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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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