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Split Products

GT-PX Split (50YDS) Series

GT-G Split (50YCS) Series

GT-S Split (38WQS) Series

Indoor and Outdoor Split

Geothermal Heat Pumps

Installation, Operation &

Maintenance Instructions

97B0048N01

Revision: 28 June, 2007D

Table of Contents

Model Nomenclature 2

Safety 3

Storage 4

Pre-Installation 4

Physical Data 5

Unit Dimensions 6-7

Equipment Selection

Air Coil Match-ups

8-10

8-9

Air Handler Selection

Water Connections

Ground Loop Applications

Open Loop - Ground Water Systems

Water Quality Standards

Refrigeration Installation

Lineset Information

Internal Hot Water Generator

Hot Water Generator Module

Electrical - Line Voltage

10

12-13

13-15

16-17

18

19-24

19

25-26

27-28

29

Power Wiring 30

Electrical - Low Voltage Wiring 31-32

Low Water Temperature Cutout Selection 31

Water Valve Wiring

Thermostat Wiring

Electrical Wiring Schematics

CXM Controls

CXM Safety Control Reset

32

33

34-36

37-40

38

Unit Start-Up and Operating Conditions

Unit and System Checkout Procedure

Unit Start-Up Procedure

Coax Pressure Drop Table

Operating Pressures

41-42

42

42-43

44

45-46

Preventive Maintenance 47

Troubleshooting 48-49

Functional & Performance Troubleshooting 50-51

Refrigerant Circuit Diagram 52

Warranty 53

MODEL NOMENCLATURE: GENERAL OVERVIEW FOR INDOOR SPLIT SERIES

5 0

1 2 3

Y D S

4 5 6 7

0 2 6 N

8

C

9

C

10

3

11

0

12

1

UNIT TYPE:

YDS = INDOOR TWO-STAGE PURON

SPLIT SYSTEM CONDENSING UNIT

YCS = INDOOR SPLIT SYSTEM

CONDENSING UNIT

PACKAGING:

1=SINGLE PACK,DOMESTIC

REVISION LEVEL:

0 = CURRENT REVISION

YCS

018

024

030

036

042

048

060

SIZE:

YDS

026

038

049

064

AIRFLOW CONFIGURATION:

N = NONE

CONTROL:

YDS - C = CXM

YCS - L = CXM

VOLTAGE:

3 = 208V, 230V/1PH/60Hz

HEAT EXCHANGER OPTIONS:

C = COPPER WATER COIL

D = COPPER WATER COIL W/HOT WATER GENERATOR

N = CUPRO-NICKEL WATER COIL

P = CUPRO-NICKEL WATER COIL W/HOT WATER GENERATOR

NOTE: Some options/configurations not availaible on all series. Please consult Engineering Guides for model specific options.

Rev.: 08/15/05D

NOTE: Above model nomenclature is a general reference. Consult individual specifi cation catalogs for detailed information.

MODEL NOMENCLATURE: FOR OUTDOOR SPLIT SERIES

38

1 2 3

WQS

4 5 6 7 8 9 10 11 12

0 2 4 SS C 3 1 1

Prefix

Series

WQS = Extended Range Ultra High

Efficiency Residential Outdoor Split

Packaging

1 = Single Pack, Domestic

Revision Level

1 = Current Revision

Unit Size

018, 024, 030, 036, 042, 048, 060

Standard

SS = Standard

Voltage

3 = 208-230/60/1

Heat Exchanger Options

Standard

Copper Cupro-Nickel

C N

2

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

SAFETY

Safety

Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment.

DANGER: Indicates an immediate hazardous situation, which if not avoided will result in death or serious injury.

DANGER labels on unit access panels must be observed.

WARNING: Indicates a potentially hazardous situation, which if not avoided could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage.

ѥ WARNING! ѥ

WARNING! All refrigerant discharged

from this unit must be recovered WITHOUT

EXCEPTION. Technicians must follow industry accepted guidelines and all local, state, and federal statutes for the recovery and disposal of refrigerants. If a compressor is removed from this unit, refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, refrigerant lines of the compressor must be sealed after it is removed.

NOTICE: Notifi cation of installation, operation or maintenance information, which is important, but which is not hazard-related.

ѥ WARNING! ѥ

WARNING! Verify refrigerant type before

proceeding. Units are shipped with Puron®

(R410A), R22 and R407c refrigerants. The unit label will indicate which refrigerant is provided. The Puron® Application Guideline and Service Manual should be read and understood before attempting to service refrigerant circuits with Puron® refrigerant.

ѥ CAUTION! ѥ

CAUTION! To avoid equipment damage,

DO NOT use these units as a source of heating or cooling during the construction process. The mechanical components and fi lters will quickly become clogged with construction dirt and debris, which may cause system damage.

ѥ WARNING! ѥ

WARNING! To avoid the release of

refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal profi ciency requirements.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

3

GENERAL INFORMATION

Inspection

Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment. If not fi led within 15 days, the freight company can deny the claim without recourse. Note: It is the responsibility of the purchaser to fi le all necessary claims with the carrier. Notify your equipment supplier of all damage within fi fteen (15) days of shipment.

compressor rides freely on the springs. Remove shipping restraints.

6. REMOVE COMPRESSOR SUPPORT PLATE 1/4”

SHIPPING BOLTS (2 on each side) TO MAXIMIZE

VIBRATION AND SOUND ATTENUATION (R22 indoor units only).

7. Locate and verify any hot water generator (HWG) or other accessory kit located in the compressor section.

Storage

Equipment should be stored in its original packaging in a clean, dry area. Store units in an upright position at all times. Stack units a maximum of 3 units high.

Unit Protection

Cover units on the job site with either the original packaging or an equivalent protective covering. Cap the open ends of pipes stored on the job site. In areas where painting, plastering, and/or spraying has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up.

ѥ CAUTION! ѥ

CAUTION! DO NOT store or install units

in corrosive environments or in locations subject to temperature or humidity extremes

(e.g., attics, garages, rooftops, etc.).

Corrosive conditions and high temperature or humidity can signifi cantly reduce performance, reliability, and service life.

Always move and store units in an upright position. Tilting units on their sides may cause equipment damage.

NOTICE! Failure to remove shipping brackets

from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.

Examine all pipes, fi ttings, and valves before installing any of the system components. Remove any dirt or debris found in or on these components.

Pre-Installation

Installation, Operation, and Maintenance instructions are provided with each unit. Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum. Other unit confi gurations are typically installed in a mechanical room. The installation site chosen should include adequate service clearance around the unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.

ѥ CAUTION! ѥ

CAUTION! CUT HAZARD - Failure to follow

this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing heat pumps.

Prepare units for installation as follows:

1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.

2. Keep the cabinet covered with the original packaging until installation is complete and all plastering, painting, etc. is fi nished.

3. Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components.

4. Inspect all electrical connections. Connections must be clean and tight at the terminals.

5. Loosen compressor bolts on units equipped with compressor spring vibration isolation until the

4

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

UNIT PHYSICAL DATA

GT-PX Two-Stage Split (50YDS) Series

Model

Compressor [1 Each)

Factory Charge R410A (oz) [kg]

Water Connection Size

IPT (in)

HWG Connection Size

IPT (in)

Line Set Connection Size

Suction Line Sweat Connection (in.)

Liquid Line Sweat Connection (in.)

Weight - Operating, (lbs) [kg]

Weight - Packaged, (lbs) [kg]

026 038 049 064

90 [2.55]

Copeland UltraTech Two-Stage Scroll

104 [2.95] 126 [3.57] 168 [4.76]

1

1

3/4

3/8

203 [92]

218 [99]

1

1

7/8

3/8

221 [100]

236 [107]

1

1

7/8

3/8

250 [113]

265 [120]

1

1

1-1/8

1/2

265 [120]

280 [127]

All units have spring compressor mountings, TXV expansion devices, and 1/2” [12.2mm] & 3/4” [19.1mm] electrical knockouts.

GT-G Split (50YCS) Series

Model

Compressor [1 Each)

Factory Charge R22 (oz) [kg]

Water Connection Size

IPT (in)

HWG Connection Size

IPT (in)

Line Set Connection Size

Suction Line Sweat Connection (in.)

Liquid Line Sweat Connection (in.)

Weight - Operating, (lbs) [kg]

Weight - Packaged, (lbs) [kg]

018

90 [2.55]

1

1

3/4

3/8

165 [75]

180 [82]

024

104 [2.95]

1

1

7/8

3/8

203 [92]

218 [99]

030

108 [3.06]

1

1

7/8

3/8

205 [93]

220 [100]

036

Scroll

117 [3.32]

1

1

7/8

3/8

217 [98]

232 [105]

042

122 [3.46]

1

1

7/8

3/8

221 [100]

236 [107]

048

130 [3.69]

1

1

7/8

3/8

229 [104]

244 [111]

060

136 [3.86]

1

1

1-1/8

1/2

235 [107]

250 [113]

All units have spring compressor mountings, TXV expansion devices, and 1/2” [12.2mm] & 3/4” [19.1mm] electrical knockouts.

GT-S Split (38WQS) Series

Model

Compressor [1 Each)

Factory Charge R22 (oz) [kg]

Water Connection Size

EPT (in)

Line Set Connection Size

Suction Line Sweat Connection (in.)

Liquid Line Sweat Connection (in.)

Weight - Operating, (lbs) [kg]

Weight - Packaged, (lbs) [kg]

018

Rotary

70 [1.98]

3/4

3/8

165 [75]

180 [82]

024

74 [2.10]

3/4

3/8

203 [92]

218 [99]

030

86 [2.52]

7/8

3/8

205 [93]

220 [100]

036 042

101 [2.86]

Scroll

122 [3.46]

1-1/4

7/8

3/8

217 [98]

232 [105]

7/8

3/8

221 [100]

236 [107]

048

130 [3.69]

7/8

3/8

229 [104]

244 [111]

All units have spring compressor mountings, TXV expansion devices, weather resistant cabinet, and 1/2” [12.2mm] & 3/4”

[19.1mm] electrical knockouts. Hot Water Generator with factory installed hot gas service ports.

060

136 [3.86]

1-1/8

1/2

235 [107]

250 [113]

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

5

DIMENSIONS — GT-PX SPLIT (50YDS) SERIES

GT-PX Two-Stage Split (50YDS) Series

Model

026

038

049

064

Overall Cabinet

A

Width

in 22.4

cm 56.9

in 25.4

cm 64.5

in 25.4

cm 64.5

in 25.4

cm 64.5

B

Height

21.3

54.1

21.3

54.1

19.3

49.0

21.3

54.1

30.6

77.7

30.6

77.7

25.6

65.0

30.6

77.7

C

Depth

1

Water

In/Out

Swivel

2

HWG

In/Out

1

-

1

-

1

-

1

-

1

-

1

-

1

-

1

-

Water Connections

D1

Water

In

1.7

4.3

1.7

4.3

1.6

4.1

1.7

4.3

D2

Water

In

3.4

8.6

3.4

8.6

2.1

5.3

3.4

8.6

E

Water

Out

12.1

30.7

12.1

30.7

11.0

27.9

12.1

30.7

F

HWG

In

15.6

39.6

15.6

39.6

13.9

35.3

15.6

39.6

18.9

48.0

18.9

48.0

16.9

42.9

18.9

48.0

Refrigerant Connection

G

HWG

Out

3

Suction

7/8

-

1-1/8

-

3/4

-

7/8

-

4

Liquid

3/8

-

1/2

-

3/8

-

3/8

-

H

8.4

21.3

8.4

21.3

7.3

18.5

8.4

21.3

I

6.1

15.5

6.1

15.5

5.1

13.0

6.1

15.5

Electrical Knockouts

J K L M

3.6

9.1

3.6

9.1

3.6

9.1

3.6

9.1

6.1

15.5

6.1

15.5

6.1

15.5

6.1

15.5

8.6

21.8

8.6

21.8

8.6

21.8

8.6

21.8

1.7

4.3

1.7

4.3

1.4

3.6

1.7

4.3

C

Top View

Isometric

View

1-1/8" [28.6mm]

Knockout

7/8" [22.2mm]

Knockout

Left Side View

1.177

[29.9mm]

J

K

L

A

2 HWG Out

M

2 HWG In

1

Water Out

3

4

Suction

Liq. Line

Water

1 In

Front View

D1

D2

I

H

E

F

G

B

6

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

DIMENSIONS — GT-G SPLIT (50YCS) & GT-S SPLIT (38WQS) SERIES

GT-G Split (50YCS) Series

Model

018

024

030

036

042

048

060

in.

cm.

in.

cm.

in.

cm.

in.

cm.

in.

cm.

in.

cm.

in.

cm.

Overall Cabinet

A B C

Width Height Depth

22.4

19.3

25.6

[56.9] [49.0] [65.0]

22.4

19.3

25.6

[56.9] [49.0] [65.0]

22.4

19.3

25.6

[56.9] [49.0] [65.0]

22.4

19.3

25.6

[56.9] [49.0] [65.0]

25.4

21.3

30.6

[64.5] [54.1] [77.7]

25.4

21.3

30.6

[64.5] [54.1] [77.7]

25.4

21.3

30.6

[64.5] [54.1] [77.7]

Water Connections

1 - Water In & Out 2 - HWG In & Out

D

Swivel Swivel In

1"

1"

1"

1"

1"

1"

1"

1"

1"

1"

1"

1"

1"

1"

E

Out

F G

HWG In HWG Out

2.4

5.4

13.9

[6.1] [13.7] [35.3]

2.4

5.4

13.9

[6.1] [13.7] [35.3]

2.4

5.4

13.9

[6.1] [13.7] [35.3]

2.4

5.4

13.9

[6.1] [13.7] [35.3]

2.4

5.4

15.9

[6.1] [13.7] [40.4]

2.4

5.4

15.9

[6.1] [13.7] [40.4]

2.4

5.4

15.9

[6.1] [13.7] [40.4]

16.9

[42.9]

16.9

[42.9]

16.9

[42.9]

16.9

[42.9]

18.9

[48.0]

18.9

[48.0]

18.9

[48.0]

Refrigerant Connections

3-Size

Suction

3/4"

3/4"

7/8"

7/8"

7/8"

7/8"

1-1/8"

4-Size

Liquid Suction Liquid

3/8"

3/8"

3/8"

3/8"

3/8"

3/8"

1/2"

H

8.1

[20.6]

8.1

[20.6]

8.1

[20.6]

8.1

[20.6]

9.1

[23.2]

9.1

[23.2]

9.1

[23.2]

I

11.1

[28.3]

11.1

[28.3]

11.1

[28.3]

11.1

[28.3]

12.1

[30.8]

12.1

[30.8]

12.1

[30.8]

Electrical Knockouts

J K L

5.7

5.7

5.7

5.7

8.1

8.1

8.1

9.7

[14.5] [24.6]

9.7

[14.5] [24.6]

9.7

[14.5] [24.6]

9.7

[14.5] [24.6]

11.7

[20.6] [29.7]

11.7

[20.6] [29.7]

11.7

[20.6] [29.7]

12.2

[31.0]

12.2

[31.0]

12.2

[31.0]

12.2

[31.0]

14.2

[36.1]

14.2

[36.1]

14.2

[36.1]

Rev.: 08/10/05D

A

1.6

1.1

3/4" HV

Knockout

2

1/2" LV

Knockout

B

3

4

1.6

1

D E H I F G

C

J

K

L

GT-S Split (38WQS) Series

22

[55.9cm]

33

[83.8cm]

26

[66.0cm]

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

7

EQUIPMENT SELECTION

The installation of geothermal heat pump units and all associated components, parts, and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

General

Proper indoor coil selection is critical to system effi ciency.

Using an older-model coil can affect effi ciency and may not provide the customer with rated or advertised EER and COP. Coil design and technology have dramatically improved operating effi ciency and capacity in the past

20 years. Homeowners using an older coil are not reaping these cost savings and comfort benefi ts. NEVER

MATCH AN R-22 INDOOR COIL WITH AN R-410A

COMPRESSOR SECTION.

Indoor Coil Selection - GT-PX (50YDS) Puron®

Geothermal Split System

Geothermal split system heat pumps are rated in the ARI directory with a specifi c indoor coil match. GT-PX Puron split system (50YDS) models are rated with Carrier/

Bryant FV4 or FE4 series variable speed air handlers as shown in Table 1a. Other combinations (e.g. variable speed furnace with cased coil) may attain the same ARI ratings providing that the specifi cations meet or exceed those listed in Table 1a AND Table 1b. An ECM motor and TXV is required. Cap tubes and fi xed orifi ces are not acceptable. PSC fans may be used if matched to

Table 1b, but will not meet ARI ratings. If using PSC fan, compressor section must be operated as a single stage unit (i.e. wired for either 1st stage or 2nd stage). Without the ability to vary the airfl ow, supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor.

Newer indoor coils have a larger surface area, enhanced fi n design, and grooved tubing. These features provide a larger area for heat transfer, improving effi ciency and expanding capacity. Typical older coils may only have onethird to one-half the face area of these redesigned coils.

Table 1a: GT-PX (50YDS) Puron® Geothermal Split System Air Handler Matches for ARI Ratings

Compressor Section

Air Handler

Model FV4 or FE4

Refrigerant

Metering Device

Air Coil

Type

Rows - Fins/in.

Face Area (sq. ft.)

Cabinet Confi guration

ECM Settings for

ARI Ratings

(FV4 Fan Coil)

Fan Motor Type - HP

026

003

038

005

R-410A

TXV (required)

049

006

Slope

3 - 14.5

3.46

A

3 - 14.5

5.93

Upfl ow / Downfl ow / Horizontal (Multipoise)

A

3 - 14.5

7.42

AC/HP size: 036

System Type:

Comfort AC/HP

CFM Adjust: Nom

ECM - 1/2

AC/HP size: 036

System Type:

HP-Effi c AC/HP

CFM Adjust: High

ECM - 1/2

AC/HP size: 048

System Type:

Comfort AC/HP

CFM Adjust: High

ECM - 3/4

064

006

A

3 - 14.5

7.42

AC/HP size: 060

System Type:

Comfort AC/HP

CFM Adjust: High

ECM - 3/4

8

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

EQUIPMENT SELECTION

Table 1b: Selection of Coils other than Above Models for Puron® Geothermal Split Systems

Model*

026 - Part Load

026 - Full Load

038 - Part Load

038 - Full Load

049 - Part Load

049 - Full Load

064 - Full Load

Nominal

Tons*

1.5

2.0

2.5

3.0

3.5

4.0

5.0

Evaporator

Temp (ºF)

50

52

51

50

47

48

48

CFM

530

880

700

1200

1000

1650

1850

Capacity

(MBtuh)**

19.2 - 22.4

24.2 - 28.2

25.2 - 29.2

34.5 - 40.1

34.3 - 39.9

Add-on CK5P

Coil with TXV

AND Vspd furn.

A/T/W 036

A/T/W 036

A/T/W 048

A/T 060

A/T 060

46.3 - 53.8

X060

54.5 - 63.3

2 - A/T/W 036

FX4 PSC

Fan Coil

(not an ARI rated combination)

018

030

036

036

042

048

060

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller capacity is required. For example, a model 026 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only.

If PSC fan is used, unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for ARI ratings. Size air handler for “Full Load” if operating in two-stage mode.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature, CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Indoor Coil Selection - R-22 Units

Geothermal split system heat pumps with R-22 refrigerant are rated in the ARI directory with a “generic” indoor coil match and PSC fan. Selection of air handlers that attain the published ARI ratings must meet or exceed the specifi cations listed in Table 2. A TXV is required.

Cap tubes and fi xed orifi ces are not acceptable.

Table 2: R-22 Air Handler Characteristics

Model*

018

024

030

036

042

048

060

Nominal

Tons*

1.5

2.0

2.5

3.0

3.5

4.0

5.0

Evaporator

Temp (ºF)

50

47

49

48

45

46

45

CFM

600

800

1000

1200

1400

1600

2000

Capacity

(MBtuh)**

18.5 - 21.3

25.5 - 29.3

31.5 - 36.2

37.0 - 42.5

42.2 - 48.5

50.0 - 57.5

58.0 - 66.7

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature, CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

9

EQUIPMENT SELECTION

Air Handler Selection Example

Figure 1 shows a typical peformance table for a heat pump air handler. Suppose the evaporator temperature required is 50ºF, the capacity required is 35,000 Btuh and the airfl ow required is 1,200 CFM. Each evaporator temperature listed in the table shows three wet bulb temperatures. As recommended in the table notes above, select the 67ºF WB column. At 1,200 CFM, the model 003 capacity is 36 MBtuh, which is higher than the minimum capacity required of 35,000 Btuh. In this example, model 003 would be the appropriate match.

Figure 1: Selecting Air Handler

Utilizing the Existing Air Handler or Coil (R22 units only)

It is recommended that a new coil or air handler be installed with any geothermal split system compressor section due to the low initial cost of the additional equipment versus the reliability and benefi t of new technology, increased reliability and warranty. However, if the existing air handler must be used (R22 systems only), the following conditions apply:

• If the existing coil currently uses an orifi ce, the orifi ce must be removed and replaced with a TXV. If the coil utilizes capillary tubes, it will not operate properly with the geothermal split system and should be replaced.

• If life expectancy of indoor coil (and associated components - fan, cabinet, etc.) is less than 7-10 years, indoor section should be replaced.

10

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

INSTALLATION

NOTICE! Failure to remove shipping brackets

from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.

The installation of water source heat pump units and all associated components, parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

1. Install the unit on a piece of rubber, neoprene or other mounting pad material for sound isolation. The pad should be at least 3/8” [10mm] to 1/2” [13mm] in thickness. Extend the pad beyond all four edges of the unit.

2. Provide adequate clearance for maintenance and service. Do not block access panels with piping, conduit or other materials.

3. Provide access for servicing the compressor and coils without removing the unit.

4. Provide an unobstructed path to the unit within the closet or mechanical room. Space should be suffi cient to allow removal of the unit, if necessary.

5. In limited side access installations, pre-removal of the control box side mounting screws will allow control box removal for future servicing (R22 units only).

6. Provide access to water valves and fi ttings and screwdriver access to the unit side panels and all electrical connections.

Removing Existing Condensing Unit (Where Applicable)

1. Pump down condensing unit. Close the liquid line service valve of existing condensing unit and start compressor to pump refrigerant back into compressor section. Then, close suction service valve while compressor is still running to trap refrigerant in outdoor section. Immediately kill power to the condensing unit.

2. Disconnect power and low voltage and remove old condensing unit. Cut or unbraze line set from unit.

Remove condensing unit.

3. If condensing unit is not operational or will not pump down, refrigerant should be recovered using appropriate equipment.

4. Replace line set, especially if upgrading system from R-22 to R-410A refrigerant. If line set cannot be replaced, it must be thoroughly fl ushed before installing new compressor section. R-410A compressors use POE oil instead of mineral oil (R-22 systems). Mineral oil is not compatible with POE oil, and could cause system damage if not completely fl ushed from the line set.

“Indoor” Compressor Section Location

Both “indoor” and “outdoor” versions of the geothermal split system compressor section are available. “Indoor” version is not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit. Units are typically installed in a mechanical room or closet. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Consideration should be given to access for easy removal of service access panels. Provide suffi cient room to make water, electrical, and line set connections.

“Outdoor” Compressor Section Loacation

Locate the unit in an outdoor area that allows easy loop and lineset access and also has enough space for service personnel to perform typical maintenance or repairs. The “outdoor” compressor section is usually installed on a condensor pad directly outside the lineset access into the building. The service valve side can be located toward the building, keeping the loop access end away from the building. Conform to the following guidelines when selecting unit location:

1. Provide adequate access for loop trench excavation.

2. Locate unit directly outside lineset penetration if possible. Utilize existing condensor pad where possible.

3. Provide access for servicing and maintenance.

“Outdoor” compressor section may be mounted on a vibration isolation pad with loop access hole as shown in Figure 3. When mounting on an existing concrete condenser pad, 3” [76mm] holes should be bored through the pad to accomodate the pipe (1-1/4” - 32mm) and insulation (1/2” [13mm] wall thickness). Figure 3 illustrates location and dimensions of the holes required.

Air Handler Installation

This manual specifi cally addresses the compressor section of the system. Air handler location and installation should be according to the instructions provided with the air handling unit.

Any access panel screws that would be diffi cult to remove after the unit is installed should be removed prior to setting the unit. Refer to Figure 2 for an illustration of a typical installation. Refer to “Physical Dimensions” section for dimensional data. Conform to the following guidelines when selecting unit location:

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

11

Figure 2: 50YDS/YCS Installation

INSTALLATION

Figure 3: 38WQS Installation

Existing Pad larger than 22" x 33" [54 x 84cm]

Bottom view of Unit

22" x 33"

[56 x 84cm]

Drill 3" [76mm] holes for clearance of 1-1/4" [32mm] pipe with 1/2" [13mm] wall insulation

25"

[63.5cm]

Air Pad with access hole

Flow

Controller

5.5"

[14.0cm]

8.25"

[21.0cm]

8.00"

External Flow Controller Mounting

The Flow Controller can be mounted beside the unit as shown in Figure 7. Review the Flow Controller installation manual for more details.

Water Connections-Residential (Distributor) Models

Residential models utilize swivel piping fi ttings for water connections that are rated for 450 psi (3101 kPa) operating pressure. The connections have a rubber gasket seal similar to a garden hose gasket, which when mated to the fl ush end of most 1” threaded male pipe fi ttings provides a leak-free seal without the need for thread sealing tape or joint compound. Insure that the rubber seal is in the swivel connector prior to attempting any connection (rubber seals are shipped attached to the swivel connector). DO NOT OVER TIGHTEN or leaks may occur.

The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket, and seals the joint. HAND TIGHTEN ONLY! DO

NOT OVERTIGHTEN!

Figure 4: Water Connections (Indoor

Compressor Section)

Swivel Nut

Stainless steel snap ring

Gasket

Hand Tighten

Only!

Do Not

Overtighten!

Brass Adaptor

12

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

INSTALLATION

Internal Flow Controller Mounting -

“Outdoor” Compressor Section Only

The Flow Controller can be mounted in the “outdoor” compressor section directly inside the cabinet as shown in Figure 5. Remove the water legs from the outdoor unit at the union fi ttings. Attach the AFC4T 1” MPT x o-ring fi ttings to the removed water legs. Carefully attached the Flow Controller to the loop piping and mount to the outdoor unit using the mounting lugs attached to the unit.

Insert the water legs into the Flow Controller using the oring fi ttings. Re-connect the water leg unions.

Figure 5: Water Connections (Outdoor

Compressor Section)

1” IPT Water Connections

Mount Flow Controller on studs provided

NOTICE! Opening in the bottom of the unit for loop piping must be sealed to prevent rodents from getting into the cabinet and damaging control wiring. Spray type foam may be used to seal the opening(s).

Figure 6: AFC4T Connector

Wire pump power using provided wires for L1 and L2

GROUND-LOOP HEAT PUMP APPLICATIONS

ѥ CAUTION! ѥ

CAUTION! The following instructions

represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

Pre-Installation

Prior to installation, locate and mark all existing underground utilities, piping, etc. Install loops for new construction before sidewalks, patios, driveways, and other construction has begun. During construction, accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation.

Piping Installation

The typical closed loop ground source system is shown in

Figures 7 and 8. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of the loop. Galvanized or steel fi ttings should not be used at any time due to their tendency to corrode. All plastic to metal threaded fi ttings should be avoided due to their potential to leak in earth coupled applications. A fl anged fi tting should be substituted. P/T plugs should be used so that fl ow can be measured using the pressure drop of the unit heat exchanger.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

13

GROUND-LOOP HEAT PUMP APPLICATIONS

Earth loop temperatures can range between 25 and

110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity is recommended in these applications.

Test individual horizontal loop circuits before backfi lling.

Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kPa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled.

Flushing the Earth Loop

Once piping is completed between the unit, Flow

Controller and the ground loop (Figures 7 and 8), the loop is ready for fi nal purging and charging. A fl ush cart with at least a 1.5 hp [1.1 kW] pump is required to achieve enough fl uid velocity in the loop piping system to purge air and dirt particles. An antifreeze solution is used in most areas to prevent freezing. All air and debris must be removed from the earth loop piping before operation.

Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below must be followed for proper fl ushing.

1. Fill loop with water from a garden hose through the fl ush cart before using the fl ush cart pump to insure an even fi ll.

2. Once full, the fl ushing process can begin. Do not allow the water level in the fl ush cart tank to drop below the pump inlet line to avoid air being pumped back out to the earth loop.

3. Try to maintain a fl uid level in the tank above the return tee so that air cannot be continuously mixed back into the fl uid. Surges of 50 psi (345 kPa) can be used to help purge air pockets by simply shutting off the return valve going into the fl ush cart reservoir.

This “dead heads” the pump to 50 psi (345 kPa). To purge, dead head the pump until maximum pumping pressure is reached. Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system.

4. Notice the drop in fl uid level in the fl ush cart tank when the return valve is shut off. If air is adequately purged from the system, the level will drop only 1-2 inches (2.5 - 5 cm) in a 10” (25 cm) diameter PVC fl ush tank (about a half gallon [2.3 liters]), since liquids are incompressible. If the level drops more than this, fl ushing should continue since air is still being compressed in the loop fl uid. Perform the “dead head” procedure a number of times.

Note: This fl uid level drop is your only indication of air in the loop.

Loop static pressure will fl uctuate with the seasons.

Pressures will be higher in the winter months than during the cooling season. This fl uctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature.

This is a good time for tool cleanup, piping insulation, etc. Then, perform fi nal fl ush and pressurize the loop to a static pressure of 50-75 psi [345-517 kPa] (winter) or

35-40 psi [241-276 kPa] (summer). After pressurization, be sure to loosen the plug at the end of the Grundfos loop pump motor(s) to allow trapped air to be discharged and to insure the motor housing has been fl ooded. This is not required for Taco circulators. Insure that the Flow Controller provides adequate fl ow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual.

Antifreeze

In areas where minimum entering loop temperatures drop below 40°F [5°C] or where piping will be routed through areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F [9°C] below the lowest expected entering loop temperature. For example, if

30°F [-1°C] is the minimum expected entering loop temperature, the leaving loop temperature would be 25 to

22°F [-4 to -6°C] and freeze protection should be at 15°F

[-10°C]. Calculation is as follows:

30°F - 15°F = 15°F [-1°C - 9°C = -10°C].

All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes.

Calculate the total volume of fl uid in the piping system.

Then use the percentage by volume shown in Table

1 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specifi c gravity.

Low Water Temperature Cutout Setting

CXM or DXM Control

When antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature

(antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE: Low water temperature operation requires extended range equipment.

Antifreeze may be added before, during or after the fl ushing procedure. However, depending upon which time is chosen, antifreeze could be wasted when emptying the fl ush cart tank. See antifreeze section for more details.

14

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

GROUND-LOOP HEAT PUMP APPLICATIONS

Table 1: Approximate Fluid Volume (U.S. gal. [L]) per 100' of Pipe

Figure 7: Loop Connection (Indoor

Compressor Section)

Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)

Pipe Size Volume (gal) [liters]

Copper

Rubber Hose

Polyethylene

Unit Heat Exchanger

Flush Cart Tank

1”

1.25”

2.5”

1”

3/4” IPS SDR11

1” iPS SDR11

1.25” IPS SDR11

1.5” IPS SDR11

2” IPS SDR11

1.25” IPS SCH40

1.5” IPS SCH40

2” IPS SCH40

Typical

10” Dia x 3ft tall

[254mm x 91.4cm tall]

4.1 [15.3]

6.4 [23.8]

9.2 [34.3]

3.9 [14.6]

2.8 [10.4]

4.5 [16.7]

8.0 [29.8]

10.9 [40.7]

18.0 [67.0]

8.3 [30.9]

10.9 [40.7]

17.0 [63.4]

1.0 [3.8]

10 [37.9]

AH & Thermostat

Wiring

Air Pad or

Extruded polystyrene insulation board

Unit Power

Disconnect

Flow

Controller

Insulated

Hose Kit

To Loop

P/T Plugs

Figure 8: Loop Connection (Outdoor

Compressor Section)

P/T Ports

Flow Controller

Insulate all piping with 1/2"

[13mm] closed cell insulation

Backfill carefully to avoid stress on piping and flow controller connection

Header Pit

NOTICE! Cabinet opening around loop

piping (outdoor compressor section) must be sealed to prevent entry of rodents that could potentially damage unit wiring by chewing on the insulation.

Air Pad with access hole

NOTICE! Outdoor compressor section may

not be tilted more than 5 degrees from level.

Damage to the compressor or stress on the loop piping could result if unit is tilted.

A concrete pad, anchor posts and/or soil compaction may be required to avoid tilting as ground settles.

Table 2: Antifreeze Percentages by Volume

Type

Methanol

100% USP food grade Propylene Glycol

Ethanol*

* Must not be denatured with any petroleum based product

Minimum Temperature for Low Temperature Protection

10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]

25%

38%

29%

21%

25%

25%

16%

22%

20%

10%

15%

14%

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

15

GROUND-WATER HEAT PUMP APPLICATIONS -

“INDOOR” COMPRESSOR SECTION ONLY

Open Loop - Ground Water Systems (“Indoor”

Compressor Section Only)

The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in

Figure 9. Shut off valves should be included for ease of servicing. Boiler drains or other valves should be “tee’d” into the lines to allow acid fl ushing of the heat exchanger.

Shut off valves should be positioned to allow fl ow through the coax via the boiler drains without allowing fl ow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80.

Note: Due to the pressure and temperature extremes,

PVC SCH40 is not recommended.

tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain fi eld, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal.

Consult your local building and zoning department to assure compliance in your area.

The pump should be sized to handle the home’s domestic water load (typically 5-9 gpm [23-41 l/m]) plus the fl ow rate required for the heat pump. Pump sizing and expansion tank must be chosen as complimentary items. For example, an expansion tank that is too small can causing premature pump failure due to short cycling. Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements.

Water quantity should be plentiful and of good quality.

Consult Table 3 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 3 for recommendations.

Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualifi ed technician, as acid and special pumping equipment is required. Desuperheater coils can likewise become scaled and possibly plugged.

In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional acid fl ushing. In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required.

Water Control Valve

Note the placement of the water control valve in fi gure 9.

Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle.

Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. Insure that the total ‘VA’ draw of the valve can be supplied by the unit transformer. For instance, a slow closing valve can draw up to 35VA. This can overload smaller 40 or 50

VA transformers depending on the other controls in the circuit. A typical pilot operated solenoid valve draws approximately 15VA (see Figure 24). Note the special wiring diagrams for slow closing valves (Figures 25 & 26).

Water Quality Standards

Table 3 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the

Calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F

[66°C] for direct use (well water/open loop) and

DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3.

Expansion Tank and Pump

Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion

Flow Regulation

Flow regulation can be accomplished by two methods.

One method of fl ow regulation involves simply adjusting the ball valve or water control valve on the discharge line. Measure the pressure drop through the unit heat exchanger, and determine fl ow rate from Tables 11a through 11c. Since the pressure is constantly varying, two pressure gauges may be needed. Adjust the valve until the desired fl ow of 1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved. A second method of fl ow control requires a fl ow control device mounted on the outlet of the water control valve. The device is typically a brass fi tting with an orifi ce of rubber or plastic material that is designed to allow a specifi ed fl ow rate. On occasion, fl ow control devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line. Slightly closing the valve will spread the pressure drop over both devices, lessening the velocity noise. NOTE: When EWT is below 50°F

[10°C], 2 gpm per ton (2.6 l/m per kW) is required.

16

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

GROUND-WATER HEAT PUMP APPLICATIONS

Water Coil Low Temperature Limit Setting

For all open loop systems the 30°F [-1.1°C] FP1 setting

(factory setting-water) should be used to avoid freeze damage to the unit. See “Low Water Temperature Cutout

Selection” in this manual for details on the low limit setting.

Figure 9: Water Well Connections

Water

Control

Valve

Flow

Regulator

Pressure

Tank

Water Out ѥ CAUTION! ѥ

CAUTION! Many units installed with a factory

or fi eld supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any fi eld provided shutoff valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The fi eld installed high pressure switch shall have a cut-out pressure of 235 psig and a cut-in pressure of 190 psig. This pressure switch can be ordered with a 1/4” internal fl are connection as part number 39B0005N01.

ѥ CAUTION! ѥ

CAUTION! Refrigerant pressure activated

water regulating valves should never be used with geothermal heat pump equipment.

P/T Plugs

Boiler

Drains

Optional

Filter

Shut-Off

Valve

Water In

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

17

WATER QUALITY STANDARDS

Table 3: Water Quality Standards

Water Quality

Parameter

HX

Material

Closed

Recirculating

Open Loop and Recirculating Well

Scaling Potential - Primary Measurement

Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below.

pH/Calcium Hardness

Method

All

pH < 7.5 and Ca Hardness <100ppm

Index Limits for Probable Scaling Situations -

(Operation outside these limits is not recommended)

Scaling indexes should be calculated at 150°F [66°C] for direct use and HWG applications, and at 90°F [32°C] for indirect HX use. A monitoring plan should be implemented.

Ryznar

Stability Index

All

6.0 - 7.5

If >7.5 minimize steel pipe use.

-

Langelier

Saturation Index

All

-0.5 to +0.5

If <-0.5 minimize steel pipe use. Based upon 150°F [66°C] HWG and

Direct well, 85°F [29°C] Indirect Well HX

Iron Fouling

Iron Fe 2+ (Ferrous)

(Bacterial Iron potential)

All

-

<0.2 ppm (Ferrous)

If Fe 2+ (ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria

-

Iron Fouling

All

<0.5 ppm of Oxygen

Above this level deposition will occur.

Corrosion Prevention

pH

All

6 - 8.5

Monitor/treat as needed

-

6 - 8.5

Minimize steel pipe below 7 and no open tanks with pH <8

Hydrogen Sulfide (H

2

S)

All

<0.5 ppm

At H

2

S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.

Rotten egg smell appears at 0.5 ppm level.

Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.

Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds

All

-

<0.5 ppm

Maximum

Chloride Levels

Copper

CuproNickel

304 SS

316 SS

Titanium

Erosion and Clogging

-

-

-

-

-

Maximum Allowable at maximum water temperature.

50°F (10°C)

<20ppm

<150 ppm

<400 ppm

<1000 ppm

>1000 ppm

75°F (24°C)

NR

NR

<250 ppm

<550 ppm

>550 ppm

100°F (38°C)

NR

NR

<150 ppm

< 375 ppm

>375 ppm

Particulate Size and

Erosion

All

<10 ppm of particles and a maximum velocity of 6 fps [1.8 m/s].

Filtered for maximum

800 micron [800mm,

20 mesh] size.

<10 ppm (<1 ppm "sandfree" for reinjection) of particlesand a maximum velocity of 6 fps [1.8 m/s]. Filtered for maximum 800 micron [800mm,

20 mesh] size.Any particulate that is not removed can potentially clog components.

Rev.: 11/17/06D

Notes:

• Closed Recirculating system is identified by a closed pressurized piping system.

• Recirculating open wells should observe the open recirculating design considerations.

• NR - Application not recommended.

18

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

REFRIGERATION INSTALLATION

ѥ CAUTION! ѥ

CAUTION! R-410A systems operate at

higher pressures than R-22 systems. Be certain that service equipment (gauges, tools, etc.) is rated for R-410A. Some R-22 service equipment may not be acceptable.

A reversible heat pump fi lter drier is installed on the liquid line inside the compressor section cabinet (R-22 units only). R-410A models are shipped with a fi lter drier (loose) inside the cabinet that must be installed in the liquid line at the line set. All brazing should be performed using

nitrogen circulating at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the tubing. All linesets should be insulated with a minimum of 1/2” [13mm] thick closed cell insulation. All insulation tubing should be sealed using a UV resistant paint or covering to prevent deterioration from sunlight.

ѥ CAUTION! ѥ

CAUTION! Installation of a factory

supplied liquid line bi-directional fi lter drier is required. Never install a suction line fi lter in the liquid line.

Line Set Installation

Figures 12a through 13b illustrate typical installations with the “indoor” and “outdoor” versions of the compressor section matched to either an air handler (fan coil) or addon furnace coil. Table 4 shows typical line-set diameters at various lengths. Lineset lengths should be kept to a minimum and should always be installed with care to avoid kinking. Line sets over 60 feet [18 meters] long are not recommended due to potential oil transport problems and excessive pressure drop. If the line set is kinked or distorted, and it cannot be formed back into its original shape, the damaged portion of the line should be replaced. A restricted line set will effect the performance of the system.

When passing refrigerant lines through a wall, seal opening with silicon-based chaulk. Avoid direct contact with water pipes, duct work, fl oor joists, wall studs, fl oors or other structural components that could transmit compressor vibration. Do not suspend refrigerant tubing from joists with rigid straps. Do not attach line set to the wall. When necessary, use hanger straps with isolation sleeves to minimize tranmission of line set vibration to the structure.

Installing the Lineset at the Compressor Section

Braze the line set to the service valve stubs as shown in Figure 10. On installations with long line sets, copper adapters may be needed to connect the larger diameter tube to the stubs. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections. Compressor section is shipped

with a factory charge. Therefore, service valves should not be opened until the line set has been leak tested,

purged and evacuated. See “Charging the System.”

Table 4: Lineset Diameters and Charge Information

Model

018

024

030

036

042

048

060

026

038

049

064

Factory†

Charge (oz)

[kg]

70 [1.98]

74 [2.10]

108 [3.06]

117 [3.32]

122 [3.46]

130 [3.69]

136 [3.86]

90 [2.55]

104 [2.95]

126 [3.57]

168 [4.76]

Basic*

Charge (oz)

[kg]

55 [1.56]

59 [1.67]

93 [2.64]

102 [2.89]

107 [3.03]

115 [3.26]

121 [3.43]

75 [2.13]

89 [2.52]

111 [3.15]

138 [3.91]

20 Feet [6 meters]

Liquid

3/8”

3/8”

3/8”

1/2”

Suction

40 Feet [12 meters]

Liquid

50YCS/38WQS Series

3/8”

3/8”

3/8”

3/8”

3/8”

3/8”

3/8”

3/4”

3/4”

3/4”

3/4”

7/8”

7/8”

1-1/8”

3/8”

3/8”

3/8”

3/8”

3/8”

3/8”

1/2”

50YDS Series

3/4”

7/8”

7/8”

1-1/8”

3/8”

3/8”

3/8”

1/2”

Suction

3/4”

3/4”

7/8”

7/8”

7/8”

7/8”

1-1/8”

3/4”

7/8”

7/8”

1-1/8”

60 Feet [18 meters]

Liquid

3/8”

3/8”

3/8”

3/8”

3/8”

1/2”

1/2”

3/8”

3/8”

1/2”

1/2”

• Basic charge includes only the amount required for the condensing unit and the evaporating coil.

An additional amount should be added allowing 0.6oz per ft. for 3/8” [0.6g per cm] and 1.2oz per ft. for 1/2” [1.1g per cm] of lineset used.

†Factory charge is preset for 25’ [7.6 meters] lineset.

Suction

7/8”

7/8”

1-1/8”

1-1/8”

3/4”

7/8”

7/8”

7/8”

7/8”

1-1/8”

1-1/8”

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

19

REFRIGERATION INSTALLATION

Figure 10: Braze Instructions Figure 11: Air Coil Connection

TXV (‘IN’ toward compressor section)

Fully Insulated

Suction Line

Bulb

(Must be

Insulated)

Equalizer

Line

Suction Line

TXV has internal check valve

Fully Insulated

Liquid Line

Liquid Line

Nitrogen Braze

Replace Caps after adjusting service valves

CCW

CCW

Service ports for gauges

Rev. 05/31/00

Replace caps after adjusting service valves

Service ports for attaching refrigerant gauges

Braze connection

Add-On Heat Pump Applications

The indoor coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger for add-on heat pump applications.

A high temperature limit switch should be installed as shown in Figures 12b and 13b just upstream of the coil to de-energize the compressor any time the furnace is energized to avoid blowing hot air directly into the coil, elevating refrigerant pressures during operation. The heat pump will trip out on high pressure lockout without some method of disengaging the compressor during furnace operation. Alternatively, some thermostats with “dual fuel” mode will automatically de-energize the compressor when second stage (backup) heat is required.

The TXV should be brazed into place as shown in

Figure 11, keeping the “IN” side toward the compressor section. The TXV has an internal check valve and must be installed in the proper direction for operation. Always keep the valve body cool with a brazing shield and wet rags to prevent damage to the TXV. Attach the bulb to the suction line using the supplied hose clamp. Be careful not to overtighten the clamp and deform the bulb.

Table 5: Service Valve Positions

Position

CCW - Full Out

CCW - Full Out 1/2 turn CW

CW - Full In

Description

Operation Position

Service Position

Shipping Position

NOTICE! The air coil should be thoroughly washed with a fi lming agent, (dishwasher detergent like Cascade) to help condensate drainage. Apply a 20 to 1 solution of detergent and water. Spray both sides of coil, repeat and rinse thoroughly with water.

Open

Open

Closed

Service

Port

Closed

Open

Open

Installing the Indoor Coil and Lineset

Figure 11 shows the installation of the lineset and TXV to a typical indoor coil. An indoor coil or air handler (fan coil) with a TXV is preferred. Coils with cap tubes may not be used.

If coil includes removable fi xed orifi ce, the orifi ce must be removed and a TXV must be installed as shown in Figure

11. Fasten the copper line set to the coil. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the refrigerant tubing. Use a low silver phos-copper braze alloy on all brazed connections.

20

Evacuation and Charging the Unit

LEAK TESTING - The refrigeration line set must be pressurized and checked for leaks before evacuating and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60-90 psig [413-

620 kPa]. Never use oxygen or acetylene to pressure test.

Use a halogen leak tester or a good quality bubble solution to detect leaks on all connections made in the fi eld. Check the service valve ports and stem for leaks. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize system above 150 psig [1034 kPa]. System is now ready for evacuation and charging.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

REFRIGERATION INSTALLATION

Figure 12a: Typical Split / Air Handler Installation (Indoor Compressor Section)

Power

Disconnects

Insulated

Linesets

Air Handler

TXV 'IN' toward

Compressor

Section

Return Plenum

PVC Condensate with vented trap

Compressor Section

Low Voltage

Air pad or Extruded polystryene

Figure 12b: Typical Split / Add-on Coil Fossil Fuel Furnace Installation (Indoor

Compressor Section)

TXV 'IN' toward

Compressor

Section

Power

Disconnects

Add-On

‘A’ Coil

PVC Condensate with vented trap

Insulated

Linesets

Fossil Furnace

Compressor Section

Low Voltage

Air pad or Extruded polystryene

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

21

REFRIGERATION INSTALLATION

Figure 13a: Typical Split / Air Handler Installation (Outdoor Compressor Section)

Compressor

Section

Power

Disconnects

Insulated line set with UV Paint

Air Handler

TXV ‘IN’ toward compressor section

Return Plenum

Pad

Low Voltage

Wiring

PVC

Condensate with vented trap

Figure 13b: Typical Split / Add-on Coil Fossil Fuel Furnace Installation (Outdoor

Compressor Section)

TXV ‘IN’ toward compressor section

Compressor

Section

Power

Disconnects

Insulated line set with

UV Paint

Fossil

Furnace

Add-On

‘A’ Coil

Air

Temperature

Limit Switch

Return

Plenum

Pad

Low Voltage

Wiring

PVC

Condensate with vented trap

22

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

REFRIGERATION INSTALLATION

Evacuation Of The Lineset And Coil

The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables.

Evacuate the system through both service ports in the shipping position (full CW in - see table 5) to prevent false readings on the gauge because of pressure drop through service ports. A vacuum gauge or thermistor capable of accurately meausuring the vacuum depth is crucial in determining if the system is ready for charging. If the system meets the requirements in Figure 14, it is ready for charging.

Charging The System

There are two methods of charging a refrigerant system.

One method is the total charge method, where the volume of the system is determined and the refrigerant is measured and added into the evacuated system. The other method is the partial charge method where a small initial charge is added to an evacuated system, and remaining refrigerant added during operation.

Figure 14: Evacuation Graph

TOTAL CHARGE METHOD - See Table 4 for the compressor section basic charge. For line sets with 3/8” liquid lines add 0.6 ounces of refrigerant to the basic charge for every installed foot of liquid line [0.6 grams per cm]. Add 1.2 oz. per foot [1.1 grams per cm] if using l/2” line. Once the total charge is determined, the factory precharge (Table 4) is subtracted and the remainder is the amount needed to be added to the system. This method should be used with the ARI matched air handler.

EXAMPLE: R22 model 048 with 40 feet [12 meters] of installed liquid line (3/8” O.D.). The basic charge of model

048 is 115 oz [3.26 kg]. The 40 ft. [12 meter] 3/8” line set requires 24 oz. [0.72 kg] (40 ft. x 0.6 oz./ft = 24 oz.

-- 1200cm x 0.6g/cm = 720g). Total charge = 115 + 24 =

139 oz [3.26 + 0.72 = 3.98 kg]. The compressor section is shipped from the factory with 130 oz. [3.69 kg] of refrigerant (for 25 ft [7.6m] lineset), so the amount to be added is 9 oz. [0.29 kg] (total charge - shipped charge = charge to be added).

Table 6a: R-22 Charging Values

ѥ NOTICE! ѥ

NOTICE: Use tables 14a to 15 for

superheat/subcooling values. These tables use discharge pressure (converted to saturation temperature) and liquid line temperature for subcooling calculations. If using liquid line pressure, subtract 3°F from the table values.

Table 6b: R-410A Charging Values

ѥ NOTICE! ѥ

NOTICE: Use tables 14a to 15 for

superheat/subcooling values. These tables use discharge pressure (converted to saturation temperature) and liquid line temperature for subcooling calculations. If using liquid line pressure, subtract 3°F from the table values.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

23

REFRIGERATION INSTALLATION

Turn service valves full out CCW (see Table 5) and then turn back in one-half turn to open service ports. Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system. Open the service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use. Start unit in the heating mode and measure superheat and subcooling values after 5 minutes of run time. See tables 13a to 14 for superheat and sub-cooling values. Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 13a to

14 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in

TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured.

After values are measured, compare to the chart and go to “FINAL EVALUATION.” cooling mode and check the cooling superheat against

Tables 13a to 14. If unit runs satisfactorily, charging is complete. If unit does not perform to specifi cations the cooling TXV (air coil side) may need to be readjusted (if possible) until the cooling superheat values are met.

Checking Superheat and Subcooling

Determining Superheat:

1. Measure the temperature of the suction line at a point near the expansion valve bulb.

2. Determine the suction pressure by attaching refrigeration gauges to the suction schrader connection at the compressor.

3. Convert the pressure obtained in step 2 to saturation temperature (boiling point) by using the pressure/ temperature conversion table on the gauge set.

4. Subtract the temperature obtained in step 3 from step 1. The difference will be the superheat of the unit or the total number of degrees above saturation temperature. Refer to Tables 13a to 14 for superheat ranges at specifi c entering water conditions.

Example (R-22 refrigerant):

The temperature of the suction line at the sensing bulb is

50°F. The suction pressure at the compressor is 65 psig which is equivalent to 38°F saturation temperature from the R-22 press/temp conversion table on the gauge set.

38°F subtracted from 50°F = 12°F Superheat.

PARTIAL CHARGE METHOD - Open service valve fully counterclockwise and then turn back in one-half turn to open service port. Add vaporized (Gas) into the suction side of the compressor until the pressure in the system reaches approximately 60-70 psig (R-22 systems) or 100-

120 psig (R-410A systems). Never add liquid refrigerant into the suction side of a compressor. Start the unit in heating and add gas to the suction port at a rate not to exceed fi ve pounds [2.27 kg] per minute. Keep adding refrigerant until the complete charge has been entered.

Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 13a to 14 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured. After values are measured, compare to the chart and go to “FINAL EVALUATION.”

FINAL EVALUATION -In a split system, cooling subcooling values can be misleading depending on the location of the measurement. Therefore, it is recommended that charging be monitored in the heating mode. Charge should be evaluated by monitoring the subcooling in the heating mode. After initial check of heating sub-cooling, shut off unit and allow to sit 3-5 minutes until pressures equalize. Restart unit in the

Determining Sub-Cooling:

1. Measure the temperature of the liquid line on the smaller refrigerant line (liquid line) just outside of the cabinet. This location will be adequate for measurement in both modes unless a signifi cant temperature drop in the liquid line is anticipated.

2. Determine the condensor pressure (high side) by attaching refrigerant gauges to the schrader connection on the liquid line service valve. If the hot gas discharge line of the compressor is used, refer to the appropriate column in Tables 13a to 14.

3. Convert the pressure obtained in step 2 to the saturation temperature by using the press/temp conversion table on the gauge set.

4. Subtract the temperature of Step 3 from the temperature of Step 1. The difference will be the sub-cooling value for that unit (total degrees below the saturation temperature). Refer to Tables 13a or 6b for sub-cooling values at specifi c entering water temperatures.

Example (R-22 refrigerant):

The condenser pressure at the service port is 225 psig, which is equivalent to 110°F saturation temperature.

Discharge pressure is 236 psig at the compressor

(113°F saturation temperature). Measured liquid line temperature is 100°F. 100°F subtracted from 110°F = 10 degrees sub-cooling (13 degrees if using the compressor discharge pressure).

24

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

HOT WATER GENERATOR

The HWG (Hot Water Generator) or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements. The HWG is active throughout the year, providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode. Actual HWG water heating capacities are provided in the appropriate heat pump performance data.

tank connection fi tting eliminates the need to tie into the hot water tank cold water piping, but is more susceptible to scaling. The optional concentric fi tting (part # S69619804) is available from your equipment supplier and should be installed as shown in Figure 17 for applications with low scaling potential or where a water softener is used.

Consult Table 3 for scaling potential tests.

“Indoor” compressor section heat pumps equipped with the HWG option include a built-in water to refrigerant heat exchanger that eliminates the need to tie into the heat pump refrigerant circuit in the fi eld. The control circuit and pump are also built in for residential equipment.

Figure 15 shows a typical example of HWG water piping connections on a unit with built-in pump. This piping layout minimizes scaling potential.

It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life. In extreme water conditions, it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings.

The outdoor compressor section utilizes an add-on HWG module that ties into the hot gas line of the compressor section. The HWG module is remotely mounted near the water heater and includes a water to refrigerant heat exchanger, pump and controls. Figure 18 is a typical example of a remote module HWG system.

R-410 systems inherently have a lower hot gas temperature than R-22 systems because the equipment is more effi cient (i.e. less waste heat is available). It is possible that energy could be transferred from the water heater to the hot gas line instead of from the hot gas line to the water heater during certain times of the year. To prevent this from occuring, a temperature switch will deactivate the pump at those conditions that typically occur in the cooling mode with entering water temperatures of less than 50°F [10°C].

Electric water heaters are recommended. If a gas, propane, or oil water heater is used, a second preheat tank must be installed (Figure 16). If the electric water heater has only a single center element, the dual tank system is recommended to insure a usable entering water temperature for the HWG.

Typically a single tank of at least 52 gallons (235 liters) is used to limit installation costs and space. However, a dual tank, as shown in Figure 16, is the most effi cient system, providing the maximum storage and temperate source water to the HWG. Using a concentric or coaxial hot water

Installation

The HWG high limit temperature switch is set at 125°F

[52°C] and is located on the HWG heat exchanger

“Water In” line. If the HWG is connected incorrectly or if circulation is reversed, the aquastat will sense leaving water temperature and prevent HWG operation. UNDER

NO CIRCUMSTANCES SHOULD THE LIMIT BE

DISCONNECTED OR REMOVED! Full load conditions could drive hot water tank temperatures far above desirable temperature levels if the aquastat has been disconnected or removed.

Figure 15: Typical HWG Installation

(Indoor Compressor Section)

Cold Inlet

Domestic

Cold Supply

Hot Outlet to home

Shut-off Valve with Waste

Vent at high point

Shut-off Valve

Powered

Water

Heater

Upper element to

120 - 130°F

[49-54

°C]

Lower element to

100-110

°F

[38-43

°C]

Figure 16: HWG Double Tank In stal la tion

(Indoor Compressor Section)

Shut Off Valves with Waste

Vent at high point

Hot Outlet

Cold Inlet from

Domestic supply

Hot Outlet to house

Cold Inlet

Upper element to 130°F

[54°C] (or owner

preference)

Unpowered

Water Heater

Powered

Water Heater

Lower element to 120°F

[49°C]

Insulated water lines -

5/8” OD 50 ft [15m] maximum

Tee and drain

Tee and Drain

Insulated water lines - 5/8” OD

50 ft [15m] maximum

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

25

Figure 17: Alternate HWG Piping with concentric/coaxial fi tting (part #S69619804 not included with unit)

(Indoor Compressor Section)

Insulated water lines -

5/8" OD, 50 ft [15m] maximum

Waste Vent Coupling at high point

Compressor Section

Coaxial

Fitting

HOT WATER GENERATOR

Hot Outlet

Cold Inlet

Upper element to

120-130°F

[49-54°C]

Water Heater

Lower element to

100-110 ° F

[38-43 ° C]

Water Tank Refi ll

1. Open the cold water supply to the tank.

2. Open a hot water faucet to vent air from the system until water fl ows from the faucet; turn off faucet.

3. Depress the hot water tank pressure relief valve handle to ensure that there is no air remaining in the tank.

4. Inspect all work for leaks.

5. Before restoring power or fuel supply to the water heater, adjust the temperature setting on the tank thermostat(s) to insure maximum utilization of the heat available from the refrigeration system and conserve the most energy. On tanks with both upper and lower elements and thermostats, the lower element should be turned down to 100°F [38°C] or the lowest setting; the upper element should be adjusted to 120-130°F

[49-54°C]. Depending upon the specifi c needs of the customer, you may want to adjust the upper element differently. On tanks with a single thermostat, a preheat tank should be used (fi gure 16).

6. Replace access cover(s) and restore power or fuel supply.

The heat pump, water piping, pump, and hot water tank should be located where the ambient temperature does not fall below 50°F [10°C]. Keep water piping lengths at a minimum. DO NOT use a one way length greater than 50 ft. [15 m].

All installations must be in accordance with local codes. The installer is responsible for knowing the local requirements, and for performing the installation accordingly. DO NOT connect the pump wiring until “Initial

Start-Up” section, below. Powering the pump before all installation steps are completed will damage the pump.

Water Tank Preparation

1. Turn off power or fuel supply to the hot water tank.

2. Connect a hose to the drain valve on the water tank.

3. Shut off the cold water supply to the water tank.

4. Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank.

5. When using an existing tank, it should be fl ushed with cold water after it is drained until the water leaving the drain hose is clear and free of sediment.

6. Close all valves and remove the drain hose.

7. Install HWG water piping.

Initial Start-Up

1. Make sure all valves in the HWG water circuit are fully open.

2. Turn on the heat pump and allow it to run for

10-15 minutes.

3. Turn the heat pump and heat pump power supply

“OFF” and CONNECT POWER TO THE HWG PUMP as shown in the unit wiring diagram. Connect the pump power lead as instructed on the tag attached to the pump wiring.

4. The HWG pump should not run if the compressor is not running.

5. The temperature difference between the water entering and leaving the HWG coil should be approximately 5-10°F [3-6°C].

6. Allow the unit to operate for 20 to 30 minutes to insure that it is functioning properly.

Figure 18: HWG In stal la tion (shown with optional concentric/coaxial fi tting part

#S69619804 not included with unit)

(Outdoor Compressor Section)

Hot

Outlet

Cold

Inlet

HWG Water Piping

1. Using at least 5/8” [16mm] O.D. copper, route and install the water piping, valves and air vent as shown in Figures 15 to 18. The air vent MUST be at the high point of the HWG water piping.

2. Insulate all HWG water piping with no less than 3/8”

[10mm] wall closed cell insulation.

3. Open both shut off valves and make sure the tank drain valve is closed.

Insulated line set with

UV Paint

Insulated water lines

Insulated lineset enters structure

Add-On Hot Water

Generator with internal pump

Water

Heater

Waste Vent

Coupling

Coaxial

Fitting

26

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

HWG MODULE REFRIGERATION INSTALLATION -

OUTDOOR COMPRESSOR SECTION ONLY

General Information

The HWG Module consists of an all-copper, vented

Table 7: HWG Module Lineset Sizing

double-wall heat exchanger and a water-cooled water circulating pump. The pump is controlled by the use of one or more limit switches. Power for the pump is provided from either the compressor contactor of the outdoor section of the heat pump, or it may come from a remote power source if the appropriate controls are used.

Capacity

2 Ton

3 Ton

1/2” OD

Up to 16 ft.

[4.9m]

Up to 9 ft.

[2.7m]

Line Set Size

5/8” OD

Up to 30 ft.

[9.1m]

Up to 25 ft.

[7.6m]

3/4” OD

N/A

Up to 30 ft.

[9.1m]

Location/Mounting

The HWG module should be mounted as close to the heat pump outdoor section as possible, in order to minimize the length of refrigerant run. Indoor mounting is preferred, where practical, to reduce the likelihood of freezing ambient temperature. It is recommended that the HWG module be mounted above the system compressor in order to promote proper oil movement and drain-down.

This means that the HWG module can be wall mounted

in any orientation except for stubs up. Mounting should be accomplished by fastening the HWG module cabinet to the wall or other selected vertical surface. A fl ange is provided at the top rear of the unit. Any fastener suitable for supporting a 12 pound [5.4] vertical load is acceptable.

4 Ton

5 Ton

Up to 5 ft.

[1.5m]

N/A

Up to 13 ft.

[4.0m]

Up to 9 ft.

[2.7m]

Up to 30 ft.

[9.1]

Up to 25 ft.

[7.6m]

As a guideline add 1.0 oz. of R-22 for the heat exchanger plus

1.0 oz. for each 10 ft of 1/2” OD refrigerant line, if the weighed charge method is used (28g for the heat exchanger plus 9g per meter of 1/2” OD refrigerant line).

Figure 19: HWG Connection Details

SPECIAL NOTE: The selected mounting location and orientation must allow the circulator pump to be positioned with the motor shaft horizontal. DO NOT

install the Heat Recovery Unit fl at on its back.

Refrigerant Line Installation

Before starting the installation into the refrigerant circuit, inspect and note the condition and performance of the heat pump. Disconnect power to the heat pump outdoor unit. Any system defi ciencies must be corrected prior to installing the HWG module. Addition of the unit will not correct system problems. Record the suction and discharge pressures and compressor amperage draw.

These will be used for comparison with system operation after the refrigerant line installation is complete and before the water line installation is performed. Install the Add-On HWG kit using the installation instructions below. Locate the HWG as close to the water heater as possible. Unbraze the hot gas u-bend as shown in Figure

19. Take care to avoid overheating components. Install the dual 1/2” lineset to the HWG. Maximum length should be 30 feet one way. Evacuate the lineset to 500 microns through the hot gas valves in the outdoor unit. Open the valves up fully (CCW looking up from cap end). Check the lineset for leaks. Pinch the bypass tubing as shown in

Figure 19 being careful not to damage the tubing. Verify that lineset tubing is completely insulated with a minimum

1/2” thick closed cell and painted to prevent deterioration of the insulation due to ultra violet light and weather.

Make the connections with high temperature solder or brazing rod. The recommended line size is dependent on the one way distance between the Heat Recovery Unit and the compressor; and the size of the system. Use the

Table 7 as a guideline.

Pinch off here after evacuating lineset and opening valves

Hot Gas from

Compressor

Open Valves CW Close valves CCW as looking up from underneath

Hot water generator service valve assembly

(inside cabinet)

Unbraze u-tube

Hot Gas to

Reversing Valve

Field connection of

Hot Water lineset

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

27

HWG MODULE REFRIGERATION INSTALLATION -

OUTDOOR COMPRESSOR SECTION ONLY

Figure 20: HWG Module Wiring

ѥ WARNING! ѥ

WARNING! The HWG module is an appliance

that operates in conjunction with the heat pump system, the hot water system and the electrical system. Installation should only be performed by skilled technicians with appropriate training and experience. The installation must be in compliance with local codes and ordinances. Local plumbing and electrical building codes take precedence over instructions contained herein. The

Manufacturer accepts no liability for equipment damaged and/or personal injury arising from improper installation of the HWG module.

ѥ CAUTION! ѥ

CAUTION! The HWG module must be

installed in an area that is not subject to freezing temperatures.

NOTICE! Make sure the compressor discharge

line is connected to the “Hot Gas In” stub on the

Heat Recovery Unit.

ѥ CAUTION! ѥ

CAUTION! Locate Refrigerant lines to avoid

accidental damage by lawnmowers or children.

ELECTRICAL - LINE VOLTAGE

ѥ WARNING! ѥ

WARNING! To avoid possible injury or death

due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation.

Electrical - Line Voltage

All fi eld installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes. Refer to the unit electrical data for fuse sizes. Consult wiring diagram for fi eld connections that must be made by the installing (or electrical) contractor.

ѥ CAUTION! ѥ

CAUTION! Use only copper conductors for fi eld

installed electrical wiring. Unit terminals are not designed to accept other types of conductors.

All fi nal electrical connections must be made with a length of fl exible conduit to minimize vibration and sound transmission to the building.

28

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

ELECTRICAL - LINE VOLTAGE

Table 8a: GT-PX Split (50YDS) Series Electrical Data

Model

026

038

049

064

RLA

10.3

16.7

21.2

25.6

Compressor

LRA

52.0

82.0

96.0

118.0

Qty

1

1

1

1

HWG

Pump

FLA

0.4

0.4

0.4

0.4

External

Pump

FLA

4.0

4.0

4.0

4.0

Total

Unit

FLA

14.7

21.1

25.6

30.0

Min

Circuit

Amps

17.3

25.3

30.9

36.4

Max

Fuse/

HACR

25

40

50

60

Min

AWG

8

8

10

10

Max Wire

Ft.

(m)

107 (32.7)

73 (22.3)

95 (29.2)

81 (24.8)

Rated Voltage of 208/230/60/1 Min/Max Voltage of 197/254

HACR circuit breaker in USA only All fuses Class RK-5

Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

Table 8b: GT-G Split (50YCS) Series Electrical Data

Model

018

024

030

036

042

048

060

RLA

8.6

10.3

12.2

13.5

16.5

18.3

25.0

Compressor

LRA

40.3

56.0

67.0

73.0

95.0

109.0

148.0

Qty

1

1

1

1

1

1

1

HWG

Pump

FLA

0.40

0.40

0.40

0.40

0.40

0.40

0.40

External

Pump

FLA

4.0

4.0

4.0

4.0

4.0

4.0

4.0

Total

Unit

FLA

13.0

14.7

16.6

17.9

20.9

22.7

29.4

Min

Circuit

Amps

15.2

17.3

19.7

21.3

25.0

27.3

35.7

Max

Fuse/

HACR

20

25

30

35

40

45

60

Min

AWG

12

10

10

10

10

10

8

Max Wire

Ft

(m)

76 (23.3)

107 (32.7)

94 (28.7)

87 (26.5)

74 (22.6)

67 (20.7)

82 (25.2)

Rated Voltage of 208/230/60/1

HACR circuit breaker in USA only

Min/Max Voltage of 197/254

All fuses Class RK-5

Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

Table 8c: GT-S Split (38WQS) Series Electrical Data

Model

018

024

030

036

042

048

060

RLA

7.1

10.3

12.2

13.5

16.5

18.3

25.0

Compressor

LRA

38.0

56.0

67.0

73.0

95.0

109.0

148.0

Qty

1

1

1

1

1

1

1

Crankcase

N/A

0.17

0.17

0.17

0.17

0.17

0.29

HWG

Pump

FLA

0.40

0.40

0.40

0.40

0.40

0.40

0.40

Ext Loop

Pump

FLA

4.0

4.0

4.0

4.0

4.0

4.0

4.0

Total

Unit

FLA

11.5

14.9

16.8

18.1

21.1

22.9

29.7

Min

Circuit

Amps

13.3

17.4

19.8

21.4

25.2

27.4

35.9

Max

Fuse/

HACR

30

40

45

60

20

25

30

Min

AWG

10

10

10

8

12

10

10

Max

Wire Ft

(m)

87 (26.6)

106 (32.5)

93 (28.6)

86 (26.4)

73 (22.4)

67 (20.6)

82 (25.1)

Rated Voltage of 208-230/60/1 Min/Max Voltage of 197/254

HACR circuit breaker in USA only All fuses Class RK-5

Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

29

ELECTRICAL - POWER WIRING

Electrical - Line Voltage

All fi eld installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes. Refer to the unit electrical data for fuse sizes. Consult wiring diagram for fi eld connections that must be made by the installing (or electrical) contractor.

Figure 21c: R-22 Outdoor Compressor

Section Line Voltage Field Wiring

T2 T1

FCR

CXM Control

All fi nal electrical connections must be made with a length of fl exible conduit to minimize vibration and sound transmission to the building.

CC

L2

Grnd

L1

CRC

Low Voltage

Connector

General Line Voltage Wiring

Be sure the available power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the

National Electric Code, whichever is applicable.

Consult Electrical Table for wire and fuse size.

All power wiring per local code

Note: See FC Mounting for Flow Controller Wiring

Power Connection

Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the contactor as shown in Figures 21a through 21c. Consult Tables 8a through 8c for correct fuse size.

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

ELECTRICAL - HWG WIRING

Figure 21a: R-410A Compressor Section

Line Voltage Field Wiring

Unit Power Supply

(see electrical table for wire and breaker size)

HWG Wiring - “Indoor” Compressor Section

The hot water generator pump power wiring is disabled at the factory to prevent operating the HWG pump “dry.”

After all HWG piping is completed and air purged from the water piping, the pump power wires should be applied to terminals on the HWG power block PB2 as shown in the unit wiring diagram. This connection can also serve as a HWG disable when servicing the unit.

Figure 21b: R-22 Indoor Compressor Section

Line Voltage Field Wiring

HWG Wiring - “Outdoor” Compressor Section

The HWG module should be wired to the outdoor section pump controls (see Figure 20). A safety disconnect should be installed at the HWG module to allow servicing of the module. If wired as shown, any time the compressor is energized, the HWG module pump will be activated, which will circulate water from the water heater tank to the HWG module. DO NOT energize the pump until all HWG piping is completed and air is purged from the water piping to avoid running the pump “dry.”

Capacitor

Contactor -CC

Unit Power Supply

See electrical table for wire and breaker size

L2

L1

Grnd

Loop PB1

T2

T1

Circ Brkr

HWG PB2

T2 T1

Blk

BR

CXM Control

Install HWG Pump

Power after insuring water is in HWG circuit

External Pump

Power Supply

See electrical table for wire and breaker size

CB

Transformer

Low Voltage

Connector

30

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

ELECTRICAL - LOW VOLTAGE WIRING

Thermostat Connections

The thermostat should be wired directly to the CXM board.

Figures 22a through 22c show low voltage wiring. Note that the air handler or furnace transformer will be used to power the CXM board in the compressor section. See

“Electrical – Thermostat” for specifi c terminal connections.

Figure 22c: 38WQS Low Voltage Field Wiring

T2 T1

FCR

CXM Control

Figure 22a: 50YDS Low Voltage Field Wiring

CC

Low Voltage

Connector

L2 L1

Grnd

CRC

Thermostat Connection

See Thermostat section for Wiring Details

Low voltage fi eld wiring

Figure 22b: 50YCS Low Voltage Field Wiring

Contactor -CC

L2

L1

Capacitor

Grnd

Loop PB1

Circ Brkr

HWG PB2

BR

CXM Control

Low Water Temperature Cutout Selection

The CXM control allows the fi eld selection of low water

(or water-antifreeze solution) temperature limit by clipping jumper JW3, which changes the sensing temperature associated with thermistor FP1. Note that the FP1 thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion device (TXV).

Therefore, FP1 is sensing refrigerant temperature, not water temperature, which is a better indication of how water fl ow rate/temperature is affecting the refrigeration circuit.

The factory setting for FP1 is for systems using water

(30°F [-1.1°C] refrigerant temperature). In low water temperature (extended range) applications with antifreeze

(most ground loops), jumper JW3 should be clipped as shown in Figure 23 to change the setting to 10°F [-12.2°C] refrigerant temperature, a more suitable temperature when using an antifreeze solution. All residential units include water/refrigerant circuit insulation to prevent internal condensation, which is required when operating with entering water temperatures below 59°F [15°C].

Low Voltage

Connector

Figure 23: FP1 Limit Setting

JW3-FP1 jumper should be clipped for low temperature operation

CXM PCB

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

31

ELECTRICAL - LOW VOLTAGE WIRING

Accessory Connections

A terminal paralleling the compressor contactor coil has been provided on the CXM control. Terminal “A” is designed to control accessory devices, such as water valves. Note: This terminal should be used only with

24 Volt signals and not line voltage. Terminal “A” is energized with the compressor contactor. See Figure 24 or the specifi c unit wiring diagram for details.

Figure 24: Accessory Wiring

gpm [8 l/m] fl ow regulator. When stage one is operating, the second solenoid valve will be closed. When stage two is operating, both valves will be open, allowing full load fl ow rate.

Figure 27 illustrates piping for two-stage solenoid valves.

Review fi gures 24-26 for wiring of stage one valve. Stage two valve should be wired between “Y2” (compressor solenoid -- wire nut connection) and terminal “C.” NOTE:

When EWT is below 50°F [10°C], 2 gpm per ton (2.6 l/m per kW) is required.

Terminal Strip

Figure 25: AVM Valve Wiring

C

A

24VAC

Typical

Water

Valve

Water Solenoid Valves - “Indoor” Compressor

Section Only

An external solenoid valve(s) should be used on ground water installations to shut off fl ow to the unit when the compressor is not operating. A slow closing valve may be required to help reduce water hammer. Figure 24 shows typical wiring for a 24VAC external solenoid valve.

Figures 25 and 26 illustrate typical slow closing water control valve wiring for Taco 500 series (ClimateMaster

P/N AVM…) and Taco ESP series valves. Slow closing valves take approximately 60 seconds to open (very little water will fl ow before 45 seconds). Once fully open, an end switch allows the compressor to be energized. Only relay or triac based electronic thermostats should be used with slow closing valves. When wired as shown, the slow closing valve will operate properly with the following notations:

1

2

Heater Switch

3

AVM

Taco Valve

Thermostat

Figure 26: Taco ESP Valve Wiring

1. The valve will remain open during a unit lockout.

2. The valve will draw approximately 25-35 VA through the “Y” signal of the thermostat.

Note: This valve can overheat the anticipator of an electromechanical thermostat. Therefore, only relay or triac based thermostats should be used.

Two-stage Units

Two-stage units should be designed with two parallel valves for ground water applications to limit water use during fi rst stage operation. For example, at 1.5 gpm/ton

[2.0 l/m per kW], a model 049 unit requires 6 gpm [23 l/m] for full load (2nd stage) operation, but only 4 gpm [15 l/m] during 1st stage operation. Since the unit will operate on fi rst stage 80-90% of the time, signifi cant water savings can be realized by using two parallel solenoid valves with two fl ow regulators. In the example above, stage one solenoid would be installed with a 4 gpm [15 l/m] fl ow regulator on the outlet, while stage two would utilize a 2

Figure 27: Two-Stage Piping

Solenoid

Valve

Flow

Regulator

OUT

IN

Stage 2

To Discharge

Stage 1

From Water Source

NOTE: Shut-off valves, strainers and other required components not shown.

32

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

ѥ CAUTION! ѥ

CAUTION! Many units installed with a factory

or fi eld supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any fi eld provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The fi eld installed high pressure switch shall have a cut-out pressure of 235 psig and a cut-in pressure of 190 psig. This pressure switch can be ordered from ClimateMaster with a 1/4” internal fl are connection as part number 39B0005N01.

ELECTRICAL - THERMOSTAT WIRING

Thermostat Installation

The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls. The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement. Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude through the middle of the back plate. Mark the position of the back plate mounting holes and drill holes with a 3/16”

(5mm) bit. Install supplied anchors and secure plate to the wall. Thermostat wire must be 18 AWG wire. Wire the appropriate thermostat as shown in Figures 28a through

28c to the low voltage terminal strip on the CXM control board. Practically any heat pump thermostat will work with these units, provided it has the correct number of heating and cooling stages.

Figure 28b: Typical Thermostat Wiring,

Single-Stage Units (2 Heat / 1 Cool)

From Compressor

Solenoid Valve

CXM Board

(Compressor

Section)

FV4

Air Handler

Y/Y2

TSTAT CCPRH01 or BBPRH01

Y/Y2

Y

O

Y1

O

Y1/W2

O/W2

R

C

G

R

Remove Jumper for Dehum Mode

DH

W1

W2

C

Humidifier

Sol. Vlv. 24VAC

Outdoor

Sensor

S1

S2

C

Hum

G

R

DHum

W/W1

Notes:

1. Thermostat DIP switches must be configured for two-speed heat pump.

2. Compressor 2nd stage connection is not part of the terminal strip on

the CXM board. A wire nut connection is required between the

compressor solenoid valve and Y/Y2 connection at the fan coil.

Figure 28a: Typical Thermostat Wiring, Two-

Stage Units (3 Heat / 2 Cool)

From Compressor

Solenoid Valve

(Notes 1,2)

CXM Board

(Compressor

Section)

Network

Interface Module

Y2

Figure 28b: Typical Thermostat Wiring,

Infi nity / Evolution Controls

From Compressor

Solenoid Valve

CXM Board

(Compressor

Section)

FV4

Air Handler

Y/Y2

TSTAT CCPRH01 or BBPRH01

Y/Y2

Y Y1 Y1/W2

Y Y1

O O O/W2

O O

G G

C C

R R

A

FE4 or Other

Communicating

Indoor Unit

A

User

Interface

A

R

C

R

Remove Jumper for Dehum Mode

DH

W1

R

DHum

W/W1

W2

B B B

C

C

C

C C

Humidifier

Sol. Vlv. 24VAC

Hum

D

D D

S1

Outdoor

Sensor

S2

Notes:

1. Compressor 2nd stage connection is not part of the terminal strip onthe

CXM board. A wire nut connection is required between the compressor

solenoid valve and N.I.M.

2. Y2 connection on N.I.M. is not used for single stage units.

3. Do not connect W from the CXM board to the N.I.M.

Notes:

1. Thermostat DIP switches must be configured for two-speed heat pump.

2. Compressor 2nd stage connection is not part of the terminal strip on

the CXM board. A wire nut connection is required between the

compressor solenoid valve and Y/Y2 connection at the fan coil.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

33

TYPICAL WIRING DIAGRAM - 50YDS UNITS WITH CXM BOARD

34

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

TYPICAL WIRING DIAGRAM - 50YCS UNITS WITH CXM BOARD

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

35

TYPICAL WIRING DIAGRAM - 38WQS UNITS WITH CXM BOARD

36

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

CXM CONTROLS

CXM Control

For detailed control information, see CXM/DXM

Application, Operation and Maintenance (AOM) manual

(part #97B0003N08).

Field Selectable Inputs

Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will fl ash a code representing the last fault.

For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds.

Retry Mode: If the control is attempting a retry of a fault, the status LED will slow fl ash (slow fl ash = one fl ash every 2 seconds) to indicate the control is in the process of retrying.

DIP switch 3: Not Used.

DIP switch 4: DDC Output at EH2 - provides selection for

DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output.

On = EH2 Normal. Off = DDC Output at EH2.

NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.

Jumper not clipped = EH2 Normal. Jumper clipped =

DDC Output at EH2.

DIP switch 5: Factory Setting - Normal position is “On.”

Do not change selection unless instructed to do so by the factory.

Table 9a: CXM LED And Alarm

Relay Operations

Field Confi guration Options

Note: In the following fi eld confi guration options, jumper wires should be clipped ONLY when power is removed from the CXM control.

Water coil low temperature limit setting: Jumper 3 (JW3-

FP1 Low Temp) provides fi eld selection of temperature limit setting for FP1 of 30°F or 10°F [-1°F or -12°C]

(refrigerant temperature).

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Air coil low temperature limit setting: Jumper 2 (JW2-FP2

Low Temp) provides fi eld selection of temperature limit setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory.

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides fi eld selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection).

Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection).

Description of Operation

Normal Mode

Normal Mode with UPS Warning

CXM is non-functional

Fault Retry

Lockout

Over/Under Voltage Shutdown

LED

On

On

Off

Slow Flash

Fast Flash

Slow Flash

Test Mode - No fault in memory Flashing Code 1

Alarm Relay

Open

Cycle (closed 5 sec., Open 25 sec.)

Open

Open

Closed

Open (Closed after 15 minutes)

Cycling Code 1

Test Mode - HP Fault in memory Flashing Code 2

Test Mode - LP Fault in memory Flashing Code 3

Test Mode - FP1 Fault in memory Flashing Code 4

Cycling Code 2

Cycling Code 3

Cycling Code 4

Test Mode - FP2 Fault in memory Flashing Code 5

Test Mode - CO Fault in memory Flashing Code 6

Test Mode - Over/Under shutdown in memory

Test Mode - UPS in memory

Flashing Code 7

Flashing Code 8

Test Mode - Swapped Thermistor Flashing Code 9

Cycling Code 5

Cycling Code 6

Cycling Code 7

Cycling Code 8

Cycling Code 9

-Slow Flash = 1 fl ash every 2 seconds

-Fast Flash = 2 fl ashes every 1 second

-Flash code 2 = 2 quick fl ashes, 10 second pause, 2 quick fl ashes, 10 second pause, etc.

-On pulse 1/3 second; off pulse 1/3 second

DIP Switches

Note: In the following fi eld confi guration options, DIP switches should only be changed when power is removed from the CXM control.

DIP switch 1: Unit Performance Sentinel Disable - provides fi eld selection to disable the UPS feature.

On = Enabled. Off = Disabled.

DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage

2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will

NOT cycle during test mode.

On = Stage 1. Off = Stage 2

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

37

CXM CONTROLS

Safety Features – CXM Control

The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.

Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor.

Note: The 5 minute anti-short cycle also occurs at power up.

Random start: The control features a random start upon power up of 5-80 seconds.

Fault Retry: In Fault Retry mode, the Status LED begins slowly fl ashing to signal that the control is trying to recover from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the thermostat input call is satisfi ed, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into “lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode. Note: FP1/FP2 faults are factory set at only one try.

Lockout: In lockout mode, the status LED will begin fast fl ashing. The compressor relay is turned off immediately.

Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset

(disconnecting power to the control) resets the control and erases fault memory.

Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur.

High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before de-energizing the compressor).

High pressure lockout code = 2

Example: 2 quick fl ashes, 10 sec pause, 2 quick fl ashes,

10 sec. pause, etc.

Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault.

The low pressure switch input is bypassed for the initial 60 seconds of a compressor run cycle.

Low pressure lockout code = 3

Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault.

The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle. FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred.

FP1 lockout code = 4

Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault.

The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred.

FP2 lockout code = 5

Condensate overfl ow: The condensate overfl ow sensor must sense overfl ow level for 30 continuous seconds to be recognized as a CO fault. Condensate overfl ow will be monitored at all times.

CO lockout code = 6

Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC. Over/under voltage shut down is a self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the

CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close.

Over/under voltage shut down code = 7

Unit Performance Sentinel-UPS (patent pending): The

UPS feature indicates when the heat pump is operating ineffi ciently. A UPS condition exists when: a) In heating mode with compressor energized, FP2 is greater than 125°F [52°C] for 30 continuous seconds, or: b) In cooling mode with compressor energized, FP1 is greater than 125°F [52°C] for 30 continuous seconds, or: c) In cooling mode with compressor energized, FP2 is less than 40°F [4.5°C] for 30 continuous seconds. If a

UPS condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for 5 seconds, “off” for 25 seconds, etc.

UPS warning code = 8

Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout, with code 9, after 30 seconds if: a) The compressor is on in the cooling mode and the

FP1 sensor is colder than the FP2 sensor, or: b) The compressor is on in the heating mode and the

FP2 sensor is colder than the FP1 sensor.

Swapped FP1/FP2 thermistor code = 9.

Diagnostic Features

The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory, the LED will fl ash Code 1 (when in test mode).

38

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

CXM CONTROLS

CXM Control Start-up Operation

The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a 5 minute anti-short cycle delay at power-up. The fi rst time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.

Table 9b: Unit Operation

T-stat signal

G

G, Y or Y1

G, Y1, Y2

G, Y1, Y2, W

G, W

G, Y or Y1, O

G, Y1, Y2, O

Variable Speed

Air Handler

Fan only

Stage 1 heating

1

Stage 2 heating

1

Stage 3 heating

1

Emergency heat

Stage 1 cooling

2

Stage 2 cooling

2

Variable Speed

Air Handler

Fan only

Stage 1 heating

3

Stage 2 heating

3

Stage 3 heating

Emergency heat

Stage 1 cooling

4

Stage 2 cooling

4

3

PSC Air Handler

1 Stage 1 = 1st stage compressor, 1st stage fan operation

Stage 2 = 2nd stage compressor, 2nd stage fan operation

Stage 3 = 2nd stage compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings)

2 Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve

Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve

3 Stage 1 = compressor, 1st stage fan operation

Stage 2 = compressor, 2nd stage fan operation

Stage 3 = compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings)

4 Stage 1 = compressor, 1st stage fan operation, reversing valve

Stage 2 = compressor, 2nd stage fan operation, reversing valve

5 Stage 1 = compressor, fan

Stage 2 = compressor, auxiliary electric heat, fan

6 Cooling = compressor, fan, reversing valve

Fan only

Stage 1 heating

5

Stage 2 heating

N/A

Emergency heat

Cooling

6

N/A

5

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

39

Table 10: Nominal resistance at various temperatures

Temp (°C) Temp (°F)

Resistance

(kOhm)

29

30

31

32

33

34

19

20

21

22

23

24

25

26

27

28

13

14

15

16

9

10

11

12

17

18

5

6

3

4

7

8

-3

-2

-1

0

1

2

-9

-8

-7

-6

-5

-4

-17.8

-17.5

-16.9

-12

-11

-10

41

42

43

44

45

46

35

36

37

38

39

40

47

48

49

50

51

52

53

54

84.2

86.0

87.8

89.6

91.4

93.2

66.2

68.0

69.8

71.6

73.4

75.2

77.0

78.8

80.6

82.4

48.2

50.0

51.8

53.6

55.4

57.2

59.0

60.8

62.6

64.4

37.4

39.2

41.0

42.8

44.6

46.4

26.6

28.4

30.2

32.0

33.8

35.6

15.8

17.6

19.4

21.2

23.0

24.8

0.0

0.5

1.5

10.4

12.2

14.0

95.0

96.8

98.6

100.4

102.2

104.0

105.8

107.6

109.4

111.2

113.0

114.8

116.6

118.4

120.2

122.0

123.8

125.6

127.4

129.2

13.07

12.49

11.94

11.42

10.92

10.45

10.00

9.57

9.17

8.78

8.41

8.06

7.72

7.40

7.10

6.81

28.00

26.60

25.30

24.10

23.00

21.90

20.80

19.90

18.97

18.09

17.25

16.46

15.71

15.00

14.32

13.68

85.41

84.16

81.43

61.70

58.40

55.30

52.40

49.60

47.00

44.60

42.30

40.10

38.10

36.10

34.30

32.60

31.00

29.40

5.12

4.92

4.73

4.54

4.37

4.20

6.53

6.27

6.02

5.78

5.55

5.33

4.04

3.89

3.74

3.60

3.47

3.34

3.22

3.10

Temp (°C) Temp(°F)

Resistance

(kOhm)

95

96

97

98

91

92

93

94

85

86

87

88

89

90

79

80

81

82

83

84

73

74

75

76

77

78

105

106

107

108

109

110

99

100

101

102

103

104

117

118

119

120

121

122

123

111

112

113

114

115

116

67

68

69

70

71

72

61

62

63

64

65

66

55

56

57

58

59

60

185.0

186.8

188.6

190.4

192.2

194.0

195.8

197.6

199.4

201.2

203.0

204.8

206.6

208.4

163.4

165.2

167.0

168.8

170.6

172.4

174.2

176.0

177.8

179.6

181.4

183.2

210.2

212.0

213.8

215.6

217.4

219.2

221.0

222.8

224.6

226.4

228.2

230.0

231.8

233.6

235.4

237.2

239.0

240.8

242.6

244.4

246.2

248.0

249.8

251.6

253.4

131.0

132.8

134.6

136.4

138.2

140.0

141.8

143.6

145.4

147.2

149.0

150.8

152.6

154.4

156.2

158.0

159.8

161.6

0.89

0.86

0.84

0.81

0.79

0.76

0.74

0.72

1.07

1.04

1.00

0.97

0.94

0.92

1.30

1.26

1.22

1.18

1.14

1.10

1.58

1.53

1.48

1.43

1.38

1.34

0.59

0.57

0.56

0.54

0.53

0.51

0.70

0.68

0.66

0.64

0.62

0.60

0.42

0.41

0.40

0.39

0.38

0.37

0.36

0.50

0.48

0.47

0.46

0.45

0.43

1.94

1.88

1.81

1.75

1.69

1.64

2.40

2.32

2.23

2.16

2.08

2.01

2.99

2.88

2.77

2.67

2.58

2.49

Rev.: 5/23/00 m

CXM CONTROLS

CXM Thermostat Details

Thermostat Compatibility - Most all heat pump thermostats can be used with the CXM control. However

Heat/Cool stats are NOT compatible with the CXM.

Anticipation Leakage Current - Maximum leakage current for "Y" is 50 mA and for "W" is 20mA. Triacs can be used if leakage current is less than above.

Thermostats with anticipators can be used if anticipation current is less than that specifi ed above.

Thermostat Signals -

• "Y" and "W" have a 1 second recognition time when

being activated or being removed.

• "O" and "G" are direct pass through signals but are

monitored by the micro processor.

• "R" and "C" are from the transformer.

• "AL1" and "AL2" originate from the alarm relay.

• "A" is paralleled with the compressor output for use

with well water solenoid valves.

• The "Y" 1/4" quick connect is a connection point to the

"Y" input terminal P1 for factory use. This "Y" terminal

can be used to drive panel mounted relays such as the

loop pump relay.

40

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

UNIT STARTING AND OPERATING CONDITIONS

Operating Limits

Environment – “Indoor” compressor section is designed for indoor installation only. Never install “indoor” compressor section in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). “Outdoor” unit is designed for conditions where ambient air is below freezing

(see Table 11).

Power Supply – A voltage variation of +/– 10% of nameplate utilization voltage is acceptable.

start-up conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a regular basis.

2. Voltage utilization range complies with ARI

Standard 110.

Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature, and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should be at normal levels to insure proper unit operation.

Starting Conditions

Consult Table 11 for the particular model number.

Starting conditions vary depending upon model number and are based upon the following notes:

Extreme variations in temperature and humidity and/or corrosive water or air will adversely affect unit performance, reliability, and service life.

Notes:

1. Conditions in Table 11 are not normal or continuous operating conditions. Minimum/maximum limits are

Table 11: Unit Operation

Operating Limits

Air Limits

Min. ambient air, DB

Rated ambient air, DB

Max. ambient air, DB

Min. entering air, DB/WB

Rated entering air, DB/WB

Max. entering air, DB/WB

Water Limits

Min. entering water

Normal entering water

Max. entering water

Normal water fl ow

Cooling Heating Cooling Heating

45°F [7°C]

80.6°F [27°C]

110°F [43°C]

50°F [10°C]

80.6/66.2°F [27/19°C]

110/83°F [43/28°C]

39°F [4°C]

68°F [20°C]

85°F [29°C]

40°F [4.5°C]

68°F [20°C]

80°F [27°C]

-10°F [-23°C]

80.6°F [27°C]

110°F [43°C]

50°F [10°C]

80.6/66.2°F [27/19°C]

110/83°F [43/28°C]

-10°F [-23°C]

68°F [20°C]

85°F [29°C]

50°F [10°C]

68°F [20°C]

80°F [27°C]

30°F [-1°C]

50-110°F [10-43°C]

120°F [49°C]

20°F [-6.7°C]

30-70°F [-1 to 21°C]

90°F [32°C]

1.5 to 3.0 gpm/ton

2.0 to 3.9 l/m per kW

30°F [-1°C]

50-110°F [10-43°C]

120°F [49°C]

20°F [-6.7°C]

30-70°F [-1 to 21°C]

90°F [32°C]

1.5 to 3.0 gpm/ton

2.0 to 3.9 l/m per kW

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

41

UNIT STARTING AND OPERATING CONDITIONS

Unit and System Checkout

BEFORE POWERING SYSTEM, please check the following:

UNIT CHECKOUT

φ Balancing/shutoff valves: Insure that all isolation valves are open and water control valves are wired.

φ Line voltage and wiring: Verify that voltage is within an acceptable range for the unit and wiring and fuses/ breakers are properly sized. Verify that low voltage wiring is complete.

φ Unit control transformer: Insure that transformer has the properly selected voltage tap. Residential

208-230V units are factory wired for 230V operation unless specifi ed otherwise.

φ Loop/water piping is complete and purged of air.

Water/piping is clean.

φ Antifreeze has been added if necessary.

φ Entering water and air: Insure that entering water and air temperatures are within operating limits of Table 10.

φ Low water temperature cutout: Verify that low water temperature cut-out on the CXM/DXM control is properly set.

φ Unit fan: Manually rotate fan to verify free rotation and insure that blower wheel is secured to the motor shaft. Be sure to remove any shipping supports if needed. DO NOT oil motors upon start-up. Fan motors are pre-oiled at the factory. Check unit fan speed selection and compare to design requirements.

φ Condensate line: Verify that condensate line is open and properly pitched toward drain.

φ HWG pump is disconnected unless piping is completed and air has been purged from the system.

φ System controls: Verify that system controls function and operate in the proper sequence.

φ Low water temperature cutout: Verify that low water temperature cut-out controls are set properly

(FP1 - JW3).

φ Miscellaneous: Note any questionable aspects of the installation.

ѥ CAUTION! ѥ

CAUTION! Verify that ALL water control

valves are open and allow water fl ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

NOTICE! Failure to remove shipping brackets

from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.

ѥ CAUTION! ѥ

CAUTION! To avoid equipment damage, DO

NOT leave system fi lled in a building without heat during the winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.

temperatures for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity water fl ow that could erode heat exchangers.

φ Unit air coil and fi lters: Insure that fi lter is clean and accessible. Clean air coil of all manufacturing oils.

φ Unit controls: Verify that CXM fi eld selection options are properly set. Low voltage wiring is complete.

φ Blower speed is set.

φ Service/access panels are in place.

SYSTEM CHECKOUT

φ System water temperature: Check water temperature for proper range and also verify heating and cooling set points for proper operation.

φ System pH: Check and adjust water pH if necessary to maintain a level between 6 and 8.5. Proper pH promotes longevity of hoses and fi ttings (see Table 3).

system. Air in the system can cause poor operation or system corrosion. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Some antifreeze solutions may require distilled water.

φ Flow Controller pump(s): Verify that the pump(s) is wired and in operating condition.

Unit Start-up Procedure

1. Turn the thermostat fan position to “ON.” Blower should start.

2. Balance air fl ow at registers.

3. Adjust all valves to their full open position. Turn on the line power to all heat pump units.

4. Room temperature should be within the minimummaximum ranges of Table 11. During start-up checks, loop water temperature entering the heat pump should be between 30°F [-1°C] and 95°F [35°C].

5. Two factors determine the operating limits of water source heat pumps, (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal level to insure proper unit operation.

a. Adjust the unit thermostat to the warmest setting.

Place the thermostat mode switch in the “COOL” position. Slowly reduce thermostat setting until the compressor activates.

b. Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate.

Note: Units have a fi ve minute time delay in the

42

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

UNIT START-UP PROCEDURE

control circuit that can be eliminated on the CXM/

DXM control board as shown below in Figure 29.

See controls description for details.

c. Verify that the compressor is on and that the water fl ow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Tables 12a through 12b.

d. Check the elevation and cleanliness of the condensate lines. Dripping may be a sign of a blocked line. Check that the condensate trap is fi lled to provide a water seal.

e. Refer to Table 12. Check the temperature of both entering and leaving water. If temperature is within range, proceed with the test. If temperature is outside of the operating range, check refrigerant pressures and compare to Tables 14 and 15.

Verify correct water fl ow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b. Heat of rejection (HR) can be calculated and compared to catalog data capacity pages. The formula for HR for systems with water is as follows:

HR = TD x GPM x 500, where TD is the temperature difference between the entering and leaving water, and GPM is the fl ow rate in U.S.

GPM, determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b.

f. Check air temperature drop across the air coil when compressor is operating. Air temperature drop should be between 15°F and 25°F [8°C and 14°C].

g. Turn thermostat to “OFF” position. A hissing noise indicates proper functioning of the reversing valve.

6. Allow fi ve (5) minutes between tests for pressure to equalize before beginning heating test.

a. Adjust the thermostat to the lowest setting. Place the thermostat mode switch in the “HEAT” position.

b. Slowly raise the thermostat to a higher temperature until the compressor activates.

c. Check for warm air delivery within a few minutes after the unit has begun to operate.

d. Refer to Table 11. Check the temperature of both entering and leaving water. If temperature is within range, proceed with the test. If temperature is outside of the operating range, check refrigerant pressures and compare to Tables 14 and 15.

Verify correct water fl ow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b. Heat of extraction (HE) can be calculated and compared to submittal data capacity pages. The formula for HE for systems with water is as follows:

HE = TD x GPM x 500, where TD is the temperature difference between the entering and leaving water, and GPM is the fl ow rate in U.S.

GPM, determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b.

e. Check air temperature rise across the air coil when compressor is operating. Air temperature rise should be between 20°F and 30°F [11°C and 17°C]. f. Check for vibration, noise, and water leaks.

7. If unit fails to operate, perform troubleshooting analysis (see troubleshooting section). If the check described fails to reveal the problem and the unit still does not operate, contact a trained service technician to insure proper diagnosis and repair of the equipment.

8. When testing is complete, set system to maintain desired comfort level.

9. BE CERTAIN TO FILL OUT AND RETURN ALL

WARRANTY REGISTRATION PAPERWORK.

Note: If performance during any mode appears abnormal, refer to the CXM section or troubleshooting section of this manual. To obtain maximum performance, the air coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended.

ѥ WARNING! ѥ

WARNING! When the disconnect switch is

closed, high voltage is present in some areas of the electrical panel. Exercise caution when working with energized equipment.

ѥ CAUTION! ѥ

CAUTION! Verify that ALL water control

valves are open and allow water fl ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

Figure 29: Test Mode Pins

Short test pins together to enter Test

Mode and speed-up timing and delays for

20 minutes.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

43

UNIT OPERATING CONDITIONS

Table 12a: Two-Stage R-410A Compressor

Section Coax Water Pressure Drop

Table 13: Water Temperature Change

Through Heat Exchanger

Model

026

038

049

064

GPM

5.5

8.3

11.0

12.0

7.0

10.5

14.0

15.0

4.0

6.0

7.0

8.0

4.0

6.0

8.0

9.0

1.2

2.6

4.5

5.7

1.1

2.2

3.9

4.5

30°F

1.5

3.1

4.1

5.1

0.5

1.9

3.9

4.8

0.9

2.1

3.6

4.2

0.3

1.8

3.5

4.3

Pressure Drop (psi)

50°F 70°F

1.3

2.6

3.4

4.3

1.0

2.5

4.2

5.2

1.1

2.3

3.0

3.8

0.8

2.3

4.0

4.8

0.8

2.0

3.2

3.8

0.2

1.7

3.2

3.9

0.6

2.1

3.7

4.4

0.7

1.8

3.1

3.5

90°F

1.0

2.1

2.7

3.4

0.1

1.6

2.9

3.5

Water Flow, gpm (l/m)

For Closed Loop: Ground Source or Closed Loop

Systems at 3 gpm per ton (3.9 l/m per kw)

Rise, Cooling Drop, Heating

¡F (¡C) ¡F (¡C)

9 - 12

(5 - 6.7)

4 - 8

(2.2 - 4.4)

For Open Loop: Ground Water Systems at

1.5 gpm per ton (2.0 l/m per kw)

20 - 26

(11.1 - 14.4)

10 - 17

(5.6 - 9.4)

Table 12b: R-22 Compressor Section Coax

Water Pressure Drop

Model

018

024

030

036

042

048

060

GPM

6

9

12

15

6

8

11

13

8

11

15

18

5

7

9

12

4

6

8

10

3

5

6

8

2

4

5

6

2.1

3.9

6.4

9.4

1.2

2.1

3.6

5.0

1.6

2.6

3.9

6.4

2.1

3.2

5.5

7.3

0.6

1.3

1.8

2.9

0.9

1.8

2.9

4.2

30°F

0.6

1.6

2.1

2.8

Pressure Drop (psi)

1.9

3.7

5.9

8.7

1.2

2.0

3.4

4.7

1.4

2.4

3.7

5.9

1.9

3.0

5.1

6.8

0.6

1.2

1.7

2.7

0.9

1.7

2.7

3.9

50°F

0.6

1.4

2.0

2.6

1.8

3.4

5.5

8.1

1.1

1.8

3.1

4.3

1.3

2.3

3.4

5.5

1.8

2.8

4.7

6.3

0.5

1.1

1.5

2.5

0.8

1.5

2.5

3.6

70°F

0.5

1.3

1.8

2.4

1.7

3.2

5.2

7.6

1.0

1.7

2.9

4.1

1.3

2.1

3.2

5.2

1.7

2.6

4.5

5.9

0.5

1.1

1.4

2.3

0.8

1.4

2.3

3.4

90°F

0.5

1.3

1.7

2.3

44

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

UNIT OPERATING CONDITIONS

Table 14a: Size 026 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/ton

30

50

70

90

110

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

Suction

Pressure

PSIG

122-132

122-132

122-132

132-142

132-142

132-142

139-149

139-149

139-149

141-151

141-151

141-151

145-155

145-155

145-155

Full Load Cooling - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Rise °F

159-179

146-166

132-152

186-206

172-192

158-178

13-18

13-18

14-19

8-13

8-13

8-13

9-14

7-12

7-12

8-13

6-11

6-11

16.7-18.7

12.3-14.3

7.9-9.9

16.3-18.3

12.1-14.1

7.8-9.8

281-301

267-287

253-273

374-394

360-380

346-366

473-493

458-478

441-461

7-12

7-12

7-12

7-12

7-12

7-12

7-12

7-12

7-12

8-13

8-13

7-12

9-14

9-14

8-13

10-15

10-15

9-14

15.7-17.7

11.6-13.6

7.6-9.6

14.6-16.6

10.7-12.7

6.9-8.9

13.6-15.6

9.9-11.9

6.2-8.2

18-24

18-24

18-24

17-23

17-23

17-23

16-22

16-22

16-22

Air Temp

Drop °F

DB

18-24

19-25

19-25

18-24

19-25

19-25

Suction

Pressure

PSIG

77-87

79-89

82-92

107-117

111-121

115-125

139-149

145-155

152-162

177-187

181-191

186-196

Full Load Heating - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Drop °F

278-298

280-300

282-302

314-334

315-335

317-337

350-370

352-372

354-374

392-412

397-417

402-422

4-9

4-9

4-9

6-11

6-11

6-11

7-12

7-12

7-12

9-14

10-15

11-16

10-15

10-15

10-15

13-18

13-18

13-18

15-20

15-20

15-20

17-22

17-22

17-22

5.9-7.9

4.2-6.2

2.7-4.7

8.9-10.9

6.7-8.7

4.5-6.5

11.3-13.3

8.5-10.5

5.8-7.8

14.4-16.4

10.8-12.8

7.1-9.1

Operation Not Recommended

Air Temp

Rise °F

DB

18-24

19-25

20-26

25-31

26-32

26-32

31-38

32-39

32-39

37-45

38-46

38-46

Table 14b: Size 038 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/ton

30

50

70

90

110

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

Suction

Pressure

PSIG

122-132

121-131

121-131

131-141

130-140

130-140

138-148

137-147

137-147

142-152

142-152

142-152

147-157

147-157

147-157

Full Load Cooling - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Rise °F

153-173

145-165

135-155

18-23

18-23

18-23

9-14

8-13

8-13

22.1-24.1

16.8-18.8

10.5-12.5

222-242

208-228

194-214

299-319

280-300

263-283

388-408

367-387

347-367

486-506

465-475

444-464

13-18

13-18

14-19

8-13

8-13

8-13

6-11

7-12

7-12

6-11

7-12

7-12

10-15

9-14

9-14

13-18

12-17

12-17

13-18

8-13

8-13

13-18

8-13

8-13

21.9-23.9

16.1-18.1

10.3-12.3

21.5-23.5

15.8-17.8

10-12

20.5-22.5

14.9-16.9

9.3-11.3

19-21

14-16

9-11

Air Temp

Drop °F

DB

19-25

20-26

20-26

19-25

20-26

20-26

19-25

20-26

20-26

18-24

18-24

18-24

18-24

18-24

18-24

Suction

Pressure

PSIG

71-81

75-85

78-88

103-113

107-117

112-122

134-144

140-150

146-156

172-182

184-194

196-206

Full Load Heating - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Drop °F

263-283

267-287

270-290

5-10

5-10

5-10

2-5

2-5

2-5

8.1-10.1

5.9-7.9

3.7-5.7

292-312

296-316

301-321

322-342

328-358

334-354

360-380

369-389

378-398

6-11

6-11

6-11

7-12

7-12

7-12

8-13

8-13

8-13

2.5-7

2.5-7

2.5-7

2.5-7

2.5-7

2.5-7

2.5-7

2.5-7

2.5-7

11.5-13.5

8.6-10.6

5.7-7.7

14.5-16.5

11.1-13.1

7.7-9.7

20.5-22.5

15-17

10-12

Operation Not Recommended

Air Temp

Rise °F

DB

17-23

18-24

19-25

23-29

24-30

24-30

28-35

29-36

30-37

36-44

37-45

39-47

Table 14c: Size 049 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/ton

30

30

30

50

50

50

70

70

70

90

90

90

110

110

110

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

Suction

Pressure

PSIG

112-122

111-121

111-121

125-135

123-133

122-132

133-143

132-142

131-141

138-148

137-147

136-146

144-154

143-153

142-152

Full Load Cooling - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Rise °F

187-207

167-187

147-167

18-23

18-23

18-23

23-28

21-26

20-25

20.7-22.7

15.5-17.5

10.2-12.2

245-265

227-247

208-228

314-334

294-314

274-294

401-421

379-399

357-377

502-522

477-497

452-472

13-18

13-18

14-19

9-14

9-14

10-15

8-13

8-13

9-14

8-13

8-13

9-14

19-24

18-23

16-21

17-22

16-21

14-19

16-21

15-20

13-18

14-19

13-18

12-17

20.9-22.9

15.6-17.6

10.2-12.2

20.5-22.5

15.2-17.2

9.9-11.9

19.2-21.2

14.3-16.3

9.3-11.3

18-20

13.3-15.3

8.5-10.5

Air Temp

Drop °F

DB

19-25

19-25

19-25

20-26

20-26

20-26

20-26

20-26

20-26

19-25

19-25

19-25

18-24

18-24

18-24

Suction

Pressure

PSIG

66-76

69-79

72-82

93-103

98-108

103-113

123-133

130-140

137-147

167-177

177-187

187-197

Full Load Heating - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Drop °F

261-281

264-284

267-287

8-13

8-13

8-13

5-10

5-10

5-10

8-10

6-8

4-6

289-309

295-315

301-321

319-339

329-349

336-356

365-385

374-394

388-408

7-12

7-12

7-12

7-12

7-12

7-12

7-12

7-12

7-12

5-10

5-10

5-10

5-10

5-10

5-10

5-10

5-10

5-10

11.5-13.5

8.7-10.7

5.9-7.9

15-17

11.5-13.5

7.9-9.9

19.6-21.6

15-17

10.3-12.3

Operation Not Recommended

Air Temp

Rise °F

DB

18-24

19-25

19-25

23-29

24-30

25-31

28-35

29-36

30-37

37-45

38-46

39-47

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

45

UNIT OPERATING CONDITIONS

Table 14d: Size 064 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/ton

30

50

70

90

110

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

1.5

2.25

3

Suction

Pressure

PSIG

117-127

116-126

115-125

126-136

124-134

123-133

130-140

129-139

128-138

133-143

132-142

132-142

138-148

137-147

136-146

Full Load Cooling - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

Water Temp

Rise °F

160-180

133-153

125-145

16-21

17-22

18-23

8-13

6-11

5-10

17.5-19.5

11.9-13.9

6.3-8.3

228-248

212-232

195-215

305-325

286-306

266-286

398-418

376-396

354-374

8-13

11-16

14-19

8-13

9-14

11-16

8-13

8-13

8-13

8-13

6-11

5-10

10-15

9-14

7-12

10-15

9-14

7-12

19.8-21.8

14.2-16.2

8.5-10.5

20.3-22.3

14.8-16.8

9.3-11.3

19.4-21.4

14.1-16.1

8.8-10.8

505-525

483-503

459-479

6-11

6-11

6-11

10-15

9-14

8-13

18.3-20.3

13.3-15.3

8.3-10.3

Air Temp

Drop °F

DB

16-22

16-22

16-22

20-26

20-26

20-26

21-27

21-27

21-27

20-26

20-26

20-26

19-25

19-25

19-25

Suction

Pressure

PSIG

66-76

69-79

72-82

95-105

100-110

105-115

128-138

133-143

139-149

173-183

177-187

182-192

Full Load Heating - without HWG active

Discharge

Pressure

PSIG

282-302

285-305

289-309

Superheat

9-15

9-15

9-15

Subcooling

8-13

8-13

9-14

Water Temp

Drop °F

8-10

6-8

4-6

318-338

321-341

324-344

360-380

364-384

368-388

407-427

411-431

415-435

9-15

9-15

9-15

8-14

8-14

8-14

8-14

8-14

8-14

12-17

12-17

12-17

12-17

12-17

12-17

13-18

13-18

14-19

11.3-13.3

8.5-10.5

5.7-7.7

14-16

10.6-12.6

7.3-9.3

18.2-20.2

13.9-15.9

9.6-11.6

Operation Not Recommended

Air Temp

Rise °F

DB

21-27

21-27

22-28

27-33

28-34

30-36

33-38

34-40

35-41

42-50

43-51

44-52

Table 15: R-22 Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

30

50

70

90

Water

Flow

GPM/ton

1.5

2.3

3

1.5

2.3

3

1.5

2.3

3

1.5

2.3

3

Suction

Pressure

PSIG

61-70

62-71

62-71

79-85

75-83

72-82

78-88

78-90

78-91

79-82

80-93

80-93

Full Load Cooling - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

****

Water Temp

Rise *** °F

100-117

92-109

88-104

145-170

130-155

125-150

180-200

169-187

160-180

230-272

215-248

208-240

12-18

12-18

12-18

10-15

10-15

10-15

8-12

8-12

8-12

8-10

8-10

8-10

12-22

12-22

12-22

9-16

9-16

9-16

7-12

7-12

7-12

7-11

7-11

7-11

21-24

13-16

6-11

20-23

12-15

8-12

19-22

11-14

7-12

18-21

10-14

6-11

* Based on Nominal 400 CFM per ton per circuit arifl ow and 70°F EAT heating and 80/67°F cooling.

** Cooling air and water numbers can vary greatly with changes in humidity.

*** Water temperature difference based upon 1.5 - 3 GPM per ton of active circuit water fl ow.

**** Using liquid line pressure.

Air Temp

Drop °F

DB

21-26

21-26

21-26

20-25

20-25

20-25

19-24

19-24

19-24

17-23

17-23

17-23

Suction

Pressure

PSIG

34-39

37-42

38-44

51-58

53-62

55-65

71-82

77-89

81-92

Full Load Heating - without HWG active

Discharge

Pressure

PSIG

Superheat

Subcooling

****

Water Temp

Drop *** °F

163-183

165-185

167-186

175-202

178-206

180-208

215-250

203-235

200-235

5-10

5-10

5-10

9-12

9-12

9-12

10-14

10-14

10-14

5-9

5-9

5-9

8-12

8-12

8-12

6-10

6-10

6-10

7.6-8.4

4.8-5.6

3.4-4.2

10.8-11.9

6.7-8.1

5.1-5.9

14.0-15.2

9.0-10.2

6.7-7.9

Operation Not Recommended

Air Temp

Rise °F

DB

14-20

16-22

16-22

23-29

24-30

25-31

28-34

30-37

31-38

46

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

PREVENTIVE MAINTENANCE

Water Coil Maintenance

(Direct ground water applications only)

If the system is installed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with the heat exchanger material and copper water lines. Generally, the more water fl owing through the unit, the less chance for scaling. Therefore, 1.5 gpm per ton [2.0 l/m per kW] is recommended as a minimum fl ow. Minimum fl ow rate for entering water temperatures below 50°F [10°C] is 2.0 gpm per ton [2.6 l/m per kW].

Water Coil Maintenance

(All other water loop applications)

Generally water coil maintenance is not needed for closed loop systems. However, if the piping is known to have high dirt or debris content, it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system. Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with both the heat exchanger material and copper water lines. Generally, the more water fl owing through the unit, the less chance for scaling. However, fl ow rates over 3 gpm per ton (3.9 l/m per kW) can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Washable, high effi ciency, electrostatic fi lters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air fl ow, resulting in poor performance. It is especially important to provide consistent washing of these fi lters (in the opposite direction of the normal air fl ow) once per month using a high pressure wash similar to those found at self-serve car washes.

Condensate Drain

In areas where airborne bacteria may produce a “slimy” substance in the drain pan, it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem. The condensate pan may also need to be cleaned periodically to insure indoor air quality. The condensate drain can pick up lint and dirt, especially with dirty fi lters. Inspect the drain twice a year to avoid the possibility of plugging and eventual overfl ow.

Compressor

Conduct annual amperage checks to insure that amp draw is no more than 10% greater than indicated on the serial plate data.

Fan Motors

Consult air handler I.O.M. for maintentance requirements.

Air Coil

The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must be taken not to damage the aluminum fi ns while cleaning.

CAUTION: Fin edges are sharp.

Hot Water Generator Coils

See water coil maintenance for ground water units. If the potable water is hard or not chemically softened, the high temperatures of the desuperheater will tend to scale even quicker than the water coil and may need more frequent inspections. In areas with extremely hard water, a HWG is not recommended.

Filters

Filters must be clean to obtain maximum performance.

Filters should be inspected every month under normal operating conditions and be replaced when necessary.

Units should never be operated without a fi lter.

Cabinet - “Indoor” Compressor Section

Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. Generally, cabinets are set up from the fl oor a few inches [7 - 8 cm] to prevent water from entering the cabinet. The cabinet can be cleaned using a mild detergent.

Refrigerant System

To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal.

Reference the operating charts for pressures and temperatures. Verify that air and water fl ow rates are at proper levels before servicing the refrigerant circuit.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

47

TROUBLESHOOTING

General

If operational diffi culties are encountered, perform the preliminary checks below before referring to the troubleshooting charts.

• Verify that the unit is receiving electrical supply power.

• Make sure the fuses in the fused disconnect switches are intact.

After completing the preliminary checks described above, inspect for other obvious problems such as leaking connections, broken or disconnected wires, etc.

If everything appears to be in order, but the unit still fails to operate properly, refer to the “CXM Troubleshooting

Process Flowchart” or “Functional Troubleshooting Chart.”

CXM Board

CXM board troubleshooting in general is best summarized as simply verifying inputs and outputs. After inputs and outputs have been verifi ed, board operation is confi rmed and the problem must be elsewhere. Below are some general guidelines for troubleshooting the CXM control.

Test Mode

Test mode can be entered for 20 minutes by shorting the test pins. The CXM board will automatically exit test mode after 20 minutes.

CXM Troubleshooting Process Flowchart / Functional

Troubleshooting Chart

The “CXM Troubleshooting Process Flowchart” is a quick overview of how to start diagnosing a suspected problem, using the fault recognition features of the CXM board. The

“Functional Troubleshooting Chart” on the following page is a more comprehensive method for identifying a number of malfunctions that may occur, and is not limited to just the CXM controls. Within the chart are fi ve columns:

• The “Fault” column describes the symptoms.

• Columns 2 and 3 identify in which mode the fault is likey to occur, heating or cooling.

• The “Possible Cause column” identifi es the most likely sources of the problem.

• The “Solution” column describes what should be done to correct the problem.

Field Inputs

All inputs are 24VAC from the thermostat and can be verifi ed using a volt meter between C and Y, G, O, W.

24VAC will be present at the terminal (for example, between “Y” and “C”) if the thermostat is sending an input to the CXM board.

Sensor Inputs

All sensor inputs are ‘paired wires’ connecting each component to the board. Therefore, continuity on pressure switches, for example can be checked at the board connector.

ѥ WARNING! ѥ

WARNING! HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWER

INCLUDING REMOTE DISCONNECTS

BEFORE SERVICING.

Failure to disconnect power before servicing can cause severe personal injury or death.

The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured. If desired, this reading can be compared to the thermistor resistance chart shown in the CXM/DXM AOM manual. An ice bath can be used to check calibration of the thermistor.

Outputs

The compressor relay is 24VAC and can be verifi ed using a voltmeter. The fan signal is passed through the board to the external fan relay (units with PSC motors only).

The alarm relay can either be 24VAC as shipped or dry contacts for use with DDC controls by clipping the JW1 jumper. Electric heat outputs are 24VDC “ground sinking” and require a volt meter set for DC to verify operation.

The terminal marked “24VDC” is the 24VDC supply to the electric heat board; terminal “EH1” is stage 1 electric heat; terminal “EH2” is stage 2 electric heat. When electric heat is energized (thermostat is sending a “W” input to the CXM controller), there will be 24VDC between terminal “24VDC” and “EH1” (stage 1 electric heat) and/or “EH2” (stage 2 electric heat). A reading of 0VDC between “24VDC” and

“EH1” or “EH2” will indicate that the CXM board is NOT sending an output signal to the electric heat board.

48

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

CXM PROCESS FLOW CHART

ѥ WARNING! ѥ

WARNING! HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWER

INCLUDING REMOTE DISCONNECTS

BEFORE SERVICING.

Failure to disconnect power before servicing can cause severe personal injury or death.

Start

CXM Functional

Troubleshooting Chart

Did Unit

Attempt to

Start?

Yes

Did Unit

Lockout at

Start-up?

No

See “ Unit short cycles”

Yes

Unit Short

Cycles?

No

See “ Only

Fan Runs”

Yes

Only Fan

Runs?

See “ Only

Comp

Runs”

Yes

See “ Does not Operate in Clg”

No

No

Only

Compressor

Runs?

No

Did unit lockout after a period of operation?

No

Does unit operate in cooling?

Yes

Yes

No

Yes

Unit is OK!

‘See Performance

Troubleshooting’ for further help

Check Main power (see power problems)

See HP

Fault

Check fault LED code on control board

See FP2

Fault

See

LP/LOC

Fault

See FP1

Fault

See

Condensate

Fault

See Over/

Under

Voltage

No fault shown

Replace

CXM

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

49

50

FUNCTIONAL TROUBLESHOOTING

Fault

Main power Problems

HP Fault-Code 2

High pressure

LP/LOC Fault-Code 3

Low Pressure/Loss of Charge X

X

X

Htg Clg Possible Cause

X

X

X Green Status LED Off

X Reduced or no water flow in cooling

X

Water Temperature out of range in cooling

Reduced or no Air flow in heating

Solution

Check Line Voltage circuit breaker and disconnect

Check for line voltage between L1 and L2 on the contactor

Check for 24VAC between R and C on CXM/DXM

Check primary/secondary voltage on transformer

Check pump operation or valve operation/setting

Check water flow adjust to proper flow rate

Bring water temp within design parameters

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Dirty Air Coil- construction dust etc.

Too high of external static. Check static vs blower table

X

X

Air Temperature out of range in heating

Bring return air temp within design parameters

X

Overcharged with refrigerant

X

Bad HP Switch

X Insufficient charge

Compressor pump down at startup

Check superheat/subcooling vs typical operating condition table

Check switch continuity and operation. Replace

Check for refrigerant leaks

Check charge and start-up water flow

FP1 Fault - Code 4

Water Coil low temperature limit

X

FP2 fault - Code 5

Air Coil low temperature limit

Condensate Fault-Code 6

Over/Under Voltage-

Code 7

(Auto resetting)

Unit Performance

Sentinel-Code 8

X

X

X

X

X

X

X

X

X

X

Reduced or no water flow in heating

Check pump operation or water valve operation/setting

Plugged strainer or filter. Clean or replace.

Check water flow adjust to proper flow rate

Check antifreeze density with hydrometer Inadequate anti-freeze level

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C])

Clip JW3 jumper for antifreeze (10°F [-12°C]) use

Water Temperature out of range Bring water temp within design parameters

X

X

Bad thermistor

X Reduced or no Air flow in cooling

Air Temperature out of range

Check temp and impedance correlation per chart

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

Too much cold vent air? Bring entering air temp within design parameters

X

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C])

X Bad thermistor

X Blocked Drain

X Improper trap

X Poor Drainage

X

X

X

Moisture on sensor

Under Voltage

Over Voltage

Normal airside applications will require 30°F [-1°C] only

Check temp and impedance correlation per chart

Check for blockage and clean drain

Check trap dimensions and location ahead of vent

Check for piping slope away from unit

Check slope of unit toward outlet

Poor venting. Check vent location

Check for moisture shorting to air coil

Check power supply and 24VAC voltage before and during operation.

Check power supply wire size

Check compressor starting. Need hard start kit?

Check 24VAC and unit transformer tap for correct power supply voltage

Check power supply voltage and 24VAC before and during operation.

Check 24VAC and unit transformer tap for correct power supply voltage

Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit.

No Fault Code Shown

Unit Short Cycles

Only Fan Runs

X

X

X

X

X

X

X

X

X

X

X

X

Cooling Mode FP1>125°F [52°C]

OR FP2< 40°F [4°C]

X No compressor operation

X Compressor Overload

X Control board

X Dirty Air Filter

X Unit in "Test Mode"

X

X

Unit selection

Compressor Overload

Check for poor water flow, or air flow

See "Only fan operates"

Check and Replace if necessary

Reset power and check operation

Check and Clean air filter

Reset power or wait 20 minutes for auto exit.

Unit may be oversized for space. Check sizing for actual load of space.

Check and Replace if necessary

X Thermostat position

X Unit locked out

X Compressor Overload

X Thermostat wiring

Insure thermostat set for heating or cooling operation

Check for lockout codes. Reset power.

Check compressor overload. Replace if necessary.

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

FUNCTIONAL TROUBLESHOOTING

Only Compressor Runs

Unit Doesn't Operate in

Cooling

Performance

Troubleshooting

Insufficient capacity/

Not cooling or heating properly

X

X

X

X

X

X

X

X

X

X Thermostat wiring

X Fan motor relay

X Fan motor

X Thermostat wiring

X Reversing Valve

X Thermostat setup

X Thermostat wiring

X

Thermostat wiring

X Reduced or no Air flow in cooling

X Leaky duct work

X Low refrigerant charge

X Restricted metering device

X Defective Reversing Valve

X Thermostat improperly located

X Unit undersized

Check G wiring at heat pump. Jumper G and R for fan operation.

Jumper G and R for fan operation. Check for Line voltage across BR contacts.

Check fan power enable relay operation (if present)

Check for line voltage at motor. Check capacitor

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Set for cooling demand and check 24VAC on RV coil and at

CXM/DXM board.

If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.

Check for 'O' RV setup not 'B'

Check O wiring at heat pump. Jumper O and R for RV coil

'Click'.

Put thermostat in cooling mode. Check for 24VAC on O

(check between C and O); check for 24VAC on W (check between W and C). There should be voltage on O, but not on W. If voltage is present on W, thermostat may be bad or wired incorrectly.

PERFORMANCE TROUBLESHOOTING

Htg Clg Possible Cause Solution

X

X

X Dirty Filter

Reduced or no Air flow in heating

Replace or clean

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present

Check superheat and subcooling per chart

Check superheat and subcooling per chart. Replace.

Perform RV touch test

Check location and for air drafts behind stat

Recheck loads & sizing check sensible clg load and heat pump capacity

X X Scaling in water heat exchanger Perform Scaling check and clean if necessary

High Head Pressure

Low Suction Pressure

X

X

X

X

X

X

X

X

X

X Inlet Water too Hot or Cold

Reduced or no Air flow in heating

Check load, loop sizing, loop backfill, ground moisture.

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

X Reduced or no water flow in cooling

X Inlet Water too Hot

Air Temperature out of range in heating

Check pump operation or valve operation/setting

Check water flow adjust to proper flow rate

Check load, loop sizing, loop backfill, ground moisture.

Bring return air temp within design parameters

X Scaling in water heat exchanger Perform Scaling check and clean if necessary

X Unit Overcharged Check superheat and subcooling. Reweigh in charge

X Non-condensables insystem

X Restricted metering device

Vacuum system and reweigh in charge

Check superheat and subcooling per chart. Replace.

Reduced water flow in heating

Check pump operation or water valve operation/setting

Plugged strainer or filter. Clean or replace.

Check water flow adjust to proper flow rate

X Reduced Air flow in cooling

X

X

Water Temperature out of range Bring water temp within design parameters

Air Temperature out of range

Insufficient charge

Check for dirty air filter and clean or replace

Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

Too much cold vent air? Bring entering air temp within design parameters

Check for refrigerant leaks

Low discharge air temperature in heating

High humidity

X

X

Too high of air flow

Poor Performance

X Too high of air flow

X Unit oversized

Check fan motor speed selection and airflow chart

See 'Insufficient Capacity'

Check fan motor speed selection and airflow chart

Recheck loads & sizing check sensible clg load and heat pump capacity

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

51

TROUBLESHOOTING FORM

Customer: _____________________________________ Antifreeze: ________________

Model#: ________________________ Serial#: ________________ Loop type: _________

Complaint: _________________________________________________________________

HEATING CYCLE ANALYSIS -

AIR HANDLER SECTION COMPRESSOR SECTION

PSI

°F

SAT

Refrigerant Type:

R410A

R22

R407C

°F

AIR

COIL

°F

SUCTION

COMPRESSOR

COOLING

EXPANSION

VALVE*

HEATING

EXPANSION

VALVE**

COAX

DISCHARGE

HWG

Look up pressure drop in

I.O.M. or spec. catalog to determine flow rate.

°F

LIQUID LINE

°F °F

PSI PSI

WATER IN WATER OUT

COOLING CYCLE ANALYSIS -

AIR HANDLER SECTION COMPRESSOR SECTION

°F

PSI

SAT

PSI

°F

SAT

AIR

COIL

SUCTION

°F °F

COMPRESSOR

COOLING

EXPANSION

VALVE*

HEATING

EXPANSION

VALVE**

COAX

DISCHARGE

HWG

Look up pressure drop in

I.O.M. or spec. catalog to determine flow rate.

°F

LIQUID LINE

°F °F

PSI PSI

WATER IN WATER OUT

*Cooling expansion valve meters in the cooling mode, and bypasses in the heating mode.

**Heating expansion valve meters in the heating mode, and bypasses in the cooling mode.

°F

PSI

SAT

Heat of Extraction ( Absorbtion) or Heat of Rejection =

________ flow rate (gpm) x ________ temp. diff. (deg. F) x __________ fluid factor

= _____________

(Btu/hr)

Superheat

= suction temperature - suction saturation temp.

=

(deg F)

Subcooling

= discharge saturation temp. - liquid line temp.

=

(deg F)

Use 500 for water, 485 for antifreeze.

Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water fl ow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.

52

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

WARRANTY

Residential Split - 60Hz R22 & R410A - Geothermal Heat Pumps - Rev.: 28 June, 2007D

53

IOM Revision Log:

Date

28 June, 2007

Page # Description

13 Updated fl ow controller mounting instructions

24 Aug, 2006 All Various Formatting Changes and Corrections

24 Aug, 2006 29, 30 Updated Electrical Data

24 Aug, 2006 17, 33 Added Motorized Water Valve Cautions

10 Aug, 2005 All First Published

*97B0048N01*

97B0048N01

7300 S.W. 44th Street

Oklahoma City, OK 73179

Phone: 405-745-2920

Fax: 405-745-6620

The Manufacturer works continually to improve its products. As a result, the design and specifi cations of each product at the time for order may be changed without notice and may not be as described herein. Please contact Manufacturer’s Customer Service Department at 1-405-745-2920 for specifi c information on the current design and specifi cations. Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely Manufacturer’s opinion or commendation of its products.

The management system governing the manufacture of The Manufacturer’s products is ISO 9001:2000 certifi ed.

© LSB, Inc. 2005

Rev.: 28 June, 2007D

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