot water pump is water lu-
!
bricated; damage will occur to the pump if it is run
dry for even a short period of time.
Connect the brown wire with the
blue insulated terminal
to L1 of the compressor contactor (fuse terminal for 575-3-60 units). Ensure the power is off when connecting the wire.
The DHW loop may have to be purged of air several times before good circulation is obtained. A temperature difference between the DHW In and DHW Out can be felt by hand when the circulator pump is operating properly.
For the pre-heat tank setup, the final tank should be set to
140°F(60°C),
unless local code requires a higher setting.
The pre-heat tank does not require electric elements. This setup takes full advantage of the desuperheater as it is the sole heat provider to the pre-heat tank. The desuperheater remains active during the compressor runtime until the pre-heat tank has been completely heated by the desuperheater alone. This setup is more energy efficient than a single tank setup.
CAUTION: If two (2) shut-off valves are located on the domestic hot water ines as shown in the diagram, a pressure relief valve must be installed to prevent possible damage to the domestic hot water circulator pump should both valves be closed.
001570MAN-03
001570MAN-03 Page 8 DATE: 12 NOV 2012
Direct Expansion Unit Operation
REFRIGERATION
Direct expansion operation is essentially the same as any other heat pump. The main difference is in the outdoor loop section. Direct expansion heat pumps eliminate the intermediate ground loop exchanger and pumping equipment by using copper loops to interact directly with the earth. For each ton of capacity, the evaporator (heating mode) consists of one threeway valve, one heating thermostatic expansion valve (TXV), a pair of check valves and one outdoor copper loop with one vapour and one liquid connection to the heat pump. For each additional ton of capacity, there is a parallel evaporator circuit added to the unit.
In heating mode, all loops are used simultaneously to create a large evaporator. This allows maximum heat transfer from the loop field. Since each loop has it’s own TXV, its superheat can be individually tailored, allowing each loop to obtain the same superheat even it may have different soil conditions. The loop select valves default to open in heating mode, and as such none of the loop select valve solenoid coils are energized.
In cooling mode (HACW only), running all loops at the same time would create far too large a condenser and the unit would have very low head pressure, causing the suction pressure to fall off until the low pressure safety control was reached.
To circumvent this problem, the direct expansion unit will begin cooling mode by using only Loop 1.
Loops are selected by activating the solenoid on the loop select valve for the loop in question. The remaining loops are scavenged to the suction line.
Using one loop greatly reduces the size of the condenser, allowing the unit to operate properly. As the ground temperature warms up, rejecting the heat to the ground becomes more difficult, causing the head pressure to increase. When the loop is sufficiently hot enough to reach the Loop Switch set point
(290psig), the unit will switch to Loop 2. This starts the cycle over with a new loop and allows the previous loop time to recover. Heat pump operation will continue, switching through the loops as required.
The time between loop changes is monitored and should it fall below the adjustable threshold (default 15 minutes), indicating that the loops are sufficiently hot, the heat pump will begin using two loops at a time, and continue cycling. If the loop switch time falls below the threshold on two loop mode, the soaker hose will be turned on (if installed). The soaker hose cools the loops down with water. The loop sequences are shown in
TABLE 4
.
TABLE 4 - Cooling Mode Loop Sequences
# of
Loops
2
1
1 & 2
2 3 4 5 6
3
4
5
1 & 2
1 & 2
1 & 2
2 & 3
3 & 4
3 & 4
1 & 3
1 & 5 2 & 3 1 & 3 4 & 5
DATE: 12 NOV 2012 Page 9
As the transition from summer to fall begins and the cooling load is greatly reduced, the loops begin to cool down on their own. Eventually a point is reached at which the loops are cooled down enough that two loops becomes too large a condenser. This may occur naturally or there may be a few heating days and then a warm spell again (the loops settings are not affected by a switch to heating mode). Two loop operation can no longer be sustained and the unit will trip the low pressure safety control. This occurrence will set the heat pump back to one loop mode and allow the unit to run properly when it automatically restarts after the lockout timer expires.
CONTROL BOARD (HACW only)
All heating / cooling direct expansion units contain a control board that monitors the thermostat signals, safety controls and loop pressures. It controls the operation of the compressor, fan and auxiliary / emergency heat. It also activates the reversing valve and controls the loop sequencing when in cooling mode. Heating only units do not have a control board.
The number of cooling loops must be configured (done at the factory). There are two jumpers to the top right of the microcontroller. The configuration is shown in
TABLE 5.
There is also a jumper marked DEFAULT that should be left in place. The jumper marked IF NO B TERMINAL should be left place as well unless the thermostat used has a B terminal that is constantly powered in heating mode.
TABLE 5 - Cooling Loop Configuration
# of Loops Left Jumper Right Jumper
2 OFF OFF
3 ON OFF
4 OFF ON
5 ON ON
The control board has 4 connectors: one for the thermostat connections; one for the heat pump component connections; one for the loop solenoid connections; and one for the safety control and loop pressure switch connections. There are also several LEDs to indicate the status of the control board.
Refer to drawing 000301CDG
for the location of the connectors and
LEDs.
The Heart Beat LED flashes once every second. This indicates that the control board is operational. An on-board COP watchdog timer resets the microprocessor should anything affect code execution.
The high and low pressure control LEDs flash once per second when a control is open. They will stay on if there is a permanent lockout.
The loop switch LED will come on when the loop pressure switch is activated. Note that the loop switch is only for cooling mode, it does not affect heating mode operation. and also a mode switch timer (default 5 minutes). Both are adjustable through the control board communications port.
There is a compressor short-cycle timer (default 2 minutes)
001570MAN-03
The high pressure, low pressure and loop switch are 5VDC signals. The low pressure control connects to L and L on the control board. The high pressure control connects to H and H.
The loop switch connects to S and S. All other inputs and outputs are 24VAC.
When the thermostat calls for heat, the compressor will start (Stage 1), as will the fan after a short delay (adjustable).
The unit will run until the thermostat is satisfied and the unit shuts off (the fan will continue to run for an adjustable period); or, a set period of time elapses (default 40 minutes). Should the set period elapse, the auxiliary heat (Stage 2) will be engaged to help the unit on cold days when the load is too large for the unit.
When the thermostat calls for cooling, the compressor will start (Stage 1), as will the fan after a short delay (adjustable).
The unit will run until the thermostat is satisfied and the unit shuts off (the fan will continue to run for an adjustable period).
During operation, the control board will cycle through the loops as required.
The control board has an RS-232 communications port on board. A simple program such as Hyper Terminal and an adapter cable can be used to communicate with the control board.
Drawing 000301CDG
shows how to build the communications cable. The port settings are shown in
TABLE 6
. The commands available are listed in
TABLE 7
. Note that the COP must be unlocked by command U before using command C to change system settings. The list of settings for command C is shown in
TABLE 8
. It is recommended that the settings be left at the defaults values.
TABLE 6 - RS232 Port Configuration
Item Setting
Baud 9600
Data Bits 8
Parity None
Stop Bits
Flow Control
1
Xon / Xoff
TABLE 7 - Control Board Commands
Command
H
U
L
Description
Help - displays the list of commands
Lock / unlock the COP watchdog
Display loop status
!
Z
S
D
C
Display system status
Display system configuration
Change system settings (use U first)
Advance system time by 59 minutes
Reset loop timers to zero
TABLE 8 - Control Board Default Settings
Command Air Unit
Blower wait time after comp. start
Blower run time after comp. stops
Blower run time after aux. heat off
Aux. heat on time after comp. on
Comp. off if low lockout (HEAT)
Comp. off if low lockout (COOL)
Comp. off if high lockout (HEAT)
Comp. off if high lockout (COOL)
Comp. off time between heat & cool
Comp. delay since being off
Min. loop time before mode increase
Loop pressure testing wait time
Soaker start after comp. on time
Soaker hose run time (maintenance)
Soaker hose run time (emergency)
System check interval 2sec
Low pres. lockout counter reduce time 6hrs
High pres. lockout counter reduce time 6hrs
Low pres. lock ignore counter 3 times
High pres. lock ignore counter 3 times
Reset mode = 1 and loop memory time 2 weeks
Maximum mode to be allowed
Ignore low pres. for
Ignore low pres. for
2
5min
0sec
2sec
5sec
59sec
40min
5min
30min
5min
30min
5min
2min
15min
7sec
2hrs
4hrs
12hrs
001570MAN-03 Page 10 DATE: 12 NOV 2012
DATE: 12 NOV 2012 Page 11 001570MAN-03
Sizing and Ductwork
HEAT PUMP SIZING
TABLE 9
depicts a rough guideline as to the size of home each heat pump size can handle direct expansion installations.
It is recommended that an air handler with an A coil setup be selected. It is important that the air coil total volume be close to the volume shown in
TABLE 10
to minimize refrigerant charge adjustment. If a match is unavailable then select a higher air
TABLE 9 - Heat Pump Size vs. Heated Area
coil volume unit. Undersized air coils can cause problems with refrigerant back up in the coils, reducing output and efficiency.
Model
Size (tons)
Sq.ft.
Sq.m.
TABLE 10 - Air Flow and Air Coil Volume
Air Flow
Air Coil Volume
55 4 2,000
Model
Size (tons) cfm L/s
cu in
CC
80 6 3,100 290
THE TABLE ABOVE IS FOR INFORMATION ONLY, IT
SHOULD NOT BE USED TO SELECT A UNIT SIZE. It simply shows on average what size unit is required for a typical twolevel home (main level and below grade basement) with R-20 walls, R-40 ceiling and average size and number of windows.
The Heated Area is the area of the main level, The tables account for a basement the same size as the heated area.
MARITME GEOTHERMAL LTD. HIGHLY RECOMMENDS
THAT A PROPER HEAT LOSS/GAN ANALYSIS BE PER-
FORMEDE BY A PROFESSIONAL INSTALLER WITH CSA
APPROVED SOFTWARE BEFORE SELECTING THE SIZE OF
UNIT REQUIRED FOR THE APPLICATION. For heating dominant areas, we recommend sizing the unit to 100% of the heating design load for maximum long term efficiency with minimal supplementary heat. The unit should be installed as per CSA 448.2-02.
There are many factors to consider when sizing the heat pump. Some of these factors include the number of levels, the size of the windows, the orientation of the home, attached garage, bonus rooms, walk-in basement, coldest outdoor temperature, etc. The heat loss program will take all of these factors into consideration in its calculations. An undersized installation will not be as efficient and will require expensive supplementary heat to maintain a comfortable temperature in the home, and the cost savings of having a geothermal heat pump are greatly reduced.
Once the total heat loss has been calculated, the unit can be sized using the performance tables (from the specifications document) in conjunction with the minimum expected entering liquid temperature of the ground loop (well water temperature for ground water system). The heat pump output must be able to match the total heat loss at the selected entering water temperature in order to provide a comfortable environment with minimal auxiliary heat.
AIR HANDLER SELECTION AND SIZING
The air handler selected should match the size of the DXS unit as close as possible for heating and cooling loads. The air handler should be able to provide the air flow required (within
10%) by the DXS unit in order to maximize system efficiency.
See
TABLE 10
for the air flow values per unit size.
a bypass around the TXV for heating mode in order to function properly with the DXS unit.
The air handler must have its own cooling TXV as well as
001570MAN-03
80 6 2400 1133 353 5785
DUCT SYSTEMS - GENERAL
Ductwork layout for a heat pump will differ from traditional hot air furnace design in the number of leads and size of main trunks required. Air temperature leaving the heat pump is normally
95º -105ºF (35-40ºC)
, much cooler than that of a conventional warm air furnace. To compensate for this, larger volumes of lower temperature air must be moved and consequently duct sizing must be able to accommodate the greater air flow without creating a high static pressure or high velocity at the floor diffusers.
A duct system capable of supplying the required air flow is of utmost importance. Maritime Geothermal Ltd. recommends that the static pressure be kept below 0.2 inches of water total. In some instances the number of floor diffusers will actually double when compared to the number that would be used for a hot air oil-fired furnace. Refer to
TABLE 13
at the end of this section.
1. Generally allow 100 cfm for each floor grill.
2. All leads to the grills should be 6'' in diameter (28sq.in. each).
3. The main hot air trunks should be at least 75% of the square
surface area of leads being fed at any given point.
4. Return air grills should have a minimum of the same total
square surface area as the total of the supply grills.
5. The square surface area of the return trunks should equal
the square surface area of the grills being handled at any
given point along the trunk.
It is VERY IMPORTANT that all turns in both the supply trunks and the return trunks be made with
TURNING RADII
. Air acts like a fluid and, just like water, pressure drop is increased when air is forced to change direction rapidly around a sharp or irregular corner.
It is recommended that flexible collars be used to connect the main trunks to the heat pump. This helps prevent any vibrations from travelling down the ductwork. If a plenum heater is installed, the collar should be at least 12” away from the heater elements.
The first 5-10 feet of the main supply trunks should be insulated with acoustical duct insulation to further inhibit any noise from the unit from travelling down the ductwork. If a plenum heater is installed, insulation should not be placed within 12” of the heater elements.
Drawing 000644CDG
shows a typical installation.
Page 12 DATE: 12 NOV 2012
DUCT SYSTEMS - GRILL LAYOUT
Most forced air heating systems in homes have the floor grills placed around the perimeter of the room to be heated. Supply grills should be placed under a window when possible to help prevent condensation on the window. As mentioned in the previous sub-section, supply grill leads should be 6'' in diameter (28 sq.in. each) to allow 100cfm of air flow.
In a typical new construction, there should be one supply grill for every 100sq.ft. of area in the room. When rooms require more than one grill, they should be placed in a manner that promotes even heat distribution, such as one at each end of the room. It is always a good idea to place a damper in each grill supply or place adjustable grills so that any imbalances in the heat distribution can be corrected.
The total number of supply grills available is based on the heat pump nominal airflow.
TABLE 11
shows the number of grills available per heat pump size.
Return grills should be mounted on the floor. At minimum they should be the same size as the supply grill, it is highly
recommended that they be 25% to 50% larger than the total
supply. They should be placed opposite the supply grills when possible to ensure distribution across the room. For rooms requiring more than one supply grill, it may be possible to use one larger return grill if it can be centrally positioned opposite of the supply grills, however it is preferred to have one return for each supply to maximize heat distribution across the room.
TABLE 11 - Heat Pump Size vs. Hot Air Grills
Model
Size (tons)
# of Grills (@100cfm)
25 2
45 3
55 4
65 5
80 6
8
12
15
19
24
THERMOSTAT LOCATION
Most homes are a single zone with one thermostat. The thermostat should be centrally located within the home, typically on the main floor. It should be placed away from any supply grills, and should not be positioned directly above a return grill. Most installations have the thermostat located in a hallway, or in the inner wall of the living room. It should be noted that most homes do not have any supply ducts in the hallway. This can lead to a temperature lag at the thermostat if there is very little air movement in the hallway, causing the home to be warmer than indicated by the thermostat.
PLENUM HEATER (OPTIONAL)
For installations that do not already have a backup heat source such as electric baseboard, wood stove, propane etc, it is recommended that a plenum heater be installed. This provides two functions.
The first function of the plenum heater is to act as an auxiliary heat source. As such it will provide additional heat on extremely cold days if the heat pump is unable to bring the home temperature up quickly enough, eliminating any discomfort to the homeowner.
The second function of the plenum heater is to provide emergency heat should a problem occur that causes the heat pump to be locked out. This can be engaged by setting the thermostat to emergency heat, allowing the plenum heater to function while preventing the heat pump from operating. Should the heat pump fail while the home is vacant, the auxiliary function of the thermostat will maintain the temperature setting of the thermostat.
The plenum heater is powered separately from the heat pump. Only two control wires are needed to connect the plenum heater to the heat pump. Refer to the label on the plenum heater or the electrical box diagram on the inside of the electrical box cover of the unit for details on the connections.
The plenum heater should be mounted in the supply duct in a manner that allows all of the airflow to pass through it to prevent any hot spots in the heater elements.
TABLE 12
shows the recommended size plenum heater, as well as the wire size and breaker size needed to provide power to the plenum heater.
TABLE 12 - Plenum Heater Sizing
Heat Pump Plenum Heater (230-1-60)
Model
Size
(Tons)
Size
(kW)
Current
(A)
Breaker
(A)
Wire
Size
25 2 5 21 40 #10
45 3 10 42 60 #6
55 4 15 62 100 #3
65 5 20 84 125 #3
80 6 20 84 125 #3
CONDENSATE DRAIN
The air handler will have a condensate drain that allows the condensate which forms during the air-conditioning cycle to be removed from the unit. The drain should be connected as per the instruction provided with the air handler as well as local codes. During high humidity weather, there could be as much as 25 gallons of water formed per day.
Care should be taken in the spring to ensure that this pipe is not plugged with dust that has collected during the winter causing the condensate to overflow into the bottom of the heat pump and onto the floor. The condensate drain is internally trapped; however, proper venting is required external to the heat pump.
Refer to local codes to ensure the installation is done properly.
Drawing 000644CDG
shows a typical installation.
DATE: 12 NOV 2012 Page 13 001570MAN-03
001570MAN-03 Page 14 DATE: 12 NOV 2012
380
452
452
531
616
616
707
201
254
254
314
314
380
707
804
804
908
908
6500
7250
7800
8500
9200
9800
10900
1450
1750
2000
2250
2600
2900
3400
3600
4300
5250
6125
TABLE 13 - Duct Sizing Guide (external static of 0.20”H2O)
Airflow
(CFM)
37
Minimum
Duct Area
(sq.in)
Diameter
(in)
20 5
Rectangular Equivalents (in)
2.25 x 10 3 x 8 3.5 x 6 4 x 5.5 5 x 5
63
100
20
28
5
6
2.25 x 10 3 x 8
3.25 x 10 4 x 8
3.5 x 6 4 x 5.5 5 x 5
5 x 6 5.5 x 5.5 6 x 6
152
212
226
277
304
393
38
50
50
64
64
79
113
7
8
8
9
9
10
3.25 x 14 4 x 11
4 x 15 5 x 12
4 x 15
5 x 15
5 x 15
6 x 15
5 x 12
6 x 12
6 x 12
7 x 13
5 x 8.5
6 x 10
6 x 10
7 x 10
7 x 10
8 x 11
6 x 7 6.5 x 6.5
7 x 8 8 x 8
7 x 8 8 x 8
8 x 9 8.5 x 8.5
8 x 9 8.5 x 8.5
9 x 10 9.5 x 9.5
411
655
680
995
1325
113
154
154
201
12
12
14
14
16
7 x 18
7 x 18
8 x 22
8 x 22
8 x 30
8 x 16
8 x 16
9 x 19
`
9 x 14
9 x 14
10 x 12
10 x 12
11 x 11
11 x 11
10 x 17 11 x 15 12 x 14 13 x 13
9 x 19 10 x 17 11 x 15 12 x 14 13 x 13
10 x 22 12 x 18 14 x 16 15 x 15
Return Air
Diameter
(in)
Airflow
(L/s)
5 17
6
7
30
47
10
10
12
12
8
9
72
100
107
131
143
185
194 12
14
14
16
18
309
321
470
625
32
32
34
34
28
30
30
24
26
28
20
22
22
24
16
18
18
20
8 x 30 10 x 22 12 x 18 14 x 16 15 x 15
8 x 40
8 x 40
10 x 30
10 x 30
12 x 24
12 x 24
14 x 20
14 x 20
16 x 17 16.5 x 16.5
16 x 17 16.5 x 16.5
10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18.5 x 18.5
10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18.5 x 18.5
12 x 36 14 x 30 16 x 26 18 x 23 20 x 20
12 x 36 14 x 30 16 x 26 18 x 23 20 x 20
14 x 38 16 x 32 18 x 28 20 x 25 22 x 22
14 x 38 16 x 32 18 x 28 20 x 25 22 x 22
16 x 38 18 x 32 20 x 30 22 x 24 24 x 24
18 x 38 20 x 34 22 x 30 24 x 28 26 x 26
18 x 38 20 x 34 22 x 30 24 x 28 26 x 26
20 x 40 22 x 38 24 x 32 26 x 30 28 x 28
20 x 40 22 x 38 24 x 32 26 x 30 28 x 28
22 x 40 24 x 38 26 x 34 28 x 32 30 x 30
22 x 40 24 x 38 26 x 34 28 x 32 30 x 30
24 x 42 25 x 40 26 x 38 28 x 34 30 x 32 31 x 31
24 x 42 25 x 40 26 x 38 28 x 34 30 x 32 31 x 31
28 x 40 30 x 36 32 x 34 33 x 33
30 x 42 32 x 38 34 x 36 35 x 35
30 x 45 34 x 40 36 x 38 37 x 37
20
684
826 20
22
944
22
1062
24 1227
24 1369
26
1605
26
1699
28 2029
30
2478
32
2891
34 3068
34 3422
36
3681
36 4012
38 4342
38
4625
40
5144
DATE: 12 NOV 2012 Page 15 001570MAN-03
Direct Expansion Loop Connection & Charging
LINE SET INTERCONNECT TUBING
AND AIR HANDLER TUBING
Once the outside loops have been installed and run into the building, the piping to the ports on the unit can be constructed. Each line set has a liquid line and a vapour line.
The vapour line is 1/2” (OD) and the liquid line is 3/8” (OD). For horizontal loops, both lines are 1/2” (OD), reduce one of the lines in each line set down to 3/8” (OD) before running the lines over to the heat pump. These reduced lines will be the liquid line for each line set.
Do a final pressure check on each line set and then remove the pressure and cut the ends off the lines. The heat pump has ports labeled Liquid 1 to 5 and Vapour 1 to 5. Run each line set over to the designated ports on the heat pump.
Refer to
Diagram 000769CDG
for more information on how to connect to the heat pump.
Piping between the DXS unit and the air handler consists of two lines, a 7/8” OD vapour line and a 3/8” OD liquid line.
Run the piping as required between each unit and connect to each unit with copper couplings.
The tubing used for this procedure must be refrigeration tubing (cleaned & dehydrated) suitable for the job. Every effort must also be made to insure that the tubing does not become contaminated during installation. We recommend that caps be placed on the open ends of tubing immediately after cuts are made and that these caps are only removed after all bends have been made and the pipe fixed in its permanent location ready to make the silver soldered joints. It is very important to keep a refrigeration system perfectly clean and dry. Removing the caps just prior to silver soldering will ensure minimum exposure to the humidity in the atmosphere.
PIPE INSULATION
All line set piping inside the structure (between the structure entry point and the heat pump), as well as the piping between the DXS unit and the air handler should be insulated with 3/8” thick closed cell pipe insulation to prevent condensation and dripping onto floors or walls during the heating season. It can be slid onto the capped tubing without having to slice it down the side. Ensure that any joints in in the line sets are accessible for leak testing.
Liquid and Vapour ports and any remaining exposed tubing should be insulated with 3/8” thick closed cell pipe insulation once the silver soldering and pressure testing is complete.
Ensure that all individual pieces of pipe insulation are glued to each other so there are no air gaps.
SILVER SOLDERING LINE SETS
Once all the line sets have been routed, insulated and fastened in place, the connections to the heat pump ports can be made. Remove the pressure from the heat pump and cut the ends off of the Liquid and Vapour ports. Remove the caps from the line set tubing. The line sets can be connected to the ports on the heat pump using couplings, or alternately the tubing can be "swaged". The joints should be silver soldered with 5% silfos.
Maritime Geothermal Ltd. absolutely requires that dry
nitrogen be bled through the system during all silver soldering procedures so that no oxidation occurs on the
inside of the copper tubing. The service ports on the unit can be used to connect the nitrogen with a refrigeration manifold.
If necessary, a wet rag can be wrapped around the each of the ports to prevent melting the grommet when silver soldering.
Ensure that no water enters any of the ports or tubing.
PRESSURE TESTING
Once all connections are complete, the system should be pressure tested to 100PSIG (690kPa) with dry nitrogen. Check all joints at the unit and any made in the interconnect tubing for leaks using soap suds, Spray nine, etc. It is important not to bypass this step as vacuuming the system with a leak will be impossible and attempting to do so will introduce moisture into the system, making the vacuum process take much longer than if the leak had been found and repaired first.
VACUUMING THE SYSTEM
Remove the pressure from the system and connect the vacuum pump to the refrigeration manifold. Tighten all hose connections, open the valves on the manifold and start the vacuum pump.
Vacuum the system until the reading on an electronic vacuum gauge remains below 500 microns for a period of 5 minutes after the vacuum pump is shut off and the system is sealed.
CHARGING THE SYSTEM
Once the system has been vacuumed, refrigerant can be added by weighing in 1/3 of the prescribed refrigerant charge into the low side of the system. Start the heat pump in the heating mode and continue to add refrigerant as a liquid at a rate of no more than 1 lb. per minute until the prescribed charge is reached.
Alternately, before the machine is started, the entire charge can be weighed into the system through the high side of the system.
TABLE 14
shows the typical charge per unit size.
This allows for:
•
20ft of distance (40ft of pipe) interconnect tubing from
the unit to the wall,
•
20ft of distance from the wall to the borehole /trench,
• standard loops (100ft borehole or 150ft trench).
•
20ft of distance to the air handler
Additional refrigerant is required as per
TABLE 14
if the installation exceeds these parameters.
TABLE 14 - DXS Charge Chart (R410a)
Model
Size (tons)
Lbs.
kg
25 2 8
80 6
Extra loop (borehole)
Extra loop (trench)
Extra distance to borehole
Extra depth of borehole
Extra distance to trench
Extra length of trench
Extra distance in structure
Extra distance to air handler
24
1
1.5
0.1oz per foot
10.9
0.5
0.7
0.003
001570MAN-03 Page 16 DATE: 12 NOV 2012
DATE: 12 NOV 2012 Page 17 001570MAN-03
Startup Procedure
The following steps describe how to perform the startup procedure of the geothermal heat pump.
The DXS-Series Two-Stage R410a Startup Record located in this manual is used in conjunction with this startup procedure to provide a detailed record of the installation. A completed copy should be left on site, a copy kept on file by the installer and a copy should be sent to Maritime Geothermal Ltd.
Check the boxes or fill in the data as each step is completed. For data boxes, circle the appropriate units. Fill in the top section of all three copies, or one copy if photocopies can be made after the startup has been completed.
PRE-START INSPECTION
Ductwork:
1. Verify that all ductwork has been completed and is firmly attached to the unit. Verify that any dampers or diverters are
properly set for operation of the heat pump.
2. Verify that all registers are open and clear of any objects that would restrict the airflow.
3. Verify that a new air filter is installed and the cover is secured.
4. Verify the condensate drain is connected, properly vented and free of debris.
5. If a plenum heater has been installed, verify that it is securely fastened to the ductwork.
Line Sets Inside structure (Loops and Air Handler Connections):
1. Verify that all line sets are connected to the proper ports on the heat pump.
2. Verify that the line sets are completely insulated and securely fastened in place.
Domestic Hot Water (if equipped):
1. Verify that all shutoff valves are fully open and there are no restrictions in the piping from the heat pump to the domestic
hot water tank.
2. Verify that the entire system has been flooded and all the air has been purged as much as possible. Further purging may
be required after the system has been operating for a while.
3. Verify that the brown wire with the insulated terminal is disconnected in the electrical box. Refer to the schematic diagram
for more information.
Electrical:
1. Ensure the power to the unit is off. Ensure the power to the plenum heater is off if equipped.
2. Verify all high voltage connections. Ensure that there are no stray wire strands, all connections are tight and the ground
wire is connected tightly to the ground connector for the heat pump, air handler and plenum heater.
3. Record the fuse / circuit breaker size and wire gauge for the heat pump. Record the fuse / circuit breaker size, wire gauge
and size of the plenum heater if installed.
4. Verify that the control connections to the thermostat, air handler and plenum heater (if installed) are properly connected and
all control signals are off, so that the unit will not start up when the power is turned on.
5. Ensure all access panels except the lower one that provides access to the electrical box are in place.
Unit Charge:
1. Ensure the unit has been vacuumed and has refrigerant in it. If the unit is not fully charged, the remainder can be added
during the start up procedure. Record the current amount of refrigerant in the system.
001570MAN-03 Page 18 DATE: 12 NOV 2012
UNIT STARTUP
The unit is now ready to be started. The steps below outline the procedure for starting the unit and verifying proper operation of the unit. It is recommended that safety glasses be worn during the following procedures.
Preparation:
!
ENSURE UNIT IS CHARGED WITH REFRIGERANT BEFORE TURNING THE POWER ON. STARTING A
COMPRESSOR UNDER VACUUM WILL DESTROY IT IN A MATTER OF SECONDS, VOIDING THE WARRANTY.
IF THE UNITIS NOT FULLY CHARGED, THE REMAINDER CAN BE ADDED DURING HEATING MODE STEP 2.
!
1. Remove the caps from the service ports and connect a refrigeration manifold set to the unit.
2. Turn the power on to the heat pump and set the thermostat to OFF. Set up the thermostat as per the instructions provided
with it so that it will function properly with the heat pump system (set for heat pump, not for heating and cooling). The O
signal should be set to active in cooling mode.
3. Measure the following voltages on the compressor contactor and record them on the startup sheet: L1-L2, L2-L3, L1-L3.
Heating Mode:
1. Set the thermostat to heating mode and adjust the setpoint to activate Stage 2. The fan should slowly ramp up
to speed after the time delay of the thermostat expires (if applicable) and the compressor will start.
2. Check the refrigeration gauges. The suction and discharge pressures will depend on the loop temperatures, but they should
be about
75-95PSIG
and
290-365PSIG
respectively for a typical start-up. If the unit was not completely charged, add the
remaining refrigerant through the suction side only.
3. Monitoring the refrigeration gauges while the unit runs. Record the following data at the time interval(s) indicated:
Numbers 1 to 4, record at 10, 15, 20, 25, 30 and then average the values. Record numbers 5 to 8 at 30 minutes.
The average superheat for each line set should be 8-14°F (4-8°C). The TXV’s are set to four turns in (from all the way out) at the
factory and typically should not require any adjustments. Should adjustment be required, follow the Heating TXV Adjustment
procedure in this manual. Proceed to Step 4 once adjustments have been completed.
1. Suction pressure
2. Discharge pressure
3. Each loop Vapour Line temperature
4. Each loop superheat (Vapour line temperature - evaporating temperature (from suction gauge)
5. Duct Return temperature (poke a small hole in the flex collar and insert probe in airstream)
6. Duct Supply temperature (poke a small hole in the flex collar and insert probe in airstream)
7. Duct Delta T (should be between
22-32°F, 12-18°C
)
8. Compressor L1(C) current (black wire, place meter between electrical box and compressor)
4. Adjust the thermostat setpoint to the desired room temperature and let the unit run through a cycle. Record the setpoint
and the discharge pressure when the unit shuts off.
5. For units with a desuperheater, turn the power off to the unit. Connect the brown wire with the blue insulated terminal to the
compressor contactor as shown in the electrical box diagram. Turn the power to the unit on.
6. Verify the DHW IN and DHW OUT temperatures (if applicable) by hand
(caution: pipes get hot).
If the DHW OUT line does
not become hotter than the DHW IN line the circulator is air locked. Bleed the air from the system and check the temperature
differential again to ensure there is flow from the circulator.
7. Remove the electrical cover from the plenum heater. Place a current clamp meter around one of the supply wires. Turn on
the power to the plenum heater. Adjust the thermostat setpoint to
85°F (29°C).
Verify that the current draw increase as
each stage is activated. (10kW has 2 stages, 15kW has 3 stages and 20kW has 4 stages).
Cooling Mode:
1. Set the thermostat to cooling mode and adjust the setpoint to activate Stage 1 and Stage 2.
2. Monitoring the refrigeration gauges while the unit runs. Record the following after 10 minutes of runtime:
1. Suction pressure
2. Discharge pressure
3. Duct Return temperature
4. Duct Supply Out temperature
5. Duct Delta T
3. Adjust the thermostat setpoint to the desired room temperature if possible, otherwise set it just low enough to allow the unit
to run (ie 1°F (0.5°C) less than room temperature) and let the unit run through a cycle. Record the thermostat setpoint and
the suction pressure when the unit shuts off.
Final Inspection:
1. Turn the power off to the unit (and plenum heater if installed) and remove all test equipment.
2. Install the electrical box cover and the access panel on the heat pump. Install the service port caps securely to prevent
refrigerant loss. Install the electrical cover on the plenum heater if applicable.
3. Do a final check around the heat pump and ensure the area is clean.
4. Turn the power on to the unit and the plenum heater if installed. Set the thermostat to the final settings.
Startup Record:
1. The installer shall sign and date the Startup Record and have the homeowner sign as well. The installer shall leave the Startup
Record with the homeowner, retain a copy for filing and send a copy to Maritime Geothermal Ltd. for warranty registration.
DATE: 12 NOV 2012 Page 19 001570MAN-03
Installation Site
City
Province
Country
Startup Record —DXS-Series Size 25-65 Two-Stage R410a
Startup Date
Installer
Company
Check boxes unless asked to record data.
Circle data units.
Model
Serial #
Homeowner Name Homeowner Phone #
Ductwork
Line Sets
Domestic Hot
Water
Electrical
Check boxes unless asked to record data. Circle data units.
PRE-START INSPECTION
Ductwork is completed, dampers/ diverters are adjusted
Registers are open and clear of objects
Air filter and end cap are installed in air handler
Condensate Drain is connected, properly vented and free of debris
Plenum heater is securely fastened (if applicable)
Connected to proper ports, insulated and secured in place
All shut-off valves are open
Lines are full and purged
Desuperheater pump wire is disconnected
High voltage connections are correct and securely fastened
Circuit breaker (or fuse) size and wire gauge for Heat Pump A Ga.
Circuit breaker (or fuse) size, wire gauge, and Plenum Heater size A Ga. kW
Unit Charge
Low voltage connections are correct and securely fastened
Refrigerant charge before power is turned on
STARTUP DATA
Lbs kg
Preparation
Heating Mode
10 minutes
15 minutes
20 minutes
25 minutes
30 minutes
Voltage across L1 and L2, L1 and L3, L2 and L3
Final refrigerant charge Lbs kg
Suction Discharge V1 S1 V2 S2 V3 S3 V4 S4 V5 S5 V6 S6
VAC
Average
Duct Return, Duct Supply, and Delta T
Compressor L1 (black wire) current
Cooling Mode
Domestic Hot Water functioning
Thermostat setpoint and discharge pressure at cycle end
Suction Pressure / Discharge Pressure
Duct Return, Indoor Out, and Delta T
Thermostat setpoint and suction pressure at cycle end
In
A
°F °C
In
°F °C
Out
°F
°C
°F °C psig kPa
Out psig kPa
°F °C psig kPa
Date:
Installer Signature:
Homeowner Signature:
A total of three copies are required, one for the homeowner, one for the installer and on to be sent to Maritime Geothermal Ltd.
001570MAN-03 Page 20 DATE: 12 NOV 2012
Heating TXV Adjustment
If it is determined during the start up procedure that one or more of the heating TXV’s need to be adjusted, the following procedure and record sheet should be used to ensure that adjustments are recorded and performed in a systematic way.
TABLE 15
describes what each of the columns in the Heating TXV record sheet table represents.
Colunm
TABLE 15 - TXV Adjustment Record Column Descriptions
Description
Time Actual
Time EL
Common S
Common ET
Common D
Loop P
Loop V
Loop S
TXV #
Turns
In/Out
Actual time of the reading
Elapsed time since the first reading
Suction pressure
Evaporating temperature (from suction gauge or P/T chart)
Discharge pressure
Loop TXV position. (Number of turns in from all the way out)
Loop Vapour Line temperature
Loop Superheat (Vapour Line temperature - Evaporating temperature
The TXV that is being adjusted
The number of turns the TXV is being adjusted
The direction the TXV is being adjusted (In=clockwise, OUT=counter-clockwise)
The heating TXV’s are set to four turns in from all the way out at the factory. This should be sufficient for most installations, however it is sometimes necessary to make adjustments if the ground conditions vary or if the loop lengths vary. The procedure below explains how to properly adjust the TXV’s so that the task can be completed in the minimum amount of time.
•
The goal is to obtain a superheat value of 8-14°F (4-8°C) on each evaporator loop. It is good practice to average out the last few readings as the TXV’s tend to cycle, causing the superheat to vary.
•
Adjusting a TXV in (clockwise) increases the superheat of its evaporator loop. Adjusting a TXV out (counter-clockwise) decreases the superheat of its evaporator loop.
•
Adjusting one TXV affects the remaining evaporator loops, adjustments must be small and done to only one TXV at a time.
•
Adjustments are done every other time interval (ie every 10 minutes). The next two intervals should be averaged together for the next adjustment.
•
Always adjust the TXV that is the furthest out.
ADJUSTMENT PROCEDURE
1. Fill in the information section at the top of the adjustment record sheet. Circle °F or °C at the top right.
2. Record all data for the initial readings (elapsed time 0). Adjust the TXV for the loop that is the furthest out. Record the number of the TXV, how much it was adjusted in turns (ie 1/4, 1/2, 1), and in which direction it was adjusted. Record the new position of the adjusted TXV in the appropriate P column of the next row. Record the remaining TXV positions in their individual P columns in the next row.
3. At the next time interval, record the data in the current row. Verify that the superheat of the adjusted TXV has changed in the desired direction. Do not adjust the TXV. Mark —- in the TXV #, Turns, and In/Out columns.
4. At the next time interval, record all data. Adjust the TXV that is the furthest out. Record the TXV #, Turns and In/Out values.
Record the new position of the adjusted TXV in the appropriate P column of the next row. Record the remaining TXV positions in their individual P columns in the next row.
5. Repeat Steps 2 and 3 until all superheat values are within 8-14°F (4-8°C).
DATE: 12 NOV 2012 Page 21 001570MAN-03
001570MAN-03 Page 22 DATE: 12 NOV 2012
General Maintenance
Item
Air Filter
(In Air Handler)
Contactor
Condensate Drain
(In Air Handler)
GENERAL MAINTENANCE SCHEDULE
Interval Procedure
6 months or as recommended in air handler manual
Inspect for dirt. Replace if necessary.
1 year Inspect for pitted or burned points. Replace if necessary.
1 year or as recommended in air handler manual
Inspect for clogs. Remove and clean if necessary.
DATE: 12 NOV 2012 Page 23 001570MAN-03
Troubleshooting Guide
The following steps are for troubleshooting the geothermal heat pump. If the problem is with the domestic hot water or the plenum heater, proceed to those sections at the end of the troubleshooting guide. Repair procedures and reference refrigeration circuit diagrams can be found at the end of the troubleshooting guide.
STEP 1: Verify that the display is present on the thermostat. If it is not, proceed to POWER SUPPLY TROUBLE
SHOOTING, otherwise proceed to STEP 2.
STEP 2: Remove the door and electrical box cover and check to see if the HI or LOW LED’s are flashing or on. Record
The results . Turn the power off, wait 10 seconds and turn the power back on.
STEP 3: Set the thermostat to call for heating or cooling depending on the season, If a 24VAC signal does not appear across Y1
and C of the terminal strip within 6 minutes, proceed to the THERMOSTAT TROUBLESHOOTING section, otherwise
proceed to STEP 4.
STEP 4: If the HI or LOW LEDs flash and the compressor does not attempt to start, proceed to the SAFETY CONTROL
TROUBLESHOOTING section, otherwise proceed to STEP 5.
STEP 5: If HI or LOW pressure LED’s are not flashing and the compressor does not attempt to start, attempts to start but
cannot, starts hard, or starts but does not sound normal, proceed to the COMPRESSOR TROUBLESHOOTING section,
otherwise proceed to STEP 6.
STEP 6: If the compressor starts and sounds normal, this means the compressor is OK and the problem lies
elsewhere. Proceed to the OPERATION TROUBLESHOOTING section.
POWER SUPPLY TROUBLESHOOTING
Fault
No power to the heat pump
No display on thermostat
Possible Cause
Disconnect switch open
(if installed).
Fuse blown /
Breaker Tripped.
Blown Primary or Secondary fuse on transformer.
Verification
Verify disconnect switch is in the
ON position.
At heat pump disconnect box, voltmeter shows 230VAC on the line side but not on the load side.
Recommended Action
Determine why the disconnect switch was opened, if all is OK close the switch.
Reset breaker or replace fuse with proper size and type. (Timedelay type “D”).
Visually inspect. Remove fuse and check for continuity if in doubt.
Replace fuse.
Blown fuse on control board.
Visually inspect. Remove fuse and check for continuity if in doubt.
Replace fuse.
Faulty transformer. 230VAC is present across H1 and
H4 of the transformer but 24VAC is not present across X1 and X4 of the transformer.
Replace transformer.
001570MAN-03
Faulty wiring between heat pump and thermostat.
24VAC is not present across C and
R(R
H
) of the thermostat.
Correct the wiring.
Faulty Thermostat. 24VAC is present across C and R
(R
H
) of the thermostat but thermostat has no display.
Page 24
Replace thermostat.
DATE: 12 NOV 2012
THERMOSTAT TROUBLESHOOTING
Fault
No Y1 signal to heat pump
(after 6 minutes)
Possible Cause
Incorrect thermostat setup.
Verification Recommended Action
Thermostat does not indicate a call for heat. No 24VAC signal present across C and Stage 1 of the thermostat.
Correct the setup.
Faulty thermostat to heat pump wiring.
24VAC signal present across Stage
1 and C of the thermostat but not present across Y1 and C of the terminal strip.
Correct or replace wiring.
Faulty thermostat. No 24VAC between Stage 1 and C of the thermostat when a call is indicated on the thermostat.
Replace thermostat.
Fault
High Pressure
Control
Low Pressure
Control
SAFETY CONTROLS TROUBLESHOOTING
Possible Cause Verification Recommended Action
Faulty High Pressure Control (open).
*HP pressures must be at static levels.
Hi LED is flashing. Short H to H on the connector at the left of the control board and verify whether the
LED stops flashing or remains flashing.
Replace high pressure control if
LED stops flashing, replace control board if it does not.
Faulty Low pressure control (open).
* Must be a signal present on Y1 for this test.
*HP pressures must be at static levels.
Lo LED is flashing. Short L to L on the connector at the left of the control board and verify whether the
LED stops flashing or remains flashing.
Replace low pressure control if
LED stops flashing, replace control board if it does not.
Unit out of refrigerant. Check static refrigeration pressure of the unit for a very low value.
Locate the leak and repair it.
Spray nine, a sniffer and dye are common methods of locating a leak.
DATE: 12 NOV 2012 Page 25 001570MAN-03
COMPRESSOR TROUBLESHOOTING
Fault
Compressor will
not start
Possible Cause Verification Recommended Action
Manual High pressure control tripped.
Faulty control board.
Press the button on the control, it will click when pressed.
Proceed to Operation Troubleshooting.
Hi and Low LED’s off, HB is flashing but Y LED is not on, or no 24VAC across Y and C of bottom right connector.
Replace control board.
Faulty run capacitor.
(Single phase only)
Loose or faulty wiring.
Faulty compressor contactor.
Check value with capacitance meter. Should match label on capacitor. Compressor will hum while trying to start and then trip its overload.
Replace if faulty.
Check all compressor wiring, including inside compressor electrical box.
Fix any loose connections. Replace any damaged wires.
Voltage on line side with contactor held closed, but no voltage on one or both terminals on the load side.
Points pitted or burned.
Or, 24VAC across coil but contactor will not engage.
Replace contactor.
Thermal overload on compressor tripped.
Burned out motor.
(open winding)
Ohmmeter shows reading when placed across R and S terminals and infinity between C & R or C & S.
A valid resistance reading is present
Proceed to Operation Troubleshooting to determine the cause of the thermal overload trip. again after the compressor has cooled down.
Remove wires from compressor.
Ohmmeter shows infinite resistance between any two terminals Note:
Be sure compressor overload has had a chance to reset. If compressor is hot this may take several hours.
Replace the compressor.
Replace the compressor. Burned out motor.
(shorted windings)
Remove wires from compressor.
Resistance between any two terminals is below the specified value.
Motor shorted to ground. Remove wires from compressor.
Check for infinite resistance between each terminal and ground.
If any terminal to ground is not infinite replace the compressor.
Seized compressor due to locked or damaged mechanism.
Compressor attempts to start but trips its internal overload after a few seconds. (Run capacitor already verified)
Attempt to “rock” compressor free. If normal operation cannot be established, replace compressor.
Compressor starts hard
Start capacitor faulty.
(Single phase only)
Potential Relay faulty.
(Single phase only)
Compressor is “tight” due to damaged mechanism.
Check with capacitance meter.
Check for black residue around blowout hole on top of capacitor.
Replace with new one and verify compressor starts properly.
Compressor attempts to start but trips its internal overload after a few seconds. Run capacitor has been verified already.
Replace if faulty.
Remove black residue in electrical box if any.
Replace if faulty.
Attempt to “rock” compressor free. If normal operation cannot be established, replace compressor.
001570MAN-03 Page 26 DATE: 12 NOV 2012
OPERATION TROUBLESHOOTING - HEATING MODE
Fault Possible Cause
High Discharge
Pressure
Air Flow.
Heating TXV’s adjusted too far closed.
One or more heating
TXV’s stuck (too far closed).
Faulty Normally Open solenoid valve (stuck closed).
Faulty cooling TXV bypass check valve.
(blocked)
Filter-drier plugged.
Verification Recommended Action
See Fan Troubleshooting section. Correct the problem.
Verify superheat. It should be between 8-14°F (3-8°C). Superheat will be high if TXV’s are closed too far.
Adjust TXV to obtain 8-14°F
(3-8°C) superheat.
Adjusting the TXV does not affect the superheat or the suction pressure.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
A click can be heard when the coil is energized but the valve is cold instead of warm.
Replace NO valve.
Temperature drop can be felt across the cooling TXV. Unit operates properly in cooling mode.
Try switching modes a few times.
Replace check valve if problem continues.
Feel each end of the filter- drier, it should be the same temperature. If there is a temperature difference then it is plugged. Also causes low suction pressure.
Replace filter-drier.
Surging
Discharge
Pressure
Low Suction
Pressure
DATE: 12 NOV 2012
Undersized Air Handler air coil.
High sub-cooling, low delta T across air coil.
Unit is overcharged. High sub-cooling, low delta T across air coil.
Verify size of air coil. Attempt to reduce charge and verify in both modes. Replace with proper size air handler
Remove 1/2lb of refrigerant at a time and verify that the discharge pressure reduces.
Heating TXV’s adjusted too far closed.
Verify superheat. It should be between 8-14°F (3-8°C). Superheat will be high if TXV is closed too far.
Adjust TXV to obtain 8-14°F
(3-8°C) superheat.
Heating TXV’s adjusted too far closed.
One or more heating
TXV’s stuck (too far closed).
Adjusting the TXV does not affect the superheat or the suction pressure.
TXV may be frosting up.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
Adjusting the TXV does not affect the superheat or the suction pressure.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
A click can be heard when the coil is energized but the valve is cold instead of warm.
Replace NO valve. Faulty Normally Open solenoid valve (stuck closed).
** May actually draw a vacuum.**
Filter-drier plugged. Feel each end of the filter- drier, it should be the same temperature. If there is a temperature difference then it is plugged. Also causes low suction pressure.
Replace filter-drier.
Low refrigerant charge. Check static refrigeration pressure of the unit for a very low value. Low discharge pressure when running.
Locate the leak and repair it.
Spray nine, a sniffer and dye are common methods of locating a leak.
Page 27 001570MAN-03
Fault
OPERATION TROUBLESHOOTING - HEATING MODE
Possible Cause Verification Recommended Action
Low Suction
Pressure
(continued)
Faulty compressor, not pumping.
Loop piping interchanged
(ie Loop 1 connected between Vapour 1 and
Liquid 2)
Loop field too small
Pressures change only slightly from static values when compressor is started.
Replace compressor.
Affected TXV’s do not seem to operate properly. Switch to cooling mode and verify all liquid line temperatures for each individual loop switch. The liquid line for the loop in use should be warmer than the others, If loops are interchanged, the wrong liquid line will be warmer.
Pump the unit down and swap the interchanged lines.
Charge is good, superheats are good, vapor line temperatures are low.
Increase loop size.
High Suction
Pressure
(may appear to not be pumping)
Leaking reversing valve. Reversing valve is the same temperature on both ends of body, common suction line is warm, compressor is running hot.
Replace reversing valve.
Heating TXV’s adjusted too far open.
Verify superheat. It should be between 8-14°F (3-8°C). Superheat will be low if TXV’s are open too far.
Adjust TXV to obtain 8-14°F
(3-8°C) superheat.
One or more heating
TXV’s stuck (too far open).
Adjusting the TXV does not affect the superheat of the loop or the suction pressure. Low super heat, low discharge pressure.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
Faulty cooling check valve
(leaking)
Also low discharge pressure. Switch to cooling mode. Unit operates correctly when loop is in use. Loop lines get cold when loop not in use instead of warming to ambient, compressor frosts up.
Identify the check valve. Try switching modes a few times.
Replace if problem continues.
Faulty heating TXV bypass check valve.
(Leaking)
Low superheat and discharge pressure. Switch to cooling mode. Unit operates properly on all loops.
Try switching modes a few times.
Replace check valve if problem continues.
Compressor frosting up
See Low Suction
Pressure in this section.
Heating TXV frosting up heavily
TXV stuck almost closed or partially blocked by foreign object.
Intermittent fan.
Adjusting the TXV does not affect the superheat or the suction pressure.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
See Fan Troubleshooting section. Correct the problem.
Random high pressure trip
(does not occur while on site)
Random manual high pressure trip (does not occur while on site)
Faulty compressor contactor.
Points pitted or burned. Contactor sometimes sticks causing the compressor to run without the fan, tripping the high pressure control.
Replace contactor.
001570MAN-03 Page 28 DATE: 12 NOV 2012
Fault
Heating instead of cooling
OPERATION TROUBLESHOOTING - COOLING MODE
Possible Cause Verification Recommended Action
Thermostat not set up properly.
Verify that there is 24VAC across
O/B/W1 and C of the terminal strip when calling for cooling.
Correct thermostat setup.
Change to a different thermostat.
Faulty reversing valve solenoid coil.
Verify solenoid by removing it from the shaft while the unit is running.
There should be a loud “whoosh” sound when it is removed. Discharge pressure will continue to rise even if there is a loop switch.
Replace solenoid if faulty.
Faulty reversing valve. A click can be heard when the coil is energized but hot gas is still directed to the air coil. Discharge pressure will continue to rise even if there is a loop switch.
Replace reversing valve.
High Discharge
Pressure
Faulty heating TXV bypass check valve.
(blocked)
Temperature drop can be felt across the cooling TXV. Unit operates properly in cooling mode.
Try switching modes a few times.
Replace check valve if problem continues.
High Pressure control trips
Faulty Loop Pressure switch
Loop LED does not come on around
480PSIG
. Shorting S and S causes the LED to come on.
Replace loop pressure switch.
Faulty Loop Pressure switch Input
Shorting S and S does not cause the Loop Switch LED to come on, or does not cause a loop change.
Replace the control board.
High Pressure control and manual high pressure control trips
(very fast)
Faulty reclaim valve solenoid.
Faulty reclaim valve.
Verify solenoid by removing it from the shaft while energized. If there is no click the solenoid is bad
A click can be heard when the valve is selected but the unit still trips out.
Replace reclaim solenoid coil.
Replace the reclaim valve
Faulty control board output. (L1 to L5).
Loop LED does not come on or there is no 24VAC across the loop output and C of the control board when the loop is selected.
Replace the control board.
Loop changes occur too frequently
Unit overcharged.
Head pressure quickly rises and loop switch value is reached very quickly.
Remove refrigerant 1/2 pound at a time until loop switching returns to normal.
Loop field saturated Head pressure rises quickly in two loop mode.
Install soaker hose.
Loop field too small Head pressure rises quickly in two loop mode.
Increase loop size.
DATE: 12 NOV 2012 Page 29 001570MAN-03
Fault
OPERATION TROUBLESHOOTING - COOLING MODE
Possible Cause Verification
High Suction
Pressure
(may appear to not be pumping)
Cooling TXV adjusted too far open.
Verify superheat. It should be between 8-12°F (3-6°C). Superheat will be low if TXV is open too far.
TXV stuck open. Adjusting the TXV does not affect the superheat or the suction pressure. Low super heat and discharge pressure.
Recommended Action
Adjust TXV to obtain 8-12°F
(3-6°C) superheat.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
Leaking reversing valve. Reversing valve is the same temperature on both ends of body, common suction line is warm, compressor is running hot.
Replace reversing valve.
Leaking reclaim valve. Scavenger line remains hot where it enters the common suction line.
Replace reclaim valve.
Low Suction
Pressure
Air Flow See Fan Troubleshooting section.
Note: low airflow will cause the air coil to ice up once the suction drops below
90PSIG
.
Correct the problem.
Cooling TXV stuck almost closed or partially blocked by foreign object.
Low or no refrigerant charge.
Leaking cooling check valve
Adjusting the TXV does not affect the superheat or the suction pressure. TXV may be frosting up.
Entering air temperature and airflow are good but suction is low.
Check static refrigeration pressure of unit for very low value.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
Locate the leak and repair it.
Spray nine, a sniffer and dye are common methods of locating a leak.
Unit operates correctly when loop is in use. Loop lines get cold when loop not in use instead of warming to ambient, compressor frosts up.
Identify the check valve. Try switching modes a few times. Replace if problem continues.
Faulty NO solenoid valve coil.
Verify solenoid by removing it from the shaft while the unit is running.
There should be an audible click sound if the solenoid is working.
Replace solenoid if faulty.
Faulty NO solenoid valve. A click can be heard when the coil is energized. Unused loops stay cold instead of gradually warming to ambient. Compressor frosts up.
Replace NO valve.
Faulty cooling TXV bypass check valve (leaking)
Also low discharge pressure.
Switch to cooling mode. Unit operates correctly.
Identify the check valve. Try switching modes a few times. Replace if problem continues.
Faulty compressor, not pumping.
Pressures change only slightly from static values when compressor is started.
Replace compressor.
Compressor frosting up
See Low Suction
Pressure in this section.
TXV frosting up
TXV stuck almost closed or partially blocked by foreign object.
Adjusting the TXV does not affect the superheat or the suction pressure.
Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work.
001570MAN-03 Page 30 DATE: 12 NOV 2012
Fault
Random Low
Pressure trip
(does not occur while there)
OPERATION TROUBLESHOOTING - COOLING MODE
Possible Cause Verification Recommended Action
Faulty compressor contactor.
Intermittent fan.
Points pitted or burned. Contactor sometimes sticks causing the compressor to run without the fan, tripping the low pressure control.
Replace contactor.
See Fan Troubleshooting section. Correct the problem.
Fault
Low Airflow
FAN TROUBLESHOOTING (AIR HANDLER)
Possible Cause
Dirty air filter Inspect.
Verification Recommended Action
Replace.
Dirty air coil.
Poor Ductwork
Inspect.
Measure delta T between supply and return ducts at the unit, it in heating mode, it should not be above 30°F(17°C).
Clean.
The ECM fan will provide proper airflow up to 0.5 inH2o for 1/2HP motors and 0.7 inH2o for 1HP motors. The ductwork is poorly designed or greatly undersized if the fan motor cannot provide the required airflow.
Select a higher setting. Air flow selected on air handler is too low.
Fan operating on wrong Stage speed
Incorrect connections to air handler.
Check selection on air handler
Refer to air handler instruction manual for proper connections.
Correct the connections.
Fan not operating or operating intermittently
Faulty air handler wiring. Verify the wiring using the air handler instruction manual.
Repair any loose connections.
Faulty fan motor. Inspect as per air handler instruction manual.
Replace motor if faulty.
DATE: 12 NOV 2012 Page 31 001570MAN-03
Fault
PLENUM HEATER TROUBLE SHOOTING
Possible Cause
No 230VAC across plenum heater L1 and L2
Disconnect switch open.
(if installed)
Fuse blown /
Breaker Tripped.
Verification Recommended Action
Verify disconnect switch is in the ON position.
Determine why the disconnect switch was opened, if all is OK close the switch.
At plenum heater disconnect box (if installed), voltmeter shows voltage on the line side but not on the load side. Check if breaker is tripped.
Reset breaker or replace fuse at plenum heater disconnect box.
Replace fuse with proper size and type. (Time-delay type “D”)
Same “Line” to L1 and L2 Measuring L1 to ground and L2 to ground both yield 115VAC, but L1 to
L2 yields 0VAC.
Correct wiring.
No W2 signal at
Heat pump terminal strip
No call for auxiliary or emergency heat from thermostat.
Verify that the thermostat is indicating that auxiliary or emergency heat should be on.
Set thermostat to engage auxiliary or emergency heat (note some thermostats require a jumper between auxiliary and emergency.
Check the thermostat manual).
Faulty thermostat.
Faulty thermostat.
Thermostat doesn’t indicate a call for auxiliary or emergency when it should.
Replace thermostat.
Thermostat indicates auxiliary or emergency but no 24VAC signal present across C and the auxiliary and/or emergency pin at the thermostat.
Replace thermostat.
Faulty thermostat wiring. 24VAC signal is present across C and the auxiliary and/or emergency pin at the thermostat but no 24VAC signal is present across W2 and C at the heat pump terminal strip.
Correct wiring.
No 24VAC signal from C to ground at the plenum heater control connector
Plenum Heater transformer is burned out.
Plenum heater control board is faulty.
Voltmeter does not show 24VAC across transformer secondary winding.
Transformer tested OK in previous step.
Replace transformer.
Replace control board.
No 24VAC signal from 1 to ground at the plenum heater control connector
Faulty wiring. 24VAC present across C and ground at the plenum heater, but not across ground of the plenum heater and I of the heat pump terminal strip
Correct wiring.
001570MAN-03
Faulty wiring. If previous step tested OK, 24VAC is present across ground of the plenum heart and 1 of the heat pump terminal strip, but not across ground of the plenum heater and 1 of the plenum heater.
Correct wiring.
Page 32 DATE: 12 NOV 2012
Fault
No 24VAC signal from 1 to ground at the plenum heater control connector
PLENUM HEATER TROUBLE SHOOTING
Possible Cause
Faulty Plenum Heater
Relay in heat pump
Verification Recommended Action
24VAC is present across pin 1 and pin 3 of the relay, 24VAC is present from heat pump terminal strip I to plenum heater ground, but not from heat pump terminal strip 1 to plenum heater ground.
Replace relay.
Thermal overload is tripped.
Fan not operating
Faulty overload
See Fan Not Operating section
Reset thermal overload
Correct problem. Reset thermal overload.
Replace if faulty.
Fault
Insufficient hot water
(Tank Problem)
DOMESTIC HOT WATER (DHW) TROUBLE SHOOTING
Possible Cause Verification Recommended Action
Thermostat on hot water tank set too low. Should be set at 120°F. (140°F if required by local code)
Breaker tripped, or fuse blown in electrical supply to hot water tank.
Reset button tripped on hot water tank.
Visually inspect the setting.
Check both line and load sides of fuses. If switch is open determine why.
Check voltage at elements with multimeter.
Readjust the setting to 120°F.
(140°F if required by local code)
Replace blown fuse or reset breaker.
Push reset button.
Insufficient hot water
(Heat Pump Prob-
lem)
Circulator pump not operating.
Visually inspect the pump to see if shaft is turning. Use an amprobe to measure current draw.
Replace if faulty.
Blockage or restriction in the water line or hot water heat exchanger.
Check water flow and power to pump. Check water lines for obstruction
Faulty DHW cutout (failed open).
Heat pump not running enough hours to make sufficient hot water.
Check contact operation. Should close at 120°F and open at 140°F.
Replace DHW cutout if faulty.
Note the amount of time the heat pump runs in any given hour.
Remove obstruction in water lines. Acid treat the domestic hot water coil.
Temporarily turn up the tank thermostats until colder weather creates longer run cycles.
Water is too hot.
Faulty DHW cutout (failed closed).
Check contact operation. Should close at 120°F and open at 140°F.
Replace DHW cutout if faulty.
Thermostat on hot water tank set too high. Should be set at 120°F. (140°F if required by local code)
Visually inspect the setting. Readjust the setting to 120°F.
(140°F if required by local code)
Trouble Shooting Tools
Refrigeration
In-line Flowmeter
DATE: 12 NOV 2012
Digital
Multimeter -
Voltmeter /
Page 33
Dole flow control Valve
The Dole® flow control is a simple, selfcleaning device designed to deliver a constant volume of water from any outlet whether the pressure is 15 psig or as high as 125 psi. The controlling mechanism consists of a flexible orifice that varies its area inversely with pressure so that a constant flow is maintained.
001570MAN-03
REPAIR PROCEDURES
PUMP DOWN PROCEDURE
STEP 1
Connect the refrigerant recovery unit to the heat pump service ports via a refrigeration charging manifold and to a recovery tank as per the instructions in the recovery unit manual. If there was a compressor
burn out, the refrigerant cannot be reused and must be disposed of according to local codes.
STEP 2
Ensure all hose connections are properly purged of air. Start the refrigerant recovery as per the instructions in the recovery unit manual.
STEP 3
Allow the recovery unit suction pressure to reach a vacuum. Once achieved, close the charging manifold valves. Shut down, purge and disconnect the recovery unit as per the instructions in its manual. Ensure the recovery tank valve is closed before disconnecting the hose to it.
STEP 4
Connect a nitrogen tank to the charging manifold and add nitrogen to the heat pump until a positive pressure of 5-10PSIG is reached. This prevents air from being sucked into the unit by the vacuum when the hoses are disconnected.
STEP 5
The heat pump is now ready for repairs. Always ensure nitrogen is flowing through the system during any soldering procedures to prevent soot buildup inside the pipes. Maritime Geothermal Ltd. recommends replacing the liquid line filter-drier anytime the refrigeration system has been exposed to the atmosphere.
VACUUM AND CHARGING PROCEDURE
STEP 1
After completion of repairs and nitrogen pressure testing, the refrigeration circuit is ready for vacuuming.
STEP 2
Release the refrigerant circuit pressure and connect the vacuum pump to the charging manifold. Start the vacuum pump and open the charging manifold valves. Vacuum until the vacuum gauge remains at less than 500 microns for at least 1 minute with the vacuum pump valve closed.
STEP 3
Close the charging manifold valves then shut off and disconnect the vacuum pump. Place a refrigerant tank with the proper refrigerant on a scale and connect it to the charging manifold. Purge the hose to the tank.
STEP 4
Weigh in the appropriate amount of refrigerant through the low pressure (suction) service port. Refer to the label on the unit or the Charging The system section for the proper charge amount.
STEP 5
If the unit will not accept the entire charge, the remainder can be added through the low pressure service port after the unit has been restarted.
REPLACMENT PROCEDURE FOR A COMPRESSOR BURN-OUT
STEP 1
Pump down the unit as per the Pump Down Procedure above.
STEP 2
Replace the compressor. Replace the liquid line filter-drier.
STEP 3
Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed.
STEP 4
Charge the unit and operate it for continuously for 2 hours. Pump down the unit and replace the filter-drier.
Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed.
STEP 5
Charge the unit (refrigerant can be re-used) and operate it for 2-3 days. Pump down the unit and replace the filter-drier.
STEP 6
Charge the unit (refrigerant can be re-used) and operate it for 2 weeks. Pump down the unit and replace the filter-drier.
STEP 7
Charge the unit a final time. Unit should now be clean and repeated future burn-outs can be avoided.
001570MAN-03 Page 34 DATE: 12 NOV 2012
REFRIGERATION CIRCUIT DIAGRAMS (continued)
DATE: 12 NOV 2012 Page 35 001570MAN-03
REFRIGERATION CIRCUIT DIAGRAMS (continued)
001570MAN-03 Page 36 DATE: 12 NOV 2012
Model Specific Information
This section provides general information particular to each model. For complete specifications please see the specifications document for the desired model
REFRIGERANT CHARGE CHART SHIPPING INFORMATION
Table 18 - Refrigerant - R410a
SIZE Lbs. kg
25
45
8.0 3.6
12.0 7.3
55
65
16.0 9.1
20.0 9.1
80
24.0 10.9
System contains POE oil.
MODEL
Table 19 - Shipping Information
WEIGHT DIMENSIONS in (cm)
SIZE
45
45
55
65
80
Lbs. (kg)
TBD
TBD
TBD
TBD
TBD
L W H
40 (102) 36 (91) 60 (152)
40 (102) 36 (91) 60 (152)
40 (102) 36 (91) 60 (152)
40 (102) 36 (91) 60 (152)
40 (102) 36 (91) 60 (152)
STADARD CAPACITY RATINGS
The tables below depict the results of standard capacity rating tests according to ARI 870-2005.
Table 16 - Standard Capacity Ratings - Heating 60Hz
EAT 70°F (21.1°C)
Model
Size
Tons
Mode Airflow
CFM L/s
Input
Energy
Watts
Capacity
BTU/Hr kW
COP
H
W/W
25
45
55
65
80
2
3
4
5
6
Stage 1 800 378
Stage 1 1200 566
Stage 1 1500 708
Stage 1 1900 897
Stage 1 2400 1133
1,435
2,285
3,375
4,180
TBD
17,700
31,100
43,500
53,300
TBD
5.2
9.1
12.7
15.6
TBD
3.60
3.99
3.78
3.74
TBD
Table 17 - Standard Capacity Ratings -
Cooling
60Hz
EAT 80°F (26.7°C)
Model
Size
Tons
Mode Airflow
CFM L/s
Input
Energy
Watts
Capacity
BTU/Hr kW
EER
BTU/W-Hr
25
45
55
2
3
4
Stage 1
Stage 1
Stage 1
800
1200
1500
378
566
708
1,295
2,240
2,900
24,900
43,200
51,500
7.3
12.6
15.1
19.3
19.3
17.8
65
80
5
6
Stage 1 1900 897
Stage 1 2400 1133
3,620
TBD
63,900
TBD
18.7
TBD
17.6
TBD
DATE: 12 NOV 2012 Page 37 001570MAN-03
CAPACITY RATINGS
DXS-25-HACW-P-1S
Heating Mode
Source Data
(Outdoor Loop)
Suction Pressure
Evap.
Temp
HAB
Power Consumption
Compressor Fan*
Total
Electrical
COPh
(
Nominal 2 ton)
Discharge
Pressure
R410a 60 Hz
Sink Data (Indoor Loop)
Cond.
Temp.
EAT
Air
Flow
LAT Delta T
Net
Output
PSIG °F BTU/Hr Watts Amps Watts Watts
W/W
PSIG °F °F CFM °F °F
BTU/Hr
kPa °C Watts kPa °C °C L/sec °C °C
Watts
62
430
70
484
79
543
88
605
97
672
108
743
119
819
131
900
10
-12.2
15
-9.4
20
-6.7
25
-3.9
30
-1.1
35
1.7
40
4.4
45
7.2
8,983 1,184 5.3 105 1,289
3.04
2,632
9,885 1,222 5.5 105 1,327
3.18
2,896
10,856 1,259 5.7 105 1,364
3.33
3,181
11,899 1,296 5.9 105 1,401
3.49
3,486
13,015 1,334 6.0 105 1,439
3.65
3,813
14,207 1,372 6.2 105 1,477
3.82
4,163
15,476 1,412 6.4 105 1,517
3.99
4,535
16,825 1,452 6.6 105 1,557
4.17
4,930
280 91 70.0 1,000 83.6 13.6
13,383
1927 32.8 21.1 472 28.7 7.5
3,921
288 93 70.0 1,000 84.6 14.6
14,413
1985 33.9 21.1 472 29.2 8.1
4,223
296 95 70.0 1,000 85.7 15.7
15,511
2044 35.0 21.1 472 29.9 8.7
4,545
305 97 70.0 1,000 86.9 16.9
16,681
2104 36.1 21.1 472 30.5 9.4
4,888
314 99 70.0 1,000 88.2 18.2
17,927
2165 37.2 21.1 472 31.2 10.1
5,252
323 101 70.0 1,000 89.5 19.5
19,249
2228 38.3 21.1 472 32.0 10.9
5,640
332 103 70.0 1,000 91.0 21.0
20,652
2292 39.4 21.1 472 32.8 11.6
6,051
342 105 70.0 1,000 92.5 22.5
22,139
2357 40.6 21.1 472 33.6 12.5
6,487
Compressor: ZPS20K4E-PFV
* @ 37.3Pa (0.15inH2o) Ext. Static
DXS-25-HACW-P-1S
Suct.
Pres.
Evap.
Temp
Cooling Mode
Source Data (Indoor Loop)
EAT Air Flow LAT Delta T Latent Sensible
HAB
Power Consumption
Compressor Fan*
R410a 60 Hz
Sink Data
(Outdoor Loop)
Total
Electrical
Efficiency
Disch.
Pres.
Cond.
Temp.
Net
Output
PSIG °F kPa °C
°F
°C
CFM °F
L/sec °C
°F BTU/Hr BTU/Hr
BTU/Hr
Watts Amps Watts Watts
°C Watts Watts
Watts
EER
COPc
PSIG kPa
°F BTU/Hr
°C Watts
143 50 80.0 1,000 62.8 17.2 7,352 18,221 25,574 1,099 4.7 110 1,209 21.1 237 80 29,701
987 10.0 26.7 472 17.1 9.5 2,154 5,339 7,493
6.20
143 50 80.0 1,000 63.3 16.7 7,164 17,753 24,917 1,185 5.1 110 1,295 19.2
1,631 26.7 8,702
255 85 29,338
987 10.0 26.7 472 17.4 9.3 2,099 5,202 7,300
5.64
1,761 29.4 8,596
143 50 80.0 1,000 63.7 16.3 6,971 17,277 24,249 1,274 5.4 110 1,384 17.5 275 90 28,973
987 10.0 26.7 472 17.6 9.0 2,043 5,062 7,105
5.13
143 50 80.0 1,000 64.2 15.8 6,776 16,793 23,569 1,367 5.8 110 1,477 16.0
1,899 32.2 8,489
296 95 28,609
987 10.0 26.7 472 17.9 8.8 1,985 4,920 6,906
4.68
143 51 80.0 1,000 64.5 15.5 6,639 16,453 23,092 1,463 6.2 110 1,573 14.7
2,044 35.0 8,382
319 100 28,462
987 10.3 26.7 472 18.1 8.6 1,945 4,821 6,766
4.30
2,196 37.8 8,339
143 51 80.0 1,000 65.0 15.0 6,435 15,948 22,383 1,565 6.6 110 1,675 13.4 342 105 28,100
987 10.3 26.7 472 18.3 8.3 1,885 4,673 6,558
3.91
143 51 80.0 1,000 65.5 14.5 6,227 15,433 21,661 1,673 7.1 110 1,783 12.2
2,357 40.6 8,233
366 110 27,745
987 10.3 26.7 472 18.6 8.1 1,825 4,522 6,347
3.56
143 51 80.0 1,000 66.0 14.0 6,016 14,909 20,925 1,787 7.6 110 1,897 11.0
2,526 43.3 8,129
392 115 27,400
987 10.3 26.7 472 18.9 7.8 1,763 4,368 6,131
3.23
2,705 46.1 8,028
Compressor: ZPS20K4E-PFV
* @ 37.3Pa (0.15inH2o) Ext. Static
001570MAN-03 Page 38 DATE: 12 NOV 2012
CAPACITY RATINGS (continued)
DXS-45-HACW-P-1S
Heating Mode
Source Data
(Outdoor Loop)
Suction
Pressure
Evap.
Temp
HAB
Power Consumption
Compressor Fan*
Total
Electrical
COPh
(
Nominal 3 ton)
Discharge
Pressure
R410a 60 Hz
Sink Data (Indoor Loop)
Cond.
Temp.
EAT
Air
Flow
LAT Delta T
Net
Output
PSIG °F BTU/Hr Watts Amps Watts Watts
W/W
PSIG °F °F CFM °F °F
BTU/Hr
kPa °C Watts kPa °C °C L/sec °C °C
Watts
62
430
70
484
79
543
88
605
97
672
108
743
119
819
131
900
10
-12.2
15
-9.4
20
-6.7
25
-3.9
30
-1.1
35
1.7
40
4.4
45
7.2
17,610 1,939 8.5 180 2,119
3.44
5,160
19,204 1,996 8.7 180 2,176
3.59
5,627
20,790 2,080 9.1 180 2,260
3.70
6,092
22,475 2,165 9.5 180 2,345
3.81
6,585
25,716 2,220 9.8 180 2,400
4.14
7,535
27,900 2,280 10.0 180 2,460
4.32
8,175
30,025 2,372 10.5 180 2,552
4.45
8,797
32,256 2,467 10.9 180 2,647
4.57
9,451
305 97 70.0 1,400 86.7 16.7
24,840
2104 36.1 21.1 661 30.4 9.3
7,278
314 99 70.0 1,400 87.9 17.9
26,630
2165 37.2 21.1 661 31.1 10.0
7,803
328 102 70.0 1,400 89.2 19.2
28,502
2259 38.9 21.1 661 31.8 10.7
8,351
342 105 70.0 1,400 90.5 20.5
30,479
2357 40.6 21.1 661 32.5 11.4
8,930
352 107 70.0 1,400 92.8 22.8
33,907
2424 41.7 21.1 661 33.8 12.7
9,935
361 109 70.0 1,400 94.4 24.4
36,297
2492 42.8 21.1 661 34.7 13.6
10,635
377 112 70.0 1,400 96.1 26.1
38,733
2597 44.4 21.1 661 35.6 14.5
11,349
392 115 70.0 1,400 97.8 27.8
41,289
2705 46.1 21.1 661 36.5 15.4
12,098
Compressor: ZPS30K4E-PFV * @ 37.3Pa (0.15inH2o) Ext. Static
DXS-45-HACW-P-1S
Suct.
Pres.
Evap.
Temp
Cooling Mode
Source Data (Indoor Loop)
EAT Air Flow LAT Delta T Latent Sensible
HAB
Power Consumption
Compressor Fan*
R410a 60 Hz
Sink Data
(Outdoor Loop)
Total
Electrical
Efficiency
Disch.
Pres.
Cond.
Temp.
Net
Output
PSIG °F kPa °C
°F
°C
CFM °F
L/sec °C
°F BTU/Hr BTU/Hr
BTU/Hr
Watts Amps Watts Watts
°C Watts Watts
Watts
EER
COPc
PSIG kPa
°F BTU/Hr
°C Watts
141 49.5 80.0 1,400 61.7 18.3 15,075 31,525 46,600 1,650 7.0 190 1,840 25.3 237 80 52,879
969 9.7 26.7 661 16.5 10.2 4,417 9,237 13,654
7.42
141 49.5 80.0 1,400 62.2 17.8 14,703 30,748 45,451 1,771 7.4 190 1,961 23.2
1,631 26.7 15,493
255 85 52,143
969 9.7 26.7 661 16.8 9.9 4,308 9,009 13,317
6.79
1,761 29.4 15,278
141 49.5 80.0 1,400 62.6 17.4 14,326 29,958 44,284 1,895 7.9 190 2,085 21.2 275 90 51,401
969 9.7 26.7 661 17.0 9.7 4,197 8,778 12,975
6.22
143 50 80.0 1,400 62.9 17.1 14,066 29,414 43,480 2,026 8.5 190 2,216 19.6
1,899 32.2 15,060
296 95 51,042
987 10.0 26.7 661 17.2 9.5 4,121 8,618 12,739
5.75
143 50 80.0 1,400 62.4 17.6 12,580 29,006 41,586 2,118 9.0 190 2,308 18.0
2,044 35.0 14,955
319 100 49,465
987 10.0 26.7 661 16.9 9.8 3,686 8,499 12,185
5.28
2,196 37.8 14,493
143 50 80.0 1,400 62.9 17.1 12,211 28,155 40,366 2,259 9.6 190 2,449 16.5 342 105 48,723
987 10.0 26.7 661 17.2 9.5 3,578 8,249 11,827
4.83
143 51 80.0 1,400 63.5 16.5 11,787 27,179 38,966 2,469 10.5 190 2,659 14.7
2,357 40.6 14,276
377 112 48,042
987 10.3 26.7 661 17.5 9.2 3,454 7,963 11,417
4.29
143 51 80.0 1,400 63.8 16.2 11,555 26,643 38,198 2,565 10.9 190 2,755 13.9
2,597 44.4 14,076
392 115 47,599
987 10.3 26.7 661 17.7 9.0 3,386 7,806 11,192
4.06
2,705 46.1 13,947
Compressor: ZPS30K4E-PFV
* @ 37.3Pa (0.15inH2o) Ext. Static
DATE: 12 NOV 2012 Page 39 001570MAN-03
CAPACITY RATINGS (continued)
DXS-55-HACW-P-1S
Heating Mode
Source Data
(Outdoor Loop)
Suction Pressure
Evap.
Temp
HAB
Power Consumption
Compressor Fan*
Total
Electrical
COPh
(
Nominal 4 ton)
Discharge
Pressure
R410a 60 Hz
Sink Data (Indoor Loop)
Cond.
Temp.
EAT
Air
Flow
LAT Delta T
Net
Output
PSIG °F BTU/Hr Watts Amps Watts Watts
W/W
PSIG °F °F CFM °F °F
BTU/Hr
kPa °C Watts kPa °C °C L/sec °C °C
Watts
62
430
70
484
79
543
88
605
97
672
108
743
119
819
131
900
10
-12.2
15
-9.4
20
-6.7
25
-3.9
30
-1.1
35
1.7
40
4.4
45
7.2
19,476 2,740 12.0 335 3,075
2.86
5,707
21,698 2,813 12.4 335 3,148
3.02
6,357
24,093 2,885 12.7 335 3,220
3.19
7,059
26,667 2,957 13.0 335 3,292
3.37
7,813
30,965 3,072 13.4 335 3,407
3.66
9,073
34,068 3,147 13.7 335 3,482
3.87
9,982
37,377 3,223 14.1 335 3,558
4.08
10,951
40,897 3,300 14.4 335 3,635
4.30
11,983
319 100 70.0 1,700 88.1 18.1
29,971
2196 37.8 21.1 802 31.2 10.0
8,781
328 102 70.0 1,700 89.6 19.6
32,441
2259 38.9 21.1 802 32.0 10.9
9,505
337 104 70.0 1,700 91.2 21.2
35,083
2324 40.0 21.1 802 32.9 11.8
10,279
347 106 70.0 1,700 92.9 22.9
37,904
2390 41.1 21.1 802 33.8 12.7
11,106
357 108 70.0 1,700 95.7 25.7
42,594
2458 42.2 21.1 802 35.4 14.3
12,480
366 110 70.0 1,700 97.7 27.7
45,951
2526 43.3 21.1 802 36.5 15.4
13,464
377 112 70.0 1,700 99.9 29.9
49,519
2597 44.4 21.1 802 37.7 16.6
14,509
387 114 70.0 1,700
2668 45.6 21.1 802 39.0 17.9
15,618
Compressor: ZPS40K4E-PFV * @ 37.3Pa (0.15inH2o) Ext. Static
DXS-55-HACW-P-1S
Suct.
Pres.
Evap.
Temp
Cooling Mode
Source Data (Indoor Loop)
EAT Air Flow LAT Delta T Latent Sensible
HAB
Power Consumption
Compressor Fan*
R410a 60 Hz
Sink Data
(Outdoor Loop)
Total
Electrical
Efficiency
Disch.
Pres.
Cond.
Temp.
Net
Output
PSIG °F kPa °C
°F
°C
CFM °F
L/sec °C
°F BTU/Hr BTU/Hr
BTU/Hr
Watts Amps Watts Watts
°C Watts Watts
Watts
EER
COPc
PSIG kPa
°F BTU/Hr
°C Watts
136 47 80.0 1,700 61.2 18.8 16,828 36,807 53,635 2,297 9.8 365 2,662 20.1 237 80 62,721
934 8.3 26.7 802 16.2 10.4 4,931 10,784 15,715
5.90
136 47 80.0 1,700 61.7 18.3 16,422 35,919 52,340 2,447 10.4 365 2,812 18.6
1,631 26.7 18,377
255 85 61,937
934 8.3 26.7 802 16.5 10.2 4,812 10,524 15,336
5.45
1,761 29.4 18,147
136 47.5 80.0 1,700 62.0 18.0 16,163 35,353 51,516 2,601 11.0 365 2,966 17.4 275 90 61,638
934 8.6 26.7 802 16.6 10.0 4,736 10,358 15,094
5.09
138 48 80.0 1,700 62.3 17.7 15,887 34,749 50,636 2,760 11.7 365 3,125 16.2
1,899 32.2 18,060
296 95 61,302
951 8.9 26.7 802 16.8 9.9 4,655 10,181 14,836
4.75
138 48 80.0 1,700 62.6 17.4 13,966 33,377 47,343 2,889 12.3 365 3,254 14.6
2,044 35.0 17,961
319 100 58,448
951 8.9 26.7 802 17.0 9.7 4,092 9,779 13,871
4.26
2,196 37.8 17,125
138 49 80.0 1,700 62.9 17.1 13,686 32,707 46,393 3,059 13.1 365 3,424 13.5 342 105 58,080
951 9.2 26.7 802 17.2 9.5 4,010 9,583 13,593
3.97
141 49 80.0 1,700 63.3 16.7 13,389 31,996 45,385 3,238 13.8 365 3,603 12.6
2,357 40.6 17,017
366 110 57,684
969 9.4 26.7 802 17.4 9.3 3,923 9,375 13,298
3.69
141 49 80.0 1,700 63.9 16.1 12,943 30,931 43,874 3,427 14.6 365 3,792 11.6
2,526 43.3 16,901
392 115 56,816
969 9.4 26.7 802 17.7 9.0 3,792 9,063 12,855
3.39
2,705 46.1 16,647
Compressor: ZPS40K4E-PFV
* @ 37.3Pa (0.15inH2o) Ext. Static
001570MAN-03 Page 40 DATE: 12 NOV 2012
CAPACITY RATINGS (continued)
DXS-65-HACW-P-1S
Heating Mode
Source Data
(Outdoor Loop)
Suction
Pressure
Evap.
Temp
HAB
Power Consumption
Compressor Fan*
Total
Electrical
COPh
(
Nominal 5 ton)
Discharge
Pressure
R410a 60 Hz
Sink Data (Indoor Loop)
Cond.
Temp.
EAT
Air
Flow
LAT Delta T
Net
Output
PSIG °F BTU/Hr Watts Amps Watts Watts
W/W
PSIG °F °F CFM °F °F
BTU/Hr
kPa °C Watts kPa °C °C L/sec °C °C
Watts
62
430
70
484
79
543
88
605
10
-12.2
15
-9.4
20
-6.7
25
-3.9
27,054 3,384 14.7 455 3,839
3.06
7,927
29,807 3,484 15.1 455 3,939
3.22
8,733
32,777 3,584 15.5 455 4,039
3.38
9,603
35,969 3,683 15.9 455 4,138
3.55
10,539
97
672
108
743
30
-1.1
35
1.7
39,930 3,712 16.3 455 4,167
3.81
11,699
43,638 3,811 16.7 455 4,266
4.00
12,786
119
819
131
900
40
4.4
45
7.2
Compressor: ZPS51K4E-PFV
47,592 3,912 17.2 455 4,367
4.19
13,944
51,799 4,016 17.6 455 4,471
4.39
15,177
301 96 70.0 2,100 88.0 18.0
40,155
2073 35.6 21.1 991 31.1 10.0
11,765
310 98 70.0 2,100 89.4 19.4
43,251
2134 36.7 21.1 991 31.9 10.8
12,672
319 100 70.0 2,100 90.9 20.9
46,560
2196 37.8 21.1 991 32.7 11.6
13,642
328 102 70.0 2,100 92.5 22.5
50,092
2259 38.9 21.1 991 33.6 12.5
14,677
337 104 70.0 2,100 95.3 25.3
54,151
2324 40.0 21.1 991 35.2 14.1
15,866
347 106 70.0 2,100 97.2 27.2
58,198
2390 41.1 21.1 991 36.2 15.1
17,052
357 108 70.0 2,100 99.2 29.2
62,498
2458 42.2 21.1 991 37.4 16.2
18,312
366 110 70.0 2,100
2526 43.3 21.1 991 38.5 17.4
19,649
* @ 49.7Pa (0.20inH2o) Ext. Static
DXS-65-HACW-P-1S
Suct.
Pres.
Evap.
Temp
Cooling Mode
Source Data (Indoor Loop)
EAT Air Flow LAT Delta T Latent Sensible
HAB
Power Consumption
Compressor Fan*
R410a 60 Hz
Sink Data
(Outdoor Loop)
Total
Electrical
Efficiency
Disch.
Pres.
Cond.
Temp.
Net
Output
PSIG °F kPa °C
°F
°C
CFM °F
L/sec °C
°F BTU/Hr BTU/Hr
BTU/Hr
Watts Amps Watts Watts
°C Watts Watts
Watts
EER
COPc
PSIG kPa
°F BTU/Hr
°C Watts
131 45.5 80.0 2,100 63.0 17.0 21,714 43,372 65,086 2,843 12.4 515 3,358 19.4
900 7.5 26.7 991 17.2 9.4 6,362 12,708 19,070
5.68
237 80 76,548
1,631 26.7 22,428
133 46 80.0 2,100 63.3 16.7 21,412 42,767 64,179 3,055 13.2 515 3,570 18.0
917 7.8 26.7 991 17.4 9.3 6,274 12,531 18,804
5.27
255 85 76,364
1,761 29.4 22,375
133 46.5 80.0 2,100 63.5 16.5 21,088 42,121 63,208 3,273 14.0 515 3,788 16.7
917 8.1 26.7 991 17.5 9.2 6,179 12,341 18,520
4.89
275 90 76,137
1,899 32.2 22,308
136 47 80.0 2,100 63.8 16.2 20,743 41,431 62,174 3,498 14.8 515 4,013 15.5 296 95 75,869
934 8.3 26.7 991 17.7 9.0 6,078 12,139 18,217
4.54
136 48 80.0 2,100 62.7 17.3 18,024 42,307 60,331 3,663 15.7 515 4,178 14.4
2,044 35.0 22,229
319 100 74,592
934 8.6 26.7 991 17.1 9.6 5,281 12,396 17,677
4.23
2,196 37.8 21,855
138 48 80.0 2,100 63.0 17.0 17,678 41,496 59,174 3,903 16.7 515 4,418 13.4 342 105 74,254
951 8.9 26.7 991 17.2 9.4 5,180 12,158 17,338
3.92
138 49 80.0 2,100 63.4 16.6 17,312 40,635 57,947 4,155 17.6 515 4,670 12.4
2,357 40.6 21,756
366 110 73,886
951 9.2 26.7 991 17.4 9.2 5,072 11,906 16,978
3.64
2,526 43.3 21,648
141 49 80.0 2,100 63.8 16.2 16,923 39,724 56,647 4,421 18.7 515 4,936 11.5
969 9.4 26.7 991 17.6 9.0 4,958 11,639 16,597
3.36
392 115 73,493
2,705 46.1 21,533
Compressor: ZPS51K4E-PFV
* @ 49.7Pa (0.20inH2o) Ext. Static
DATE: 12 NOV 2012 Page 41 001570MAN-03
ELECTRICAL TABLES
Table 18 - Heat Pump Electrical Information
Model
Compressor
(230-1-60)
FLA MCA
RLA LRA Amps Amps
Max Fuse/
Breaker
Amps
Wire
Size ga
25 15.0 58 16.0 19.8 30 #10-3
Table 19- Heat Pump Electrical Information
(208-3-60)
Model
Compressor FLA MCA
Max Fuse/
Breaker
Wire
Size
RLA LRA Amps Amps Amps ga
25 7.9
15 #14-3
45 18.6 79 19.6 24.3 40 #8-3
45 11.6 20 #10-3
55 24.3 50 #6-3
55 15.3
30 #8-3
65 29.3 60 #6-3
65 17.4
40 #8-3
80 35.7 148
36.7 45.6
60 #6-3
80 25.0 149 25.8 32.1
50 #6-3
Table 20 - Heat Pump Electrical Information
(220-1-50)
Model
Compressor FLA MCA
Max Fuse/
Breaker
Wire
Size
Table 21 - Heat Pump Electrical Information
(380-3-50)
Model
Compressor FLA MCA
Max Fuse/
Breaker
Wire
Size
RLA LRA Amps Amps Amps ga
RLA LRA Amps Amps Amps ga
25 10.0 52 11.0 13.5 20 #12-2
25 3.9 27 4.7 5.7 15 #14-4
45 15.0 67 16.0 19.8 30 #10-2
45 6.1 38 6.9 8.4 15 #14-4
55 17.7 98 18.7 23.1
30 #10-2
65 22.5
40 #8-2
80 32.9 176 33.9 42.1
50 #6-2
55 6.8 43 7.6 9.3
15 #14-4
65 8.6 52 9.4 11.6
20 #12-4
80 11.8 74 12.6 15.6
30 #10-4
001570MAN-03 Page 42 DATE: 12 NOV 2012
ELECTRICAL DIAGRAMS—HACW (230-1-60) - continued
DATE: 12 NOV 2012 Page 43 001570MAN-03
ELECTRICAL DIAGRAMS—HACW (230-1-60) - continued
001570MAN-03 Page 44 DATE: 12 NOV 2012
CASE DETAILS
Front View Back View
DATE: 12 NOV 2012
Left Side View
Page 45 001570MAN-03
001570MAN-03 Page 46 DATE: 12 NOV 2012
DATE: 12 NOV 2012
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Page 47 001570MAN-03
LIMITED EXPRESS WARRANTY
It is expressly understood that unless a statement is specifically identified as a warranty, statements made by Maritime Geothermal Ltd., a corporation registered in New
Brunswick, Canada, (“MG”) or its representatives, relating to MG’s products, whether oral, written or contained in any sales literature, catalogue or agreement, are not express warranties and do not form a part of the basis of the bargain, but are merely MG’s opinion or commendation of MG’s products.
EXCEPT AS SPECIFICALLY SET FORTH HEREIN, THERE IS NO EXPRESS WARRANTY AS TO ANY OF MG’S PRODUCTS. MG MAKES NO WARRANTY AGAINST
LATENT DEFECTS. MG MAKES NO WARRANTY OF MERCHANTABILITY OF THE GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PARTICULAR PURPOSE.
LIMITED EXPRESS RESIDENTIAL WARRANTY - PARTS
MG warrants its Residential Class products, purchased and retained in the United States of America and Canada, to be free from defects in material and workmanship under normal use and maintenance as follows:
(1) Air conditioning, heating and/or heat pump units built or sold by MG (“MG Units”) for five (5) years from the Warranty Inception Date (as defined below).
(2) Thermostats, auxiliary electric heaters and geothermal pumping modules built or sold by MG, when installed with MG Units, for five (5) years from the Warranty Inception
Date (as defined below).
(3) Sealed refrigerant circuit components of MG Units (which components only include the compressor, refrigerant to air/water heat exchangers, reversing valve body and
refrigerant metering device) for ten (10) years from the Warranty Inception Date (as defined below).
(4) Other accessories and parts built or sold by MG, when installed and purchased with MG Units, for five (5) years from the date of shipment from MG.
(5) Other accessories, when purchased separately, for (1) year from the date of shipment from MG.
The “Warranty Inception Date” shall be the date of original unit installation, as per the date on the installation Startup Record or six (6) months from date of unit shipment from MG, whichever comes first.
To make a claim under this warranty, parts must be returned to MG in Petitcodiac, New Brunswick, freight prepaid, no later than ninety (90) days after the date of the failure of the part. If MG determines the part to be defective and within MG’s Limited Express Residential Warranty, MG shall, when such part has been either replaced or repaired, return such to a factory recognized distributor, dealer or service organization, freight prepaid. The warranty on any part repaired or replaced under warranty expires at the end of the original warranty period.
LIMITED EXPRESS RESIDENTIAL WARRANTY - LABOUR
This Limited Express Residential Labour Warranty shall cover the labour incurred by MG authorized service personnel in connection with the installation of a new or repaired warranty part that is covered by this Limited Express Residential Warranty only to the extent specifically set forth in the current labour allowance schedule "A" provided by MG’s
Warranty Department and only as follows:
(1) MG Units for two (2) years from the Warranty Inception Date.
(2) Thermostats, auxiliary electric heaters and geothermal pump modules built or sold by MG, when installed with MG Units, for two (2) years from the Warranty Inception Date.
(3) Sealed refrigerant circuit components of MG Units (which components only include the compressor, refrigerant to air/water heat exchangers, reversing valve body and
refrigerant metering device) for five (5) years from the Warranty Inception Date.
Labour costs are not covered by this Limited Express Residential Warranty to the extent they exceed the amount allowed under said allowance schedule, they are not specifically provided for in said allowance schedule, they are not the result of work performed by MG authorized service personnel, they are incurred in connection with a part not covered by this Limited Express Residential Warranty, or they are incurred more than the time periods set forth in this paragraph after the Warranty Inception Date.
This warranty does not cover and does not apply to:
(1) Air filters, fuses, refrigerant, fluids, oil.
(2) Products relocated after initial installation.
(3) Any portion or component of any system that is not supplied by MG, regardless of the cause of the failure of such portion or component.
(4) Products on which the unit identification tags or labels have been removed or defaced.
(5) Products on which payment to MG, or to the owner’s seller or installing contractor, is in default.
(6) Products subjected to improper or inadequate installation, maintenance, repair, wiring or voltage conditions.
(7) Products subjected to accident, misuse, negligence, abuse, fire, flood, lightning, unauthorized alteration, misapplication, contaminated or corrosive liquid or air supply,
operation at abnormal air or liquid temperatures or flow rates, or opening of the refrigerant circuit by unqualified personnel.
(8) Mold, fungus or bacteria damage
(9) Corrosion or abrasion of the product.
(10) Products supplied by others.
(11) Products which have been operated in a manner contrary to MG’s printed instructions.
(12) Products which have insufficient performance as a result of improper system design or improper application, installation, or use of MG’s products.
(13) Electricity or fuel, or any increases or unrealized savings in same, for any reason whatsoever.
Except for the limited labour allowance coverage set forth above, MG is not responsible for:
(1) The costs of fluids, refrigerant or system components supplied by others, or associated labour to repair or replace the
same, which is incurred as a result of a defective part covered by MG’s Limited Residential Warranty.
(2) The costs of labour, refrigerant, materials or service incurred in diagnosis and removal of the defective part, or in obtaining
and replacing the new or repaired part.
(3) Transportation costs of the defective part from the installation site to MG, or of the return of that part if not covered by
MG’s Limited Express Residential Warranty.
(4) The costs of normal maintenance.
This Limited Express Residential Warranty applies to MG Residential Class products manufactured on or after February 15, 2010. MG’S LIABILITY UNDER THE TERMS OF
THIS LIMITED WARRANTY SHALL APPLY ONLY TO THE MG UNITS REGISTERED WITH MG THAT BEARS THE MODEL AND SERIAL NUMBERS STATED ON THE
INSTALLATION START UP RECORD, AND MG SHALL NOT, IN ANY EVENT, BE LIABLE UNDER THE TERMS OF THIS LIMITED WARRANTY UNLESS THIS
INSTALLATION START UP RECORD HAS BEEN ENDORSED BY OWNER & DEALER/INSTALLER AND RECIEVED BY MG LIMITED WITHIN 90 DAYS OF START UP.
Limitation: This Limited Express Residential Warranty is given in lieu of all other warranties. If, not withstanding the disclaimers contained herein, it is determined that other warranties exist, any such express warranty, including without imitation any express warranties or any implied warranties of fitness for particular purpose and merchantability, shall be limited to the duration of the Limited Express Residential Warranty.
LIMITATION OF REMEDIES In the event of a breach of the Limited Express Residential Warranty, MG will only be obligated at MG’s option to repair the failed part or unit, or to furnish a new or rebuilt part or unit in exchange for the part or unit which has failed. If after written notice to MG’s factory in Petitcodiac, New Brunswick of each defect, malfunction or other failure, and a reasonable number of attempts by MG to correct the defect, malfunction or other failure, and the remedy fails of its essential purpose, MG shall refund the purchase price paid to MG in exchange for the return of the sold good(s). Said refund shall be the maximum liability of MG. THIS REMEDY IS THE SOLE AND
EXCLUSIVE REMEDY OF THE BUYER OR PURCHASER AGAINST MG FOR BREACH OF CONTRACT, FOR THE BREACH OF ANY WARRANTY OR FOR MG’S
NEGLIGENCE OR IN STRICT LIABILITY.
LIMITATION OF LIABILITY MG shall have no liability for any damages if MG’s performance is delayed for any reason or is prevented to any extent by any event such as, but not limited to: any war, civil unrest, government restrictions or restraints, strikes, or work stoppages, fire, flood, accident, shortages of transportation, fuel, material, or labour, acts of God or any other reason beyond the sole control of MG. MG EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL
DAMAGE IN CONTRACT, FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, OR IN TORT, WHETHER FOR MG’s NEGLIGENCE OR AS STRICT LIABILITY.
OBTAINING WARRANTY PERFORMANCE Normally, the dealer or service organization who installed the products will provide warranty performance for the owner. Should the installer be unavailable, contact any MG recognized distributor, dealer or service organization. If assistance is required in obtaining warranty performance, write or call: Maritime
Geothermal Ltd • Customer Service • PO Box 2555 • Petitcodiac, New Brunswick E4Z 6H4 • (506) 756
‐8135 • or e-mail to [email protected] NOTE: Some states or Canadian provinces do not allow limitations on how long an implied warranty lasts, or the limitation or exclusions of consequential or incidental damages, so the foregoing exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state and from Canadian province to
Canadian province. Please refer to the MG Installation, Installation and Service Manual for operating and maintenance instructions.
001570MAN-03 DATE: 12 NOV 2012
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