User guide | ClimateMaster DC Series Unit installation

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User guide | ClimateMaster DC Series Unit installation | Manualzz

Ultra Classic (VT) Series

Residential Vertical

Two-Stage Geothermal

Heat Pumps

Installation, Operation &

Maintenance Instructions

69197343

Revision: 07/07/05D

Model Nomenclature

Storage

Pre-Installation

Physical Data

Physical Dimensions

Unit Installation

Duct System

Water Connections

Condensate Drain

Ground Loop Application

Flushing

Antifreeze

Open Loop/Well Water Installation

Water Quality Standards

Hybrid Loop/Well Applications

Hot Water Generator

Electrical - Line Voltage

Electrical Data

10

10

11

13

13

6

7

7

8

9

3

4

5

5

6

2

2

3

TABLE OF CONTENTS

ECM Fan Control

ECM Blower Data

Electrical - Low Voltage

Freeze Protection Selection

Water Valve Wiring

Thermostat Wiring

Electrical Wiring Schematic

CXM Control Description

Troubleshooting Information

Troubleshooting Analysis

Major Replacement Components

Unit Start-Up Procedure

Operating Limits

Pressure Drop Table

Operating Pressures

Warranty

Preventive Maintenance

28

28

31

BC

22

23

24

26

26

16

17

17

18

19

14

16

16

GENERAL INFORMATION

Model Nomenclature

SERIES:

VT = ULTRA CLASSIC VERTICAL

1

V

2

T

3

0

4

3

5

6

6

G

7

S

8

S

9

S

10 11

L T

12

D

13 14

A S

15

J

SIZE:

036

042

048

060

072

REVISION CODE:

S = STANDARD

HEAT EXCHANGER OPTIONS:

A = COPPER WATER COIL, E-COATED AIR COIL

B = COPPER WATER COIL,

W/HOT WATER GENERATOR, E-COATED AIR COIL

J = CUPRO-NICKEL WATER COIL, E-COATED AIR COIL

K = CUPRO-NICKEL WATER COIL,

W/HOT WATER GENERATOR, E-COATED AIR COIL

AIR FLOW CONFIGURATION:

LT = LEFT RETURN, TOP DISCHARGE

RT = RIGHT RETURN, TOP DISCHARGE

Rev.: 04/15/04D

Inspection

Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the carton or crating of each unit, and inspect each unit for damage. Assure the carrier makes proper notation of any shortages or damage on all copies of the freight bill and he completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment. If not filed within 15 days, the freight company can deny the claim without recourse. Note: It is the responsibility of the

purchaser to file all necessary claims with the carrier.

Notify the ClimateMaster Customer Service of all damage within fifteen (15) days of shipment.

Introduction

ClimateMaster UltraClassic Geothermal Heat Pump units are typically installed in a floor level closet, basement, or in a small mechanical room. The installation site chosen for these units must allow adequate clearance for maintenance and servicing of the unit without its removal from the installation location.

Storage

CAUTION: DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life.

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

Equipment should be stored in its shipping carton in a clean, dry area. Store units in an upright position at all times. Stack vertical units a maximum of 2 units high. DO

NOT remove equipment from shipping cartons until equipment is required for installation.

Unit Protection

Cover units on the job site with either shipping cartons, vinyl film, or an equivalent protective covering. Cap the open ends of pipes stored on the job site. In areas where painting, plastering, or spraying has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material.

Physical damage and contamination may prevent proper start-up and may result in costly equipment cleanup.

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

Page 2 Ultra Classic (VT) Series

Remove Fan Motor shipping bracket in rear of

Air Handler compartment.

VT Physical Data

GENERAL INFORMATION

Pre-Installation

Installation, operation and maintenance instructions are provided with each unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.

Prepare units for installation as follows:

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

2. Keep the cabinet covered with the shipping carton until installation is complete and all plastering, painting, etc., is finished.

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

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

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

To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state and federal proficiency requirements.

All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION. Technicians must follow industry accepted guidelines and all local, state and federal statutes for the recovery and disposal of refrigerants.

If a compressor is removed from this unit, system refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, the refrigerant lines of the compressor must be sealed after it is removed.

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

Table 1: Physical Data

MODEL 036 042 048

Fan Wheel (Dia. X Width), in.

Fan Motor & HP

No. Refrigerant Circuits

Compressors

No. Coaxial Heat Exchangers

R - 22 Charge (Sys A / Sys B), oz

Water Connection Size (fpt swivel)

Air Coil Length x Height, in.

Filter - 1" ElectroStatic (Std.)

Weight - Operating (lbs.)

Weight - Packaged (lbs.)

9 X 7

ECM - 1/2

2

2 - Rotary

2

40 / 40

1"

20 X 24

24 x 24

225

235

ECM - 1/2

2

2

2 - Scroll

57 / 59

1"

24 X 24

27 x 31

275

285

All units have txv expansion devices, 20 ga sheet metal, and 7/8" & 1-1/8" electrical knockouts.

All units have dual 1" Swivel water connections (4 total)

HWG utilizes 1/2" fpt water connections and is available only on circuit A.

All units have 3/4" fpt condensate drain connections.

11 X 10

ECM - 1

2

2

62 / 62

1"

24 X 32

27 x 31

305

315

Ultra Classic (VT) Series

060 072

11 X 10

ECM - 1

2 2

2 - Scroll

2

54 / 54

1"

2

58 / 58

1"

24 X 36

27 x 35

385

395

24 X 36

27 x 35

450

460

Rev.: 8/07/04D

Page 3

Revision Date

Data from Tom North 9/00

Changed filter rack and filter data checked with Enertech

10/30/00

11/13/00

Changes for new comp in 036, 060, and 072 and Electrost Filter & Rack Std 3/30/01

Removed Air Coil Data 8/07/04

Physical Dimensions

INSTALLATION

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Page 4 Ultra Classic (VT) Series

INSTALLATION

General Unit Location

Locate the unit in an indoor area that allows easy removal of the filter and access panels, and has enough space for service personnel to perform maintenance or repair.

Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc.

Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. These units are not approved for outdoor installation and, therefore, must be installed inside the structure being conditioned. Do not locate in areas where ambient conditions are not maintained with 40-100°F and up to 75% relative humidity.

Vertical Units Location and Access

Figure 1a: Vertical unit mounting

Vertical Units are typically installed in a floor level closet, basement, or in a small mechanical room. Install units with adequate clearance to allow maintenance and servicing. Conform to the following guidelines when selecting unit location:

1. Provide adequate clearance for filter replacement and drain pan cleaning. Do not block filter access with piping, conduit or other materials. Refer to the unit catalog for Vertical Unit Dimensions.

2. Provide access for fan and fan motor maintenance and for servicing the compressor and coils without removing the unit. Note: UltraClassic compressor and refrigerant circuit service requires that left side access be provided.

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

Air Pad or extruded polystyrene

If the unit is connected to existing ductwork, a previous check should have been made to assure the ducts have the capacity to handle the air required for the unit. If ducting is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired as necessary.

The duct system should be sized to handle the design airflow quietly. To maximize sound attenuation of the unit blower, the supply and return plenums should include internal duct liner of glass fiber or be of ductboard construction for the first few feet. If air noise or excessive air flow is a problem, the airflow can be changed. See the

Blower Performance and Fan Speed sections for further instruction (See Page 14).

Air Coil

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

Water Connections

4. Provide access to water valves and fittings and screwdriver access to the unit side panels, discharge collar and all electrical connections.

Setting Vertical Units

Vertical units are available in left or right air return configurations. Vertical units should be mounted level on a vibration absorbing pad or extruded polystyrene slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see Figure 1a).

Duct System

A field installed air outlet bracket is provided on vertical units to facilitate duct connection. A flexible connector is recommended for both discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of one-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected.

The UltraClassic Heat Exchanger water connections are swivel piping fittings that accept a 1" Male Pipe Thread

(MPT) connector. The swivel connector has a rubber gasket seal similar to a garden hose gasket, which when mated to the flush end of any 1" threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to insure that the rubber seal is in the swivel connector prior to attempting any connection. (The rubber seals are shipped attached the swivel connector.) DO

NOT OVERTIGHTEN or leaks may occur.

Never use flexible hoses smaller than 1" inside diameter on the unit and limit hose length to 10 ft. per connection.

Check carefully for water leaks. Figure 3 shows a manifold being used in an earth loop application. Flow

(pressure drop) and temperature measurements in the configuration will represent the total flow going through both coaxes regardless of which refrigerant circuits are active. Figure 4 illustrates a well system using individual connections. Flow and temperature measurements will represent each refrigerant circuit.

Ultra Classic (VT) Series Page 5

INSTALLATION

Internally insulate supply duct for first 4’ [1.2m] each

way to reduce noise run. When some sagging in the condensate line may be anticipated (as in a long line of plastic pipe) or when

Use turning vanes in supply transition

Flexible canvas duct connector to reduce noise and vibration

“double trapping” may occur. Also vent when large units are working against higher external static pressure that other units connected to the same condensate main since this may cause poor drainage for all units on the line.

Rounded return transition

Figure 3: Loop Piping using a manifold

P/T Plugs

Rev 3/27/00

Internally insulate return transition duct to reduce noise

To make the connection to a ground loop system, mate the brass loop connection against the rubber gasket in the swivel connector, and thread the female locking to reduce noise ring onto the pipe threads, while maintaining the brass connector in the desired direction (see Figure 2). Tighten the connectors by hand to provide a leak proof joint.

When connecting to an open loop (ground water) system, thread any 1" MPT fitting (PVC or copper) into the swivel connector and tighten in the same manner as noted above.

The open and closed loop piping system must include pressure/temperature taps for serviceability.

Optional

Manifold

Figure 4: Well Piping using a individual connections

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Rev.: 11/2/00

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Figure 2: The Female Locking Ring is threaded onto the pipe threads which holds the male pipe end against the gasket, and seals the joint. HAND TIGHTEN

ONLY! DO NOT OVERTIGHTEN!

Condensate Drain

Each unit utilizes a condensate hose inside the cabinet as a trapping loop, therefore an external trap is not necessary.

Figure 5 shows typical condensate connections.

Each unit must be installed with means to flush or blowout the condensate drain line. Do not install units with a common trap and/or vent.

Install a vent in the condensate line of any application which may allow dirt or air to collect in the line. Always vent when the application requires a long, horizontal

Page 6

Figure 5: Typical drain connection

Ultra Classic (VT) Series

GROUND LOOP APPLICATION

Piping Installation

The typical closed loop ground source system is shown in Figure 10. All earth loop piping materials should be limited to only polyethylene fusion in inground sections of the loop and galvanized or steel fitting should not be used at any time due to their tendency to corrode. All plastic to metal threaded fittings should be avoided as well due to their potential to leak in earth coupled applications and a flanged fitting substituted. P/T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger in lieu of other flow measurement means. Earth loop temperatures can range between

25-110°F and 2.25 to 3 gpm of flow per ton of cooling capacity is recommended in these applications. Upon completion of the ground loop piping, pressure test the loop to assure a leak free system.

Horizontal Systems: Test individual loops as installed.

Test entire system when all loops are assembled.

Vertical U-Bends and Pool Loop Systems: Test Vertical Ubends and pond loop assemblies prior to installation with a test pressure of at least 100 psi.

Table 2: Approximate Fluid Volume (gal.) per 100' of Pipe

Pipe

Copper

Size

1"

1.25"

1.5"

Rubber Hose

Polyethylene

1"

3/4" IPS SDR11

1" IPS SDR11

3.9

2.8

4.5

1 1/4" IPS SDR11 8.0

1 1/2" IPS SDR11 10.9

2" IPS SDR11 18.0

1 1/4" IPS SCH40 8.3

1 1/2" IPS SCH40 10.9

2" IPS SCH40

Unit Heat Exchanger Typical

Flush Cart Tank 10" diam x 3 ft

17.0

1.0

10.0

Volume

4.1

6.4

9.2

Flushing the Earth Loop

Once piping is completed between the unit, flow center and the ground loop (Figure 10), final purging and charging of the loop is needed. A flush cart (at least a 1.5 hp pump) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. All air and debris must be removed from the earth loop piping system before operation. Flush the loop with a high volume of water at a high velocity (2 fps in all piping), both directions. The steps below must be followed for proper flushing. Fill loop with water from a garden hose through flush cart before using flush cart pump to ensure an even fill. Once full, do not allow the water level in the flush cart tank to drop below the pump inlet line or air can be pumped back out to the earth loop. Try to maintain a fluid level in the tank above the return tee so that air can not be continuously mixed back into the fluid. 50 psi surges can be used to help purge air pockets by simply shutting off the return valve going into the flush cart reservoir. This "dead heads" the pump to 50 psi. To purge, dead head the pump until maximum pumping pressure is reached. Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system. Notice the drop in fluid level in the flush cart tank. Note: If air is purged from the system, the level will drop only 1-2 inches in a 10" diameter PVC flush tank (about a half gallon)

since liquids are incompressible. If the level drops more than this, flushing should continue since air is still being compressed in the loop fluid. Do this "dead head" procedure a number of times.

When the fluid level is dropping less than 1-2" in a 10" diameter tank the flow can be reversed. Finally the dead head test should be checked again for an indication of air in the loop. Note: This fluid level drop is your only

indication of air in the loop.

Table 3: Antifreeze Percentages by Volume

Type

Methanol

100% USP food grade Propylene Glycol

Minimum Temperature for Freeze Protection

10°F

25%

38%

15°F

21%

30%

20°F

16%

22%

25°F

10%

15%

Ultra Classic (VT) Series Page 7

GROUND LOOP APPLICATION

Antifreeze may be added before, during or after the loop temperature would be 25-22°F and freeze protection flushing procedure. However, depending upon which time is chosen, antifreeze could be wasted when emptying the flush cart tank. See antifreeze section for more details.

Loop static pressure will fluctuate with the seasons.

Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature. This is a good time for tool cleanup, piping insulation etc. Then final flush and pressurize the loop to a static pressure of

40-50 psi (winter) 15-20 psi (summer). should be at 15°F (30°F-15°F=15°F). All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under water level to prevent fuming. Initially calculate the total volume of fluid in the piping system using Table 2. Then use the percentage by volume shown in Table 3 for the amount of antifreeze. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity. See Flow Controller IOM for more information.

Freeze Protection Setting

CXM or DXM Control:

After pressurization, be sure to remove the plug in the end of the Grundfos loop pump motor(s) to allow trapped air to be discharged and to insure the motor housing has been flooded. This is not required for Taco circulators. Insure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures shown in Table 12.

Antifreeze

In areas where minimum entering loop temperatures drop below 40°F or where piping will be routed through areas subject to freezing, anti-freeze is needed. Alcohols and glycols are commonly used as antifreezes, however your local territory manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F below the lowest expected entering loop temperature. For example, if 30°F is the minimum expected entering loop temperature, the leaving

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

(Antifreeze 10°F) setpoint to avoid nuisance faults. See

Freeze Protection Selection. Valves should be included in case of servicing. Boiler drains or other valves should be "tee’d" in the line to allow acid flushing of just the heat exchanger. Pressure temperature plugs should be used so that flow and temperature can be measured. The water freezestat should be wired. Piping materials should be limited to PVC SCH80 or copper. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Figure 10: Typical Closed Loop System.

Page 8 Ultra Classic (VT) Series

OPEN LOOP - WELL WATER SYSTEMS

Water Quality

Water quality should be plentiful and of good quality.

Water Control Valve

Note the placement of the water control valve. Always

Table 4 shows recommended water quality guidelines.

The unit can be ordered with either a copper or cupronickel water heat exchanger. Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness.

In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. Heat exchanger coils may over time lose heat exchange capabilities due to a build up of mineral deposits inside. These can be cleaned only by a qualified service mechanic as acid and special pumping equipment are required. Note: Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the home owner should be informed that the heat exchanger may require occasional acid flushing.

Expansion Tank

Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to handle at least one minute run time of the pump to prevent premature pump failure using its drawdown capacity rating. The pump should be sized to the home’s domestic water load (5-9 gpm) plus the heat pump water load. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes, i.e. recharge well, storm sewer, drain field, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area. maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Pilot operated slow closing valve’s solenoid valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. Insure that the total "VA" draw of the valve can be supplied by the unit transformer. For instance the slow closing valve can draw up to 35VA. This can overload smaller 40 or 50 VA transformers depending on the other controls employed. A typical pilot operated solenoid valve draws approximately 15VA. Note the wiring diagram in Figure 20.

Flow Regulation

Flow regulation can be accomplished by two methods.

Most water control valves have a flow adjustment built in. By measuring the pressure drop through the unit heat exchanger flow rate can be determined and compared to Table 9. Since the pressure is constantly varying two pressure gauges might be needed. Simply adjust the water control valve until the desired flow of 1.5 to 2 gpm per ton is achieved. Secondly a flow control device may be installed. The devices are typically an orifice that is designed to allow a specified flow rate. These are mounted on the outlet of the water control valve. On occasion these valves can produce a velocity noise that can be reduced by applying some back pressure. This is accomplished by slightly closing the leaving isolation valve of the well water setup.

Freeze Protection Setting

CXM or DXM Control:

When well water is used, the FP1 jumper (JW3) should

NOT be clipped, but should be left in the factory position of water setting (30°F). See Freeze Protection Selection.

Figure 11: Typical Well Water/Open Loop System

Ultra Classic (VT) Series Page 9

Table 4: Water Quality Standards

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HYBRID GROUND LOOP/WELL WATER SYSTEMS

The UltraClassic dual refrigerant circuits with individual water connections for each, allows each refrigerant circuit to utilize a different ground source and benefit from a dramatically shortened earth loop as illustrated in

Figure 12. For instance a 4 ton unit can utilize a 2.5 ton earth loop on circuit 1 and well or city water on circuit 2.

The earth loop is used as first stage with the well or city water source used as the second circuit. Using the well as second stage greatly reduces the amount of earth loop required and limits the well or city water usage.

Note: City water rates should be examined for feasibility before installation. City water should not be used as a source in areas where water temperatures fall below

45°F. ClimateMaster should be consulted when sizing earth loops for this application because of the increased runtime on the earthloop. Traditional loop sizing will be inadequate and can result in poor performance and possibly complete failure of the system.

Pete's plugs should be installed on both systems to facilitate servicing. Standard water flows can be utilized on each circuit 2.25 - 3 gpm /ton for earth loops and 1.5-

2 per ton well/city water. Each circuit should have the appropriate freezestat setting. Be sure circuit A is Earth

Loop and circuit B is Well setting or City. The Ground

Loop and Well System sections should be consulted for further details.

Figure 12: Typical Hybrid Loop/Well system

Page 10 Ultra Classic (VT) Series

HOT WATER GENERATOR

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

All Climate Master heat pumps equipped with the

HWG option include a built-in water to refrigerant heat exchanger to eliminate the need to open and tie into the heat pump’s refrigerant circuit in the field. The control circuit is also built in. The concentric fitting is optional.

Figure 14 is a typical example of HWG water piping connections on an UltraClassic unit with a built-in pump.

Using a concentric or coaxial hot water tank connection fitting eliminates the need to tie into the hot water tank cold water piping. (see Figure 16) the concentric fitting. It is always advisable to use water softening equipment on domestic well water systems to reduce the liming potential and lengthen equipment life. In extreme water conditions, it may be wise to not use the HWG option since the probable cost of frequent maintenance may offset or exceed any savings.

Installation

The HWG aquastat is set at 125 °F and is located on the

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

HWG operation. UNDER NO CIRCUMSTANCES

DISCONNECT OR REMOVE THE HWG AQUASTAT!

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

Typically a single tank of at least 52 gallons is used to limit installation costs and space. However, a dual tank, as shown in Figure 15, is the most efficient system providing the maximum storage and temperate source water to the desuperheater. Using a concentric hot water tank connection fitting eliminates the need to tie into the hot water tank water piping. In high liming areas

(hardness>100ppm or 6 grains per gallon) the alternative piping scheme in Figure 16 may be used to eliminate the

The heat pump, water piping, pump, and hot water tank should be located where the ambient temperature does not fall below 50 °F. Keep water piping lengths at a minimum

– DO NOT use a one way length greater than 50 feet.

All installations must be made in accordance with local codes. The installer is responsible for knowing the local requirements, and for performing the installation accordingly.

Figure 14: Typical UltraClassic HWG Installation

Domestic

Cold Supply

Cold Inlet

Hot Outlet to home

Shut-off Valve with Waste

Vent at high point

Shut-off Valve Upper element to

120 - 130°F

Powered

Water

Heater

Lower element to

100-110° F

Insulated water lines -

5/8” OD 50 ft maximum

Tee and drain

Ultra Classic (VT) Series Page 11

HOT WATER GENERATOR

Figure 15: UltraClassic HWG Double Tank Installation serve the most energy. On tanks with both upper and

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

(or owner preference) lower elements and thermostats, the lower element should be turned down to 100°F or lowest setting, while the upper element should be adjusted to 120°F.

Depending upon the specific needs of the customer, you may want to adjust the upper element differently.

On tanks with a single thermostat, lower the thermostat setting to 120°F or the “LOW” position.

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

Powered

Water Heater Lower element to 120°F

Initial Start-Up

Unpowered

Water Heater 1. Make sure all valves in the HWG water circuit are full open.

2. Turn on the heat pump and allow it to run for 10-15 minutes.

Field Supplied 3/4” brass nipple and “T”

Insulated water lines - 5/8” OD

50 ft maximum

Water Tank Preparation

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

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

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

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

5. In an existing tank, once drained the tank should be flushed with cold water until the water leaving the drain hose is clear and free of sediment.

6. Close all valves and remove the drain hose.

7. Install HWG water piping.

HWG Water Piping

3. Turn the heat pump and heat pump power supply

“OFF” and CONNECT POWER TO THE HWG

PUMP as shown in Figure 17. On units with the internally mounted pump, connect the pump power lead as instructed on the lead tag.

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

5. The temperature difference between the water entering and leaving the HWG coil should be approximately 10°F.

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

Figure 16: Alternate UltraClassic HWG Piping

1. Using at least 5/8" O.D. copper, route and install the water piping, valves and air vent as shown in Figures

14, 15, or 16. When used, the air vent MUST be at the high point of the HWG water piping.

2. Insulate all HWG water piping with no less than 3/8" wall closed cell installation.

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

Water Tank Refill

1. Open the cold water supply to the tank.

2. Open a hot water faucet to vent air from the system until water flows from the faucet, then close.

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

4. Inspect all work for leaks.

5. Before restoring the power or fuel supply to the water heater, adjust the temperature setting on the tank theremostat(s) to ensure maximum utilization of the heat available from the refrigeration system and con-

Page 12 Ultra Classic (VT) Series

ELECTRICAL-LINE VOLTAGE

All field installed wiring, including electrical ground,

WARNING must comply with the National Electrical Code as well as

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.

all applicable local codes.

Refer to the unit wiring diagrams for fuse sizes and a schematic of the field connections which must be made by the installing (or electrical) contractor.

WARNING

CAUTION: Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.

Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper electrical hookup.

All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building.

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Table 5: Electrical Data

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General Line Voltage Wiring

Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and

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Unit Power Connection

Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the contactor as shown in Figure 16. Consult Table 5 for correct wire and fuse size.

External Loop Power Connection

If the unit is to be used with an external loop pump, the pump(s) will be connected to the loop pump terminals in the unit electrical box as shown in Figure 17. The pumps will automatically be cycled as required by the unit.

208 Volt Operation

All 208-230 Volt units are factory wired for 230 Volt.

The transformers may be switched to 208V operation as illustrated on the wiring diagram.

HWG Pumping Wiring

Install HWG Pump power wires on HWG Pump power block after insuring water is in HWG circuit.

Figure 17: Line Voltage Field Wiring

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Pump

Circt Brkr with ground

(see Elect. Table for wire and Brkr. size)

External Loop Pump(s)

208-230/60/1

4 Amp Max.

Transformer

Compressor A

Contactor

PR

Source Pump

L2

HWG

L1

Compressor B

Contactor

Blk

Yellow

Ground

ICM2

Controller

Install HWG Pump

Power after insuring water is in HWG circuit

Ultra Classic (VT) Series Page 13

ECM FAN MOTOR

Fan speeds are selected with jumpers for version

I or via a nine position DIP switch for version II. To take full advantage of the ECM motor features, a multi-stage thermostat should be used (2-stage heat/2-stage cool or 3-stage heat/2-stage cool).

“fine tune” airflow adjustments. The TEST setting runs the ECM motor at 70% torque, which causes the motor to operate like a standard PSC motor, and disables the CFM counter.

Note: Power must be off to the unit for at least three seconds before the ECM motor will recognize a speed change. The motor will recognize a change in the CFM Adjust or dehumidification mode settings while the unit is powered.

There are four different airflow settings from lowest airflow rate (speed tap 1) to the highest airflow rate

(speed tap 4). The charts below indicate settings for both versions of the ECM interface board, followed by detailed information for each setting.

Cooling settings: The cooling setting determines the cooling (normal) CFM for all units with ECM motor. Cooling (normal) setting is used when the unit is not in dehumidification mode. This setting also determines the heating CFM for Genesis (GS) units. Tap 1 is the lowest CFM setting, while tap 4 is the highest CFM setting. To avoid air coil freeze-up, tap 1 may not be used if the dehumidification mode is selected. Consult submittal data or specifications catalog for the specific unit series and model to correlate speed tap setting to airflow in CFM.

Heating settings: The heating setting determines the heating CFM for Tranquility 27™ (TT) and

Tranquility 20™ (TS) units. This setting is not used for Genesis (GS) units. Tap 1 is the lowest CFM setting, while tap 4 is the highest CFM setting.

Consult submittal data or specifications catalog for the specific unit series and model to correlate speed tap setting to airflow in CFM.

Dehumidification Mode settings: The dehumidification mode setting provides field selection of humidity control. When operating in the normal mode, the cooling airflow settings are determined by the cooling tap setting above. When dehumidification is enabled there is a reduction in airflow in cooling to increase the moisture removal of the heat pump. Consult submittal data or specifications catalog for the specific unit series and model to correlate speed tap to airflow in CFM. The dehumidification mode can be enabled in two ways.

1. Constant Dehumidification Mode: When the dehumidification mode is selected (via DIP switch or jumper setting), the ECM motor will operate with a multiplier applied to the cooling

CFM settings (approx. 20-25% lower airflow).

Any time the unit is running in the cooling mode, it will operate at the lower airflow to improve latent capacity. The “DEHUM” LED will be illuminated at all times. Heating airflow is not affected. NOTE: Do not select dehumidification mode if cooling setting is tap 1.

2. Automatic (Humidistat-controlled)

Dehumidification Mode: When the dehumidification mode is selected (via DIP switch or jumper setting) AND a humidistat is connected to terminal DH (version II) or

HUM (version I), the cooling airflow will only be reduced when the humidistat senses that additional dehumidification is required. The DH

(or HUM) terminal is reverse logic. Therefore, a humidistat (not dehumidistat) is required. The

“DEHUM” LED will be illuminated only when the humidistat is calling for dehumidification mode.

Heating airflow is not affected. NOTE: Do not select dehumidification mode if cooling setting is tap 1.

Auxiliary/Emergency Heat settings: The auxiliary/ emergency heat setting determines the CFM when the unit is in auxiliary heat or emergency heat mode. This setting is used for residential units with internal electric heat. When auxiliary electric heat is energized (i.e. compressor and electric heat), the greater of the auxiliary/emergency or heating setting will be used. A “G” (fan) signal must be present from the thermostat for electric heat to operate. Consult the submittal data or specifications catalog for the specific unit series and model to correlate speed tap setting to airflow in CFM.

CFM Adjust settings: The CFM adjust setting allows four selections. The NORM setting is the factory default position. The + or – settings adjust the airflow by +/- 15%. The +/- settings are used to

Page 14 Ultra Classic (VT) Series

Table 6: ECM Board Tap Settings

Cooling settings: TT, TS, GS units*

Tap

Setting

1

2

3

4

Version I

69243707

HP CFM

Jumper

1

2

3

4

ON

ON

Version II

17B0019N01

DIP Switch

SW1

OFF

OFF

SW2

ON

OFF

ON

OFF

*GS units use the same settings for both cooling (normal) CFM and heating CFM.

CFM Adjust settings: TT, TS, GS units

Tap

Setting

TEST

-

+

NORM

Version I

69243707

CFM Adj

Jumper

3

4

1

2

Version II

17B0019N01

DIP Switch

SW7

ON

ON

OFF

OFF

SW8

ON

OFF

ON

OFF

ECM FAN MOTOR

Heating settings: TT, TS units*

Tap

Setting

1

2

3

4

Version I

69243707

DELAY

Jumper

1

2

3

4

*This table not used for GS units.

Version II

17B0019N01

DIP Switch

SW3

ON

ON

OFF

OFF

SW4

ON

OFF

ON

OFF

Dehum Mode settings: TT, TS, GS units

Tap

Setting

NORM

Dehumid

Version I

69243707

Dehumid

Jumper pins 1,2 pins 2,3

Version II

17B0019N01

DIP Switch

SW9

ON

OFF

Aux/Emerg Heat settings: TT, TS, GS units*

Tap

Setting

1

2

3

4

Version I

69243707

AUX CFM

Jumper

*Residential units

3

4

1

2

Version II

17B0019N01

DIP Switch

SW5

ON

ON

OFF

OFF

SW6

ON

OFF

ON

OFF

Figure 18a: ECM Version II Interface Layout

1/4" Spade

Connections to CXM or

DXM Board

Thermostat

Connections

G G G G R

Y

Thermostat

Input LEDs

Figure 18b: ECM Version I Interface Layout

CFM Counter

1 flash per 100 CFM

Thermostat

Connections

ECM Motor

Low Voltage

Connector

A L

G Y1 Y2 O W1 EM C R

LED's

CFM

J01

1/4" Spade

Connections to CXM or

DXM Board

Thermostat

Input LEDs

CFM Counter

1 flash per 100CFM

ECM Motor

Low Voltage

Connector

Test (–) (+)

Dehumidification

LED

G Dehumidification

LED

Fan Speed Selection Jumpers

Fan Speed Selection DIP Switch

Ultra Classic (VT) Series Page 15

VT Blower Performance

ECM BLOWER DATA

Table 7: Blower performance table and fan speed selection

Model

Max

ESP

(in wg)

Fan

Motor

(hp)

Tap

Setting

Normal Mode

Htg & Normal Clg

Dehumid Mode

Stg 2 Stg 1 Fan Stg 2 Stg 1 Fan

036

042

048

0.5

0.5

0.75

1/2

1/2

1

2

1

4

3

2

1

4

3

2

1

4

3

1290

1200

1110

1020

1450

1400

1300

1190

1720

1600

1480

1360

710

660

610

560

800

770

720

660

950

880

810

750

650

600

560

510

730

700

650

600

860

800

740

680

1010

940

870

1130

1090

1010

1340

1250

1150

550

520

480

620

600

560

740

690

630

650

600

560

730

700

650

860

800

740

060

072

0.75

0.75

1

1

2

1

4

3

2

1

4

3

2150

2000

1850

1700

2250

2130

2000

1900

1180

1100

1020

940

1280

1210

1140

1080

1080

1000

930

850

1130

1070

1000

950

1680

1560

1440

1760

1660

1560

920

860

800

1000

940

890

1080

1000

930

1130

1070

1000

Bold figures indicate factory settings, setting on all models.

These values represent Left return models. For right return units move the CFM adj from (norm) to the (+) setting.

During Auxiliary operation the CFM will run at the higher of the HP or AUX settings.

Airflow is controlled within ± 5% up to Max ESP shown with wet coil and with 1" throwaway filter.

Standard 1" electrostatic filter will add 0.15 in wg when clean.

When Dehumidification mode is selected, HP CFM setting must be 4, 3, or 2 only.

All units ARI/ISO/ASHRAE 13256-1 rated at maximum external static.

Aux

CFM

Setting

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

2

1

4

3

Aux

Emerg

Mode

1290

1200

1110

1020

1450

1400

1300

1190

1720

1600

1480

1360

2150

2000

1850

1700

2250

2130

2000

1900

Rev.: 07/06/05D

Pump

Circt Brkr

ELECTRICAL - LOW VOLTAGE

Thermostat Connections

control board as shown in Figure 19. Consult the

Date

10/31/04 RRB

The thermostat should be wired directly to the ECM

Thermostat section for specific wiring.

Figure 19: Low Voltage Field Wiring

Water Freeze Protection - FP1

The CXM/DXM control allows the field selection of source fluid freeze protection points. The factory setting of FP1 is set for water (30°F). In earth loop applications jumper JW3 (FP1- antifreeze 10°F) should be clipped as shown in Figure 20 to change the setting to 10°F, a more suitable temperature when using antifreezes in colder earth loops.

with ground

(see Elect. Table for wire and Brkr. size)

Transformer

Compressor A

Contactor

L1

Compressor B

Contactor

Air Coil Freeze Protection - FP2

The Air coil freeze protection is factory set at 30°F and should not need adjusting.

Figure 20: Changing FP1-Freeze Protection Setpoint

PR

Source Pump

L2

HWG

External Loop Pump(s)

208-230/60/1

4 Amp Max.

Blk

Yellow

Ground

ICM2

Controller

Install HWG Pump

Power after insuring water is in HWG circuit

Clip this JW3-FP1 jumper for anti-freeze systems

Page 16 Ultra Classic (VT) Series

CXM PCB

ELECTRICAL - LOW VOLTAGE

Accessory Connections Thermostat Selection and Wiring

A terminal paralleling the compressor contactor coil have been provided on the CXM/DXM control of the

UltraClassic line. "A" has been provided to control accessory devices, such as water valves, electronic air cleaners, humidifiers, etc. Note: This terminal should be used only with 24 Volt signals and not line voltage

signals. This signal operates with the compressor contactor.

See Figure 21 or the wiring schematic for details.

ATA32H01 - Auto Changeover electronic 3 Heat / 2

Cool thermostat

This electronic thermostat, Fig 23, is suited to all Ultra-

Classic applications.

The UltraClassic also employs an ECM board that features:

• Thermostat terminal connections

• Thermostat signal diagnostic LED's

Figure 21: Accessory Wiring

• Airflow selection

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• Airflow LED (100 cfm per flash)

• Dehumidification Mode Jumper

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Figure 23: ATA32H01 wiring

Water Solenoid Valves

When using solenoid valves on ground water installations.

Figure 21 illustrates a typical well water control valve wiring which will limit wasted water during a lockout condition. A slow closing valve may be required to prevent water hammer. When using an AVM -Taco

Slow Closing valves on UltraClassic Series equipment

Figure 20 wiring should be utilized. The valve takes approximately 60 seconds to open (very little water will flow before 45 seconds) and it activates the compressor only after the valve is completely opened (by closing its end switch). Only relay or triac based electronic thermostats should be used with the AVM valve. When wired as shown, the valve will operate properly with the following notations:

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

2 - The valve will draw approximately 25-35 VA through

the “Y” signal of the thermostat. Note: This can overheat the anticipators of electromechanical

thermostats. Therefore only relay or triac based thermostats should be used.

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Figure 22: Well Water AVM Valve Wiring

Ultra Classic

1

2

Heater Switch

3

AVM

Taco Valve

Thermostat

Ultra Classic (VT) Series Page 17

ELECTRICAL SCHEMATIC

Page 18 Ultra Classic (VT) Series

Features

CXM CONTROL DESCRIPTION

Retry Mode - If the control is attempting a retry of a fault,

• Anti-short cycle protection

• High and Low pressure cutouts the status LED will slow flash (slow flash = one flash every 2 seconds) to indicate the control is in process of retrying.

• Water Coil freeze protection

• Air Coil freeze protection

Note: In the following field configuration options, jumper wires should be clipped ONLY when power is removed from the CXM control.

• Random Start

• Unit Performance Sentinel

• Over/Under Voltage protection

Water Coil Freeze Protection Limit Setting - Jumper

2 (JW3-F12 Low Temp) provides field selection of temperature limit setting for FP1 to be 30°F or 10°F.

• Diagnostic LED

Not Clipped = 30°F. Clipped = 10°F.

• Reset Lockout at unit or disconnect

• Intelligent Reset

• Condensate Overflow sensor

Air Coil Freeze Protection Limit Setting - Jumper

3 (JW2-FP2 Low Temp) provides field selection of temperature limit setting for FP2 to be 30°F or 10°F.

• Test Mode

Not Clipped = 30°F. Clipped = 10°F.

• Electric Heat Outputs

• Accessory Water Valve Connection

Alarm Relay Setting - Jumper 1 (JW1-AL2 Dry) provides field selection of Alarm Relay terminal AL2 to be jumpered to 24Vac or to be dry (no connection).

• Optional LonWorks Control

Field Selectable Inputs

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

DIP Switches

Test Mode - Test Mode allows the service personnel to check the operation of the control in a timely manner. By

momentarily shorting the test terminals, the CXM control enters a 20 minute Test Mode period in which all time delays are sped up 15 times. Upon entering Test Mode, the

Status LED will flash a code representing the last fault.

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

Unit Performance Sentinel Disable - Dip Switch 1 provides field selection to disable The UPS Feature

On = Enabled. Off = Disabled.

Stage 2 - Dip Switch 2 provides selection of whether compressor has an on delay. If set to stage 2, the compressor will have a 3 second delay before energizing.

Also, if set for stage 2, the alarm relay will NOT cycle during test mode.

On = Stage 1. Off = Stage 2.

Table 8: LED & Alarm Relay Operations

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 Cycling Code 2

Test Mode - LP Fault in memory Flashing Code 3

Test Mode - FP1 Fault in memory Flashing 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 3

Cycling Code 4

Cycling Code 5

Cycling Code 6

Cycling Code 7

Cycling Code 8

Cycling Code 9

Special Notes and Examples:

-Slow Flash = 1 flash every 2 seconds

-Fast Flash = 2 flashes every 1 second

-Flash code 2 = 2 quick flashes, 10 sec.

pause, 2 quick flashes, 10 sec. pause, etc.

Ultra Classic (VT) Series Page 19

CXM CONTROL DESCRIPTION

Safety Features

The following safety features are provided to protect the compressor, heat exchangers, wiring and other

Water Coil Freeze Protection (FP1) - The FP1 protection limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. components from damage caused by operation outside of The FP1 input is bypassed for the initial 60 seconds of a design conditions.

compressor run cycle. FP1 Lockout Code = 4.

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.

Air Coil Freeze Protection (FP2) - The FP2 thermistor temperature must be below the selected freeze protection limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault.

The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 Lockout Code = 5.

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

Fault Retry - In Fault Retry mode, the Status LED begins slow flashing to signal that the control is trying to recover from a fault input. The CXM control will stage off the outputs and then “try again” to satisfy the thermostat "Y" input call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occured. If 3 consecutive faults occur without satisfying the thermostat

"Y" input call, then the control will go to Lockout mode.

The last fault causing the lockout will be stored in memory and can be viewed by going into test mode.

Lockout - In Lockout mode, the Status LED will begin fast flashing. The compressor relay is turned off immediately. Lockout mode can be soft reset via the thermostat “Y” input or can be hard reset via the disconnect. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode.

Condensate Overflow - The Condensate Overflow sensor must sense overflow levels for 30 continuous seconds to be recognized as a CO fault. Condensate Overflow will be monitored at all times. CO Lockout Code = 6.

Over/Under Voltage Shutdown - An Over/Under Voltage condition exists when the control voltage is outside the range of 19Vac to 30Vac. Over/Under Voltage Shutdown is self resetting in that if the voltage comes back within range of 19Vac to 30Vac for at least 0.5 seconds, then normal operation is restored. This is not considered a fault or lockout. If the CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close. Over/Under

Voltage Shutdown Code = 7.

Unit Performance Sentinel-UPS (patent pending) - The

UPS feature warns when the heat pump is operating inefficiently. A UPS condition exists when:

Lockout with Emergency Heat - While in Lockout mode, if W becomes active, then Emergency Heat mode will occur. a) in heating mode with compressor energized, if FP2 is

greater than 125°F for 30 continuous seconds, or b) in cooling mode with compressor energized, if FP1 is

greater than 125°F for 30 continuous seconds, or FP2

is less than 40°F for 30 continuous seconds.

High Pressure Switch - When the High Pressure Switch opens due to high refrigerant pressures, the Compressor relay is de-energized immediately since the High Pressure

Switch is in series with the compressor contactor coil.

The High Pressure Fault recognition is immediate as well.

High Pressure Lockout Code = 2

Example: 2 quick flashes, 10 sec pause, 2 quick flashes,

10 sec. pause, etc.

Low Pressure Switch - The Low Pressure Switch must be open and remain open for 30 continuous seconds during

"on" cycle to be recognized as a Low Pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure

(loss of charge) fault. The Low Pressure Switch input is bypassed for the initial 60 seconds of a compressor run cycle. Low Pressure Lockout Code = 3. thermistor temperature must be below the selected freeze

If a UPS condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is on Normal mode. (see"LED and Alarm Relay

Operation Table" ). Outputs of the control, excluding LED and Alarm Relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle.

During UPS warning, the alarm relay will cycle on and off. The cycle rate will be On for 5 seconds, Off for 25 seconds, On for 5 seconds, Off for 25 seconds, etc. Unit

Performance Sentinel Warning Code = 8.

Page 20 Ultra Classic (VT) Series

CXM CONTROL DESCRIPTION

Diagnostic Features

The Status LED on the CXM control advises the Heating Stage 2 - To enter Heating Stage 2 mode, W serviceman of the current status of the CXM control. The status LED can display either the current CXM mode or the last fault memory if in test mode. See Table 8 for a complete listing of codes.

becomes active (Y already active). The Compressor relay remains on. EH1 is turned on immediately. With continuing Heating Stage 2 demand, EH2 will turn on after 10 minutes. The EH2 will not turn on in heating (or will turn off if already on) if loop temperature is above approximately 50°F (FP1 >45°F).

Unit Operation Description

PowerUp - The unit will not operate until all the inputs and safety controls are checked for normal conditions.

Note: The compressor will have a 5 minute anti-short cycle delay at power-up.

Standby - In Standby mode, Y and W inputs are not active.

Inputs O and G may be active. Compressor will be off.

Emergency Heat - In Emergency Heat mode, W becomes active while Y is not active. EH1 is turned on immediately. With continuing Emergency Heat demand,

EH2 will turn on after 5 minutes. The FP1 and FP2 temperatures do not effect emergency heat operation.

Cooling - To enter Cooling mode, Y and O become active. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. There will also be a 5 min compressor anti-short cycle protection time as well. After the random start delay, the compressor relay is energized. On all subsequent compressor calls, the random start delay is omitted.

ECM Control Board

The UltraClassic also employs an ECM board that features:

• Thermostat terminal connections

• Thermostat signal diagnostic LED's

• Airflow selection

• Airflow LED (100 cfm per flash)

• Dehumidification Mode Jumper

Heating Stage 1 - To enter Heating Stage 1 mode, Y becomes active. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to

80 second random start delay. There will also be a 5 min compressor anti-short cycle protection time as well. After the random start delay, the compressor relay is energized.

On all subsequent compressor calls, the random start delay is omitted.

Table 9: Fault Description Table

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Ultra Classic (VT) Series Page 21

TROUBLESHOOTING INFORMATION

General

CXM board troubleshooting in general is best summarized as simply varifying inputs and outputs.

After this process has been varified, confidence in board operation is confirmed and the trouble must be else where. Below are some general guidelines required for developing training materials and procedures when applying the CXM control.

Field Inputs

The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured. If desired this reading can be compared to the chart shown in the thermistor section of this manual based upon the actual termperature of the thermistor clip. An ice bath can be used to check calibration of a thermistor if needed.

Outputs

All inputs are 24VAC from the thermostat.and can be varified using a Volt meter between C and Y, G, O, W. See the I/O Reference table below.

Sensor Inputs

All sensor inputs are "paired wires" connecting each component with the board. Therefore continuity on pressure switches, and the condensate switch can be checked at the board connector.

The compressor relay is 24VAC and can be varified using a voltmeter. The fan signal is passed through the board to the external fan relay. The alarm relay can either be

24VAC as shipped or dry contacts (measure continuity during fault) for use with DDC by clipping the J1 jumper.

Electric heat outputs are 24VDC ground sinking and require a voltmeter set for DC to varify operation. See the

I/O Reference table below.

Test Mode

Test mode can be entered for 20 minutes by shorting the test pins.

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Table 10: CXM Input/Output Reference Table

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Page 22 Ultra Classic (VT) Series

Preliminary Trouble Inspection

TROUBLE ANALYSIS

After completing the preliminary checks described above, be sure to inspect for other obvious problems such as

WARNING leaking connections, broken or disconnected wires, etc.

HAZARDOUS VOLTAGE! DISCONNECT

ALL ELECTRIC POWER INCLUDING

REMOTE DISCONNECTS BEFORE

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

If everything appears to be in order, but the unit still fails to operate properly, refer to the following Troubleshooting Chart.

Troubleshooting Chart

The Troubleshooting Chart that follows is provided to serve as an aid for identifying malfunctions that may occur. Within the chart are three columns:

1. The Problem column describes what the unit is doing.

If operational difficulties are encountered, be sure to perform the preliminary checks before referring to the

Troubleshooting Chart.

• Verify that the unit is receiving electrical supply power.

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

2. The Cause column identifies the most likely sources of the problem.

3. The Correction column describes what should be done to correct the problem.

Start

CXM Functional

Troubleshooting Chart

See “Unit short cycles”

See “Only

Fan Runs”

See “Only

Comp

Runs”

See “Does not Operate in Clg”

Yes

Yes

Yes

No

Did Unit

Attempt to

Start?

Yes

Did Unit

Lockout at

Start-up?

No

Unit Short

Cycles?

No

Only Fan

Runs?

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

Ultra Classic (VT) Series Page 23

Page 24

FUNCTIONAL TROUBLESHOOTING

Fault

Main power Problems

HP Fault-Code 2

High pressure

X

LP/LOC Fault-Code 3

Low Pressure/Loss of Charge X

X

X

Htg Clg Possible Cause

X

X

X Green Status LED Off

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

X Reduced or no water flow in cooling

X Water Temperature out of range in cooling

Reduced or no Air flow in heating

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

Bring return air temp within design parameters

Air Temperature out of range in heating

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 X

FP2 fault - Code 5

X

X

X

X

Reduced or no water flow in heating

Inadequate anti-freeze level

Improper temperature limit setting

(30°F vs 10°F)

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

Clip JW3 jumper for antifreeze (10°F) use

Water Temperature out of range Bring water temp within design parameters

X Bad thermistor

X Reduced or no Air flow in cooling

X 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

Condensate Fault-Code 6

Over/Under Voltage-

Code 7

(Auto resetting)

Unit Performance

Sentinel-Code 8

X

X

X

X

X

X

X Bad thermistor

X Blocked Drain

X Improper trap

X Poor Drainage

X Moisture on sensor

X Under Voltage

X

Over Voltage

Normal airside applications will require 30°F 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

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

Heating mode FP2>125°F

FP2< 40°F

° F OR

X No compressor operation

X Compressor Overload

X Control board

X Dirty Air Filter

X Unit in "Test Mode"

X Unit selection

X Compressor Overload

X Thermostat position

X Unit locked out

X Compressor Overload

X Thermostat wiring

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

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.

Ultra Classic (VT) Series

FUNCTIONAL TROUBLESHOOTING

Only Compressor Runs X

X

X Thermostat wiring

X Fan motor relay

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 X X Fan motor

Unit Doesn't Operate in

Cooling

Not cooling or heating properly

X X Thermostat wiring

X Reversing Valve

X Thermostat setup

X Thermostat wiring

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

X Thermostat wiring between W and C). There should be voltage on O, but not or wired incorrectly.

PERFORMANCE TROUBLESHOOTING

Performance

Troubleshooting

Insufficient capacity/

Htg Clg Possible Cause

X X Dirty Filter

Solution

Replace or clean

X

X

X

X

X

X

Reduced or no Air flow in heating

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 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 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

X

X

Low Suction Pressure

X

X

X

X

X

X

X

X Inlet Water too Hot or Cold Check load, loop sizing, loop backfill, ground moisture.

Reduced or no Air flow in heating

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

X Non-condensables insystem

X Restricted metering device

Reduced water flow in heating

Check superheat and subcooling. Reweigh in charge

Vacuum system and reweigh in charge

Check superheat and subcooling per chart. Replace.

Check pump operation or water valve operation/setting

Plugged strainer or filter. Clean or replace.

Check water flow adjust to proper flow rate

Water Temperature out of range Bring water temp within design parameters

X Reduced Air flow in cooling

X Air Temperature out of range

X 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

Ultra Classic (VT) Series Page 25

UNIT START UP

Operating Limits

Environment – This unit is designed for indoor installation ONLY.

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

Starting Conditions

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

GT-X Units – Units start and operate in an ambient of

45°F with entering air at 45°F, entering water at 32°F and both air and water at the stated flow rates of ISO/

ASHRAE/ARI 13256-1 for initial winter start-up.

Notes:

1. These are not normal or continuous operating conditions. It is assumed that winter start-up is to bring the building space up to occupancy temperatures.

2. Voltage utilization range complies with ARI

Standard 110.

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

Table 11: Operating Limit

Air Limits

Min. Ambient Air

Rated Ambient Air

Max. Ambient Air

Min. Entering Air

Rated Entering Air db/wb

Max. Entering Air db/wb

Water Limits

Min. Entering Water

Normal Entering Water

Max. Entering Water

Ultra Classic

Cooling Heating

45°F

80°F

100°F

50°F

80/67°F

110/83°F

30°F

50-90°F

110°F

45°F

70°F

85°F

40°F

70°F

80°F

20°F

30-60°F

90°F

BEFORE POWERING UNIT, check the following:

q High voltage is correct and matches nameplate q Fuses, breakers and wire size correct q Low voltage wiring complete q Piping completed and water system cleaned and flushed q Air is purged from closed loop system q Isolation valves are open, water control valves or

loop pumps wired q Condensate line open and correctly pitched q Transformer switched to lower voltage tap if needed q Air coil cleaned q HWG pump disconnected unless piping is completed

and air has been purged q Blower rotates freely – shipping support has been removed q Blower speed correct (taps on correct pins) q Air filter is clean and in position q Service/access panels are in place q Return air temperature is between 40-80°F in

heating and 50-110°F in cooling q CXM field selectable options such as thermistor

settings are correct.

Page 26 Ultra Classic (VT) Series

Start up Procedure

WARNING

UNIT START UP

If Delta-T Water is outside the range shown in

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

table 12, check cooling refrigerant pressure in

table 14. Verify correct water flow by comparing

unit pressure drop across the heat exchanger

versus the data in Table 12. Heat of rejection can

be calculated and compared to specification

catalog.

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

2. Balance air flow at registers.

f. Check air temperature drop across the coil when

compressor is operating. Air temperature should

drop between 15°F and 25°F.

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

4. Operate unit in cooling cycle. Room temperature should be approximately 45-100°F DB. For Start-up check, loop water temperature entering the heat pumps should be between 40°F and 90°F.

g. Turn thermostat to “OFF” position. A hissing

noise indicates proper functioning of the

reversing valve.

6. Operate the heat pump in the heating cycle immediately after checking cooling cycle operation.

Allow five (5) minutes between tests for pressure to equalize or cycle the reversing valve to equalize.

5. Two factors determine the operating limits of a

ClimateMaster UltraClassic System– (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal levels to ensure proper unit operation.

a. Turn thermostat to lowest setting and set

thermostat switch to “HEAT” position.

b. Slowly turn thermostat to a higher temperature

until the compressor activates.

a. Adjust the unit thermostat to the coolest position.

Slowly reduce thermostat setting until the

compressor activates.

c. Check for warm air delivery at the unit grille within a

few minutes after the unit has begun to operate.

b. Check for cool air delivery at the unit grille within

a few minutes after the unit has begun to operate.

Note: Units have a five minute time delay in the control circuit that can be eliminated on the CXM

PCB as shown below in Figure 24. See controls description for detailed features of the control.

c. Verify that the compressor is on and that the water

flow rate is correct by measuring pressure drop

through the heat exchanger using the Pete’s plugs

and comparing to Table 13.

d. Check the temperature of both supply and

discharge water. Refer to Table 12. If temperature

is within range, proceed with test. If temperature

is outside operating range, check heating

refrigerant pressures in Table 14.

e. Check air temperature rise across the coil when

compressor is operating. Air temperature should rise

between 20°F and 30°F. Heat of extraction can be

calculated and compared to specification catalog.

f. Check for vibration, noise, and water leaks.

d. Check the elevation and cleanliness of the

condensate lines. Dripping may be a sign of a

blocked line. Check that the condensate trap

includes a water seal.

7. If unit fails to operate, perform Troubleshooting analysis. If the check described fails to reveal the problem and the unit still does not operate, contact a trained service technician to ensure proper diagnosis and repair of the equipment.

e. Refer to Table 12. Check the difference in

temperature of supply and return water

temperature, usually referred to as Delta-T Water.

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

Figure 24: Test Mode Pins

Short test pins together to enter Test

Mode and speed-up timing and delays for

20 minutes

9. BE CERTAIN TO FILL OUT AND FORWARD

ALL WARRANTY REGISTRATION PAPERS TO

CLIMATEMASTER.

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

CXM Board

Ultra Classic (VT) Series Page 27

Table 12: Water Temperature Change Through Heat Exchanger

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Page 28 Ultra Classic (VT) Series

NOTES

Ultra Classic (VT) Series Page 29

Page 30 Ultra Classic (VT) Series

Ultra Classic (VT) Series Page 31

PREVENTIVE MAINTENANCE

Water Coil Maintenance

(Direct Ground Water Applications Only)

If the installation is performed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the heat exchanger material or copper water lines. Generally, the more water flowing through the unit the less chance for scaling therefore 1.5 gpm per ton is recommended as a minimum flow.

once per month using a high pressure wash similar to that found at self-serve car washes.

Condensate Drain – In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically with an algaecide every three months or so to minimize the problem. The condensate pan may also need to be cleaned periodically to assure indoor air quality. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect the drain twice a year to avoid the possibility of overflow.

Fan Motors - All units have lubricated fan motors. FAN

MOTORS SHOULD NEVER BE LUBRICATED UNLESS

OBVIOUS, DRY OPERATION IS SUSPECTED. Periodic maintenance oiling is not recommended because it will result in dirt accumulating on excess oil and cause eventual motor failure.

Water Coil Maintenance

(Other Water Loop Applications)

Generally water coil maintenance is not needed however, if the installation is located in a system with a known high dirt or debris content, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. These dirty installations are a result of the deterioration of iron or galvanized piping or components in the system or open cooling towers requiring heavy chemical treatment and mineral buildup through water use. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with both the heat exchanger material and copper water lines. Generally, the more water flowing through the unit, the less chance for scaling, however flow rates over 3 gpm per ton can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Filters – Filters must be clean to obtain maximum performance. They should be inspected every month under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.

Air Coil – The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean.

Care must be taken not to damage the aluminum fins while cleaning. CAUTION: Fin edges are sharp.

Hot Water Generator Coils – See water coil maintenance for ground water units. If the domestic water is hard or not chemically softened the high temperatures of the desuperheater will tend to "lime up" even quicker than the water coil and may need more frequent inspections.

Cabinet - Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. Generally the cabinet is set up from the floor a few inches for prevention. The cabinet can be cleaned using a mild detergent.

Washable high efficiency electrostatic filters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air flow resulting in poor performance. With

ECM fan motors, excessive fan watts will be used as well.

It is especially important to provide consistent washing of these filters (in opposite direction of the normal air flow)

Refrigerant System - To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating chart for pressure and temperatures. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.

*69197343*

Part # 69197343

7300 S.W. 44th Street

Oklahoma City, OK 73179

Phone: 405-745-6000

FAX: 405-745-6045 www.climatemaster.com

ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time for order may be changed without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products.

© ClimateMaster 2000 Rev.: 7/07/05D

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