Premium Installation Manual
Premium
Geothermal/Water Source Heat Pumps
• 3/4 thru 6 Ton
Installation Information
Water Piping Connections
Desuperheater Connections
Electrical
Startup Procedures
Troubleshooting
IM1555 07/04
GeoSmart Energy
Preventive Maintenance
PREMIUM INSTALLATION MANUAL
Premium
Model Nomenclature
P 040 T
L 3 2 0 C A D S S
A
Vintage
A = All Others
B = P028(Single Phase),
P056(All Voltages)
Family
P
P =- Premier
Premium
Unit Capacity
MBTUH
Non-Standard Option Details
Non-Standard Options
S = Standard
4 = FX10*
5 = FX10 w/Open N2 Com. Card*
6 = FX10 w/LonWorks Com. Card*
7 = FX10 w/BacNet Com. Card*
Discharge Air Configuration
T = Top Discharge Vertical
E = End Discharge Horizontal
S = Side Discharge Horizontal
Return Air Configuration
L = Left
R= Right
Filter Options
D = 1" Pleated Disposable
Voltage
0 = 208-230/60/1 (Commercial)
1 = 208-230/60/1 (Residential)
2 = 265-277/60/1
3 = 208-230/60/3
4 = 460/60/3
Sound Kit
A = None
B = Blanket
Coax Options
C = Copper
N = Cupronickel
Hot Water Option
0 = None
1 = Hot Water Generation
With Factory Installed Pump (Residential)
2 = Hot Water Generation
Without Pump (Commercial 022-066, 230 VAC only)
Blower Options
0 = PSC Blower
1 = ECM Blower
2 = Oversized ECM Blower Option
(040-046 Only)
Note: * FX10 available only on units with PSC blowers without desuperheaters.
2
PREMIUM INSTALLATION MANUAL
Table of Contents
General Installation Information
4-7
Closed Loop Ground Source Systems
8
Open Loop Ground Water Systems
9
Boiler/Cooling Tower Closed Loop Systems
10
System Cleaning & Flushing
11
Desuperheater Connection & Startup
12-13
Electrical Connections
15
Electronic Thermostat Installation
15
Fan Performance Data
16-17
Standard Microprocessor Control Operation
18-19
Dip Switch Settings
20-21
FX10 Control Operation
22
Startup Procedures
23
Description of Unit Operation
24-25
Troubleshooting
26
Preventive Maintenance
27
Replacement Procedures
28
3
PREMIUM INSTALLATION MANUAL
General Installation Information
WARNING: Before performing service or maintenance operations on a system, turn off main
power switches to the indoor unit. If applicable, turn off the accessory heater power switch.
Electrical shock could cause personal injury.
Safety Considerations
Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning
equipment.
Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All
other operations should be performed by trained service personnel. When working on heating and air conditioning equipment,
observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a
fire extinguisher available.
Moving and Storage
Move units in the normal “up” orientation as indicated by the arrows on each carton. Horizontal units may be moved and
stored per the information on the carton. Do not stack more than three units in total height. Vertical units may be stored one
upon another to a maximum height of two units. Do not attempt to move units while stacked.
When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and
cartons have been received. Examine units for shipping damage, removing the units from the cartons if necessary. Units
in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the
delivery receipt, acknowledging the damage. Units are to be stored in clean, dry location to prevent damage.
Unit Location
Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have
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. On horizontal units, allow adequate room below the unit for
a condensate drain trap and do not locate the unit above supply piping. Care should be taken when units are located in
unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical
components.
Installing Vertical Units
Vertical units are available in left or right air return configurations. Vertical
units should be mounted level on a vibration absorbing pad 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 right). If access to the left side of the unit will be
limited after installation, remove the two mounting screws on the left side of the
control box before setting the unit (leave the two front mounting screws intact).
This will allow the control box to be removed with only the two front mounting
screws for future service.
4
Figure 1: Vertical Unit Mounting
Vibration
Absorbing
Mesh
or
Air
Pad
PREMIUM INSTALLATION MANUAL
Installing Horizontal Units
Horizontal units are available with side or end discharge and may be field converted from one to the other by replacing the discharge panel with a new panel which must be ordered separately. Horizontal units are normally suspended from
a ceiling by four or six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits
furnished with each unit.
Lay out the threaded rods per the dimensions in Figure 3. Assemble the hangers to the unit as shown. Securely tighten
the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to
the bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filter
side should be installed 180° from the position shown in the figure below. The unit should be pitched approximately 1/4-inch
towards the drain in both direcFigure 2: Typical Horizontal Unit Installation
tions to facilitate the removal of
condensate. Use only the bolts
provided in the kit. The use of
longer bolts could damage interElectric heat
nal parts.
3/8”
assembly
Threaded rods (6)
(optional)
Some residential applications
require the installation of horiFlexible Duct
Collar
zontal units on an attic floor. In
this case, the unit should be set
To Thermostat
Insulate
in a full size secondary drain pan
To Line
supply plenum
P/T Plugs
Power
on top of a vibration absorbing
and use at least
a 90° elbow to
Hose Kits
mesh. The secondary drain pan
reduce noise
prevents possible condensate
overflow or water leakage damage to the ceiling. The secondary
drain pan is usually placed on a
Disconnects
s
plywood base isolated from the
Valve
Ball
Line Voltage
ceiling joists by additional layers
of vibration absorbing mesh.
Hanging
Building Water
Brackets
(included)
Loop
CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong
enough to support the unit. The rods must be securely anchored to the ceiling.
Figure 3: Hanger Location and Assembly
3/8”
Threaded Rod
(not supplied)
E
A
C
Compressor
Section
Air Handler
Section
B
D
P010-034, 4 hangers included
P040-066, 6 hangers included
Vibration Isolator
Washer
Hex Nuts
(not supplied)
Bolt and
Lockwasher
MODEL
A
B
C
D
E
P010, 013
24.8
42.5
22.5
44.0
–
P019
24.8
51.5
22.5
53.0
–
P022, 028, 034
24.8
61.5
22.5
63.0
–
P040, 046
27.8
70.5
25.5
72.0
29.9
P056
27.8
75.5
25.5
77.0
29.9
P066
27.8
80.5
25.5
82.0
29.9
5
PREMIUM INSTALLATION MANUAL
Duct System
An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexible
connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should
be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned
space is not recommended as the unit’s performance will be adversely affected.
If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate
the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary.
The duct system should be sized to handle the design airflow quietly and efficiently. To maximize sound attenuation of
the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard
for the first 10 feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit
and the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed (refer to pages 16-17).
CAUTION: Be sure to remove the shipping material from the blower discharge before
connecting ductwork.
Water Piping
The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/
temperature ports to determine the flow rate. These ports should be located adjacent to the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the
refrigerant-to-water heat exchanger.
All source water connections on residential units are swivel fittings that accept a 1-inch male pipe thread (MPT). The
swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any 1-inch
threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4L and CK3L connector kit)
against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to
provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fitting (SCH80
PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping
system should include pressure/temperature taps for serviceability.
All source water connections on commercial units are standard female pipe thread.
Never use flexible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection.
Check carefully for water leaks.
Water Quality
In groundwater situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in groundwater systems may, over a period of time,
lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified
service mechanic, as special solutions and pumping equipment are required. Desuperheater coils can likewise become
scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger
may require occasional flushing.
Freeze Protection
Set the freeze protection switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solution to “LOOP”. On applications using an open loop/groundwater system (or closed loop no antifreeze), set this dip switch to
“WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 20.)
6
PREMIUM INSTALLATION MANUAL
Condensate Drain
On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a
3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the
cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose is
inside all cabinets as a trapping loop; therefore, an external trap is not necessary.
On horizontal units, a copper stub is provided for condensate drain piping connection. An external trap is required (see
Figures 4 and 5 below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate
piping.
Figure 4: Horizontal Drain Connection
Figure 5: Unit Pitch for Drain
Clear PVC hose
Vent (if needed)
3/4" barb to
glue adapter
1/4'' Pitch
3/4" PVC
Copper tube stub
Plastic Hose Clamps
(Included with unit)
1.5"
1.5"
1/8" per foot
Drain
7
PREMIUM INSTALLATION MANUAL
Closed Loop Ground Source Systems
Note: For closed loop systems with antifreeze protection, set SW2-2 to the “loop” position (see table on page 20).
Once piping is completed between the unit, flow center and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) 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. Flush the
system adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 PSI (summer)
or 50-75 PSI (winter). This is normally adequate for good system operation. Loop static pressure will 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 initially charging the system.
After pressurization, be sure to remove the plug in the end of the loop pump motor(s), if applicable, to allow trapped air to
be discharged and to ensure that the motor housing has been flooded. Ensure that the loop flow center provides adequate
flow through the unit by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data
in the specification catalog. Usually 2.5 to 3 GPM of flow per ton of cooling capacity is recommended in earth loop applications. (See wiring diagram attached to the inside of the unit for pump wiring details.)
Figure 6: Closed Loop, Ground Source Application - Single unit with Flow Center
Auxiliary Heat
Supply
TO
LOOP
GeoLink®
Polyethylene w/
Armaflex®
Insulation
Unit Supply
Flexible Duct
Collar
ink ®
GeoL
lo
F w
r
Cente
Auxiliary
Heater
Knockout
Unit Power
Desuperheater
Connections
Disconnects
(If Applicable)
Drain
External
Pump Power
Low
Voltage to
Thermostat
GroundLoop Connector
Kits withArmaflex ®
(CK4S or CK4L)
P/T Plugs
Vibration Absorbing Pad
Multiple Units on One Flow Center
When two units are connected to one loop pumping system, pump control is automatically achieved by
connecting the SL terminals on connector P2 in both
units with 2-wire thermostat wire. These terminals are
polarity dependant. The loop pump(s) may be powered
from either unit, whichever is more convenient. If either
unit calls, the loop pump(s) will automatically start. The
use of two units on one flow center is generally limited to
a total of 20 GPM capacity.
Figure 7: Primary/Secondary Hook-up
Premier to Premier
Microprocessor Units
Premier Unit #1
Premier Unit #1
Shut
Down
C
C
Premier to
Electromechanical Unit
SL1 SL1 SL2 SL2
In Out In Out
Shut
Down
C
C
SL1 SL1 SL2 SL2
In Out In Out
With pump
wired to Unit 1
With pump
wired to
Unit 2
Shut
Down
C
C
SL1 SL1 SL2 SL2
In Out In Out
Premier Unit #2
8
C
S
To Electromechanical Unit
PREMIUM INSTALLATION MANUAL
Open Loop Ground Water Systems
Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent
mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensure
proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in
Capacity Tables in the Specification Catalog. Normally, about 2 GPM flow rate per ton of cooling capacity (1.5 GPM per ton
minimum at 50°F) is needed in open loop systems.
Note: For open loop/ground water systems or systems that do not contain an antifreeze solution, set SW2-Switch #2 to the
“WELL” position.
Figure 8: Open System - Groundwater Application
Unit Supply
Aux. Heat Supply
Flexible
Duct Collar
Rubber Bladder
Expansion Tank
Auxiliary
Heater
Knockout
Desuperheater
Connections
Flow Control
Valve
(on outlet of
Solenoid Valve)
Solenoid
Valve
Water Out
Water In
Drain
Shut Off Valves
Disconnects
(If Applicable)
Compressor
Line Voltage
Shut Off Valves
(to isolate solenoid
valve while acid flushing)
Low Voltage
P/T Plugs
to Thermostat
Vibration
and Valve
Absorbing Pad
Strainer
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 field,
adjacent stream or pond, etc.). Most local codes forbid using
the sanitary sewer for disposal. Consult your local building and
zoning department to assure compliance in your area.
The water control solenoid is wired between the common pin
#2 connector P1 and pin #3 connector P3, and a jumper wire is
connected between R and pin #1 connector P3 (refer to Figure
9). Notice that DIP switch 2-3, located on the PCB, must be
switched to the “Comp” position so the valve will operate with the
compressor.
Boiler Drains
For HX Flushing
Figure 9: Typical single-stage external 24V water
solenoid valves (type PPV100 or BPV100) wiring
P1
Solenoid
Valve
C
2
R
1
ACC Com
1
ACC NC
2
ACC NO
3
Note: Switch SW2 - 3 to comp position.
9
PREMIUM INSTALLATION MANUAL
Boiler/Cooling Tower Closed Loop Systems
Boiler/Cooling Tower
The water loop is usually maintained between 60°F and 90°F. Premium units allow 25°F to 110°F EWT for proper heating and cooling operation.
To reject excess heat from the water loop, the use of a closed circuit evaporative cooler or an open type cooling tower
with a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower is
used without a secondary heat, continuous chemical treatment and filtering of the water must be performed to ensure the
water is free from damaging materials.
Water Piping Connections
Units should not be connected to the supply and return piping until the water system has been cleaned and flushed
completely. Supply and return water connections are standard female pipe thread on commercial units (1-inch swivel on
residential units). Never use flexible hoses with an inside pipe diameter that is smaller than the water connections on the
unit and limit the hose length to 10 feet or less per connection. High-pressure flexible hoses provide sound attenuation for
both normal unit operating noise and hydraulic pumping noise. Hard piping can also be brought directly to the unit although
it is not recommended since no vibration or noise attenuation can be accomplished.
10
PREMIUM INSTALLATION MANUAL
System Cleaning and Flushing
Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris. If
the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit
location to prevent the introduction of dirt into the unit, (see Figure 10). The system should be filled at the water makeup
connection with all air vents open. After filling, vents should be closed.
The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked
in sequence to bleed off any trapped air and to verify circulation through all components of the system.
As water cirulates through the system, the contractor should check and repair any leaks found in the piping system.
Drain(s) at the lowest point(s) in the system should be opened for the initial flush and blowdown, making sure water fill
valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the makeup water
valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at
least two hours, or longer if required, unil drain water is clean and clear.
The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to
completely drain the system. Short circuited supply and return runouts should now be connected to the unit supply and
return connections.
Refill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly
alkaline (pH 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade
antifreeze designed for HVAC systems only. Environol™ brand antifreeze is recommended.
Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the
system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog
valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor
service life and can cause premature unit failure. In boiler/tower applications, set the loop control panel set points to desired
temperatures. Supply power to all motors and start the circulating pumps. After full flow has been established through all
components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the
units will be ready for check, test and start up and for air and water balancing.
Note: For closed loop systems with antifreeze protection, set SW2-2 to the “LOOP” position.
Figure 10: Flushing with Water Shutoff Valve Equipped Systems
Return Runout
Supply Runout
Mains
Rubber Hose
Runouts initially
connected together
11
PREMIUM INSTALLATION MANUAL
Desuperheater Connections
Water Tank Preparation
Figure 11: Water Heater Connection Kit
Electric water heaters are recommended for use with the
desuperheater in potable water systems. A tank with a 50-gallon
minimum capacity should be installed. Multiple tanks may be piped
in series to create larger buffer tanks.
Brass Nipple
Boiler Drain
Male Adapter
Brass Tee
Figure 13: Typical Desuperheater Installation
Figure 12: Desuperheater Installation In Preheat Tank
Venting Waste Valve
or Vent Coupling
3/4” x 3/4” x 1/2” tee
DHW
Water Out
Cold
Water In
Venting Waste Valve
or Vent Coupling
Hot
Water Out
P/T Relief
Valve
3/4” x 3/4” x 1/2” tee
DHW
Water Out
P/T Relief
Valve
Cold
Hot
Water In Water Out
P/T Relief
Valve
In
In
DHW
Water In
Drain Valve
DHW
Water In
Drain Valve
Note: Desuperheater pump mounted externally with commercial units; internally in residential units.
12
Drain Valve
PREMIUM INSTALLATION MANUAL
Initial Desuperheater Startup
Plumbing Installation
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove drain valve and fitting from water heater.
Thread the 3/4-inch NPT x 3 1/2-inch brass nipple into the water heater drain port.
Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.
Attach the 1/2-inch SWT x 3/4-inch NPT copper adapter to the side of the tee closest to the unit.
Install the drain valve on the tee opposite the adapter.
Run interconnecting tubing from the tee to DHW “WATER OUT” at the unit.
Cut the cold water “IN” line going to the water heater.
Insert the 3/4-inch x 3/4-inch x 1/2-inch reducing solder tee “IN” line with cold water line as shown.
Run interconnecting copper tubing between the unit DHW “WATER IN” and the tee (1/2-inch nominal) using (2) 1/2-inch
sweat x 1-inch MPT adapters. The recommended maximum distance is 50 ft.
10. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.
11. Insulate all exposed surfaces of both connection water lines with 3/8-inch wall closed cell insulation.
Note: All plumbing and piping connections must comply with local plumbing codes.
Desuperheater Startup
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Close the drain valve to the water heater.
Open the cold water supply to the tank.
Open the hot water faucet in the house to bleed air from the system. Close when full.
Depress the handle on the pressure relief valve to bleed any remaining air from the tank then close.
If so equipped, unscrew the indicator plug on the motor end of the pump until all air is purged from the pump, then
tighten the plug. Use vent couplings to bleed air from the lines.
Carefully inspect all plumbing for water leaks and correct as required.
Before restoring electrical supply to the water heater, adjust the temperature setting on the tank.
• On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting,
approximately 100°F. The upper element should be adjusted to 120°F to 130°F. Depending upon the specific
needs of the customer, you may want to adjust the upper element differently.
• On tanks with a single element, lower the thermostat setting to 120°F.
After thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater.
Make sure that any valves in the desuperheater water circulating circuit are open.
Turn on the Premium unit to first stage heating.
The DHW pump should be running. Be sure the disable switch for the DHW pump (SW4) is ON. The DHW OFF
LED on the unit should not be illuminated.
The temperature difference between the water entering and leaving the desuperheater should be 5°F to 15°F. The
water flow should be approximately 0.4 GPM per ton of nominal cooling.
Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal.
When the pump is first started, open the inspection port (if equipped) until water dribbles out, then replace. Allow
the pump to run for at least five minutes to ensure that water has filled the circulator properly.
CAUTION: Never operate the DHW circulating pump while dry. If the unit is placed in operation
before the desuperheater piping is connected, be sure that the pump switch is set to the OFF
position.
Desuperheater Note: When servicing a unit’s refrigeration circuit, it is always good practice to disable the desuperheater
pump. This can be accomplished by using the DHW pump disable switch located on the front of the unit cabinet near
the LED annunciator panel. The red DHW OFF LED will illuminate, indicating the DHW pump is disabled.
13
PREMIUM INSTALLATION MANUAL
Electrical Connections
General
Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage
wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.
Unit Power Connection
Connect the incoming line voltage wires to L1 and L2 or L1, L2, and L3 of the contactor as shown in Figures 14 and 15.
(For more information, refer to the Unit Electrical Data section in the Specification Catalog SP1555.)
External Loop Pump Power Connection
If the unit is to be used with an external loop pump (FC1 or FC2 flow center), the pump(s) will be connected to the terminals
on PB1 in the unit electrical box as shown in Figures 14 and 15. The pumps will automatically be cycled as required by the
unit or by an SL signal from another Premium unit sharing the flow center.
Accessory Relay
A set of “dry” contacts has been provided to control accessory devices, such as 2-wire water solenoid valves on open
loop installations, electronic air cleaners, humidifiers, etc. This relay contact should be used only with 24 volt signals and not
line voltage power. The relay has both normally open and normally closed contacts and can operate with either the fan or the
compressor. Use DIP switch SW2-3 to cycle the relay with fan or compressor. The relay contacts are available on terminals #2
and #3 of P3. The default value of the switch is set to operate with fan. For use with electronic air filter.
208 Volt Operation
All Premium units are factory wired for 230 volt operation. There is a switch located on the control box which allows the
installer to select 208 volt unit operation. Refer to Figures 14 and 15 below for switch location.
Figure 14: Line Voltage 208-230/60/1 Control Box
Figure 15: Line Voltage 208-230/60/3 Control Box
Compressor
Capacitor
Compressor
Contactor
208-230/60/1
Service with
Ground
Transformer
L3
L2
L1
Transformer
L2
L1
Compressor Ground
Contactor
Lugs
Ground
Lugs
Voltage
Selection
Rocker Switch
PB1
Voltage
Selection
Rocker Switch
PB1
PS
A
Unit Control
Board
208-230/60/3
Service with
Ground
PS
C D
A
External Loop Pump(s)
208-230/60/1
1/2 HP Max
Unit Control
Board
14
C D
External Loop Pump(s)
208-230/60/1
1/2 HPMax
PREMIUM INSTALLATION MANUAL
Electronic Thermostat Installation
F1
F1
N.O.
N.C.
N.O.
N.O.
N.O.
Com
Com
CR1- DHW
Pump
CR2- Loop
Pump
CC-GND
CC
CCLO
CCHI
P4
SW1
Off On
1
2
3
4
5
6
7
8
9
10
11
12
P1
1
3 4
5
7
8
R C Y1 Y2 W O G
L
2
CR4-
CR3-
9
10
11
12
13
14
15
16
8
9
10
11
12
13
14
Microprocessor
C
C
R
R
1 2 3
240V - L2
240V - L2
Fused L2
Fused L2
Fused L2
Fused L2
Fused L1
240V - L1
240V - L1
Figure 17: Logic Board Physical Layout
6
1
SW2
Off On
1
2
3
4
5
6
7
8
P2
2 3 4
Shut C
Down
SW3
Off On
5
6
1
2
3
4
5
7
C SL1 SL1 SL2 SL2
IN Out IN Out
1
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
P6
P5
P3
2 3
ACC ACC ACC
NO NC COM
15
C
Y1
Y2
W
O
G
L
24VAC (Common)
Compressor (1st Stage)
Compressor (2nd Stage)
Aux. Heat
Reversing Valve
Blower Relay
System Monitor
Thermostat Connection
Note: DIP switch SW2-#8 is required to be in the “OFF” position for
the control to recognize the 24VAC thermostat inputs. The second
stage compressor wire must be installed between the unit and the
thermostat for proper control operation.
Microprocessor Controller
Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle
of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors
and secure base to the wall. Thermostat wire must be 8-conductor 18 AWG wire. Strip the wires back 1/4-inch (longer strip
lengths may cause shorts) and insert the thermostat wires into the
connector as shown. Tighten the screws to insure tight connections.
Figure 16: Thermostat Wiring
The thermostat has the same type connectors, requiring the same
wiring. See instructions enclosed in the thermostat for detailed
24VAC (Hot)
R
installation and operation information.
PREMIUM INSTALLATION MANUAL
Fan Performance Data
ECM2 Motor
MAX
MODEL
ESP
P019
0.5
P022
0.5
P028
0.5
P034
0.5
P040
0.5
P046
0.5
P040
w/1hp*
P046
w/1hp*
0.75
0.75
P056
0.75
P066
0.75
AIRFLOW DIP SWITCH SETTINGS
1
2
3
4
5
6
7
8
9
10
11
12
300
400
500
600
700
800
–
–
–
–
–
–
L
M
H
400
500
600
700
800
900
–
–
–
–
–
L
M
H
600
700
800
900
1000
1100
–
–
–
600
700
800
900
1000
1100
1150
1225
1300
1375
1475
–
–
1325
1375
1475
1550
1600
–
–
400
500
–
–
–
L
M
H
L
650
750
850
950
L
M
1050
1150
1250
M
H
1325
H
1150
1250
650
750
850
950
1050
800
1000
1100
1300
1500
–
–
–
–
–
–
L
M
800
1000
1100
1500
1600
1800
–
–
–
–
L
M
900
1000
1600
1700
1850
2000
2200
2300
2400
2000
2200
2300
2400
L
750
750
900
M
H
–
H
1000
1300
H
1200
1400
L
M
1200
1400
H
1600
L
1700
1850
M
H
Notes: Factory settings are at recommended L-M-H DIP switch locations.
Factory L setting is minimum allowed for cooling.
M-H settings must be located within shaded CFM range.
CFM is controlled within 5% up to the maximum ESP.
Max ESP includes allowance for wet coil and standard filter.
* With optional 1 HP fan motor.
A 12-position DIP switch package on the control allows the airflow levels to be set for low,
medium, and high speed when using the ECM2 blower motor. Only three of the DIP switches
can be in the "on" position.
• The first "on" switch (the lowest position number) determines the low speed fan setting.
• The second "on" switch determines the medium speed fan setting.
• The third "on" switch determines the high speed fan setting.
The example to the right shows SW1 on the control board configured for the following P028
airflow settings.
Low Speed Fan: 500 CFM
Medium Speed Fan: 700 CFM
High Speed Fan: 900 CFM
Off
SW1
On
1
2
3
4
5
6
7
8
9
10
11
12
16
PREMIUM INSTALLATION MANUAL
Fan Performance Data
PSC Motor
AIRFLOW (CFM) AT EXTERNAL STATIC PRESSURE (IN. WG)
FAN
MOTOR
MODEL SPEED
0.05
HP
H
P010
MH
1/10
P019
P034
P040
0.40
0.45
0.50
0.60
0.70
0.80
0.90
1.00
340
330
310
300
–
–
–
–
–
380
370
350
330
310
300
280
270
–
–
–
–
–
340
330
310
290
280
270
250
240
–
–
–
–
–
L
310
300
280
270
250
240
230
220
210
200
–
–
–
–
–
450
440
420
410
390
370
350
340
320
310
–
–
–
–
–
400
390
380
370
350
340
320
310
290
280
–
–
–
–
–
ML
370
360
340
330
310
300
290
280
260
250
–
–
–
–
–
L
330
320
310
300
290
280
260
250
230
220
–
–
–
–
–
H
790
780
775
770
765
760
740
720
690
670
610
–
–
–
–
720
690
685
680
670
660
650
640
620
600
–
–
–
–
–
590
570
560
550
545
540
530
520
510
500
–
–
–
–
–
1020
990
960
930
900
870
850
830
800
770
690
–
–
–
–
860
840
820
800
780
760
740
720
690
670
–
–
–
–
–
L
720
700
680
650
640
620
600
580
570
550
–
–
–
–
–
H
1120 1100 1070 1050 1040 1030 1020 1010 1000
980
830
–
–
–
–
1020 1000
980
960
920
880
860
840
820
790
–
–
–
–
–
L
860
840
830
810
800
780
760
740
710
H
1360 1340 1300 1270 1230 1200 1170 1150 1120 1090
MH*
M
1/10
1/6
M
M
1/5
1/3
850
–
–
–
–
–
990
870
–
–
–
1190 1170 1140 1120 1090 1060 1030 1010
970
930
–
–
–
–
–
L
1010
990
860
840
–
–
–
–
–
H
–
–
–
–
–
–
–
M
M
1/2
1/2
M
1/2
H
M
3/4
H
M
L
940
920
900
880
–
–
1170 1160 1150 1140 1130 1120 1100 1080 1050 1030
–
–
–
–
1870 1820 1780 1750 1720 1680 1630 1580 1450 1330 1190
–
–
–
–
1710 1660 1630 1590 1560 1530 1490 1460 1410 1370
–
–
–
–
–
1280 1250 1230 1220 1200 1180 1150 1120 1090 1050
–
–
–
–
–
–
–
–
2180 2160 2130 2100 2070 2040 1990 1910 1810 1690
–
2030 2010 1990 1970 1950 1930 1910 1880 1850 1830 1780
–
–
–
–
1790 1770 1760 1750 1730 1720 1700 1690 1670 1640
–
–
–
–
–
1
950
–
–
L
970
1730 1700 1670 1650 1620 1580 1540 1490 1400 1290
1510 1500 1490 1480 1450 1430 1400 1380 1350 1320
–
L
P066
0.35
360
360
L
P056
0.30
380
400
H
P046
0.25
410
370
H
P028
0.20
420
410
L
P022
0.15
440
ML*
H
P013
0.10
450
–
–
–
–
2540 2520 2490 2460 2430 2410 2320 2230 2130 1980 1820
2430 2390 2360 2340 2310 2290 2270 2250 2220 2190 2120 2050
–
–
–
2000 1980 1970 1950 1930 1920 1900 1860 1830 1780
–
–
–
Notes: Includes allowance for wet coil and clean factory installed filter.
A “ – “ in the table indicates operating range is not recommended.
Factory settings indicated in bold print.
* At 265V, the P010 is shipped on ML and the P013 on MH.
17
–
–
PREMIUM INSTALLATION MANUAL
Standard Microprocessor Control Operation
The Premium control system is a microprocessor-based printed circuit board conveniently located in the unit control box
for easy accessibility. The microprocessor provides control of the entire unit as well as outputs for status modes, faults, and
diagnostics. Low voltage terminal strips provide all necessary terminals for field connections. LEDs are located on the front
of the unit for quick inspection without removing any access panels. The control offers optimal space conditioning. The
board accepts traditional 24VAC thermostat inputs.
Startup
The unit will not operate until all the inputs and safety controls are checked for normal conditions. At first power-up, a fourminute delay is employed before the compressor is energized.
Component Sequencing Delays
Components are sequenced and delayed for optimum space conditioning performance.
Accessory Relay
An accessory relay on the control board allows for field connection of solenoid valves, electronic air cleaners, etc. The
accessory relay has a normally open output and a normally closed output. The accessory relay is factory set to control the
optional electronic air-cleaner.
Short Cycle Protection
The control employs a minimum “off” time of four minutes and a minimum “on” time of two minutes to provide for short
cycle protection of the compressor.
Loop Pump SL Signals
A signal between multiple Premium control boards at the SL inputs and outputs (SL1-In and Out) will provide for remote
control of the loop pump on any unit.
Condensate Overflow Protection
The Premium control board incorporates an impedance sensing liquid sensor at the top of the drain pan. Upon a continuous
30-second sensing of the condensate, compressor operation is suspended (see fault retry), the condensate overflow lockout
LED begins flashing, and an output signal (LO) is made available for conneciton to a “fault” LED at the thermostat.
Shutdown Input
A simple grounded signal to the “shutdown” input on the control board puts the unit into shutdown mode. Compressor, hot
water pump and fan operaiotn are suspended
Safety Controls
The Premium control receives separate signals for a high pressure switch for safety, a low pressure switch to prevent loss of
charge damage, and a low suction temperature thermistor for freeze protection. Upon a continuous 30-second measurement
of the fault (immediate for high pressure), compressor operation is suspended (see fault retry), the appropriate lockout LED
begins flashing, and an output signal (LO) is made available for connection to a “fault” LED at the thermostat.
Testing
The Premium control allows service personnel to shorten most timing delays for faster diagnostics (see field selection DIP
switch #1).
Fault Retry
All faults (except for low RPM fault with the ECM2 fan motor) are retried twice before finally locking the unit out. The “fault
retry” feature is designed to prevent nuisance calls.
18
PREMIUM INSTALLATION MANUAL
Standard Microprocessor Control Operation
Diagnostics
The Premium control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board
diagnosis (see field selection DIP switches #6 and #7).
Resistance Heat Control
For units equipped with internal electric heaters, the electric heat control module contains the appropriate high-voltage
control relays. Control signals energize the relays in the proper sequence, and the LED display board indicates which stages
are energized.
Fan Speed Control
A DIP switch on the Premium control allows field selection of low and medium fan speeds for cooling in the dehumidification
mode or medium and high fan speeds for cooling in the normal mode (ECM2 version only).
Hot Water High Limit
This mode occurs when the hot water thermistor temperature is at or above 130°F for 30 continuous seconds. The DHW
limit status LED on the unit illuminates, and the hot water pump de-energizes. Hot water pump operations resume on the next
compressor cycle or after 30 minutes of continuous compressor operation during the current thermostat demand cycle.
Hot Water Pump Switch
When the pump switch is engaged, hot water pump operation is disabled, and the pump status LED on the unit illuminates.
ECM2 Airflow Selection DIP Switches (SW1)
A 12-position DIP switch package on the Premium control allows the airflow levels to be set for low, medium and high speed
when using the ECM2 blower motor (refer to the Blower table on page 16).
Only three of the DIP switches can be in the “on” position. The first “on” switch (the lowest position number) determines
the “low speed fan” setting. The second “on” switch determines the “medium speed fan” setting, and the third “on” switch
determines the “high speed fan” setting.
19
PREMIUM INSTALLATION MANUAL
Dip Switch Settings
Field Selection DIP Switches (SW2)
An eight-position DIP switch package on the control allows the field selectable options shown in the table below.
FIELD SELECTION DIP SWITCHES (SW2)
DIP SWITCH
NUMBER
DESCRIPTION
OFF POSITION
ON POSITION
SW 2-
1
Service Test Mode
Allows field selection of “normal” or “test”
operational modes. Test mode accelerates most timing
functions 16 times to allow faster troubleshooting. Test
mode also allows viewing the current status of the fault
inputs on the LED display.
Test Mode
Normal Timing
Operation
SW 2-
2
Freeze Protection Setting
Allows field selection of freeze thermistor fault sensing
temperatures for well water (30°F) or antifreeze-protected (15°F) earth loops.
Loop Water
Freeze Protection
15°F
Well Water
Freeze Protection
30°F
SW 2-
3
Accessory Relay
Allows field selection of the accessory relay to operate
with the compressor or fan.
Acc Relay Tracks
Fan
Acc Relay Tracks
Compressor
SW 2-
4
Fan Speed Control
Allows field selection of reduced fan speed (85% of selected medium and high speed - ECM only) for cooling
in the dehumidification mode.
Dehumidification
Fan Speeds
Normal Fan
Speeds
SW 2-
5
Auxiliary Off
Disables third-stage heating. Full emergency heat
would still be available if needed.
Disable Heating
Stage 3
Enable Heating
Stage 3
SW 2-
6
Diagnostics-Inputs
Allows viewing the inputs from the thermostat to the
control board such as Y1, Y2, O, G, W, and SL1-In on
the LED display.
Diagnostic
Inputs/Output
Viewed at LEDs
Normal Display
Viewd at LEDs
SW 2-
7
Diagnostics-Outputs
Allows viewing the outputs from the control board such
as compressor, reversing valve, blower, hot water
pump, and loop pump on the LED display
Diagnostic
Outputs Viewed
at LEDs
Normal Display
Viewed at LEDs
SW 2-
8
Thermostat Selection
Allows field seleciton of the type of thermostat being connected to the Premium control. The DIP switch should be
in the “off” position for 24VAC thermostats.
24 VAC
Thermostats
N/A
20
PREMIUM INSTALLATION MANUAL
Dip Switch Settings
Factory Setup DIP Switches (SW3)
A five-position DIP switch package on the control allows the field selectable options shown in the table below.
FACTORY SETUP DIP SWITCHES (SW3)
DIP SWITCH
NUMBER
DESCRIPTION
OFF POSITION
ON POSITION
SW 3-
1
Single-Speed
Configures the control for single-speed compressor
operation and should always be left in the “ON” position.
Two-Speed Operation
Single-Speed
Operation
SW 3-
2
ECM/ECM2
ECM Fan Motor
ECM2 Fan Motor
Operation
SW 3-
3
No RPM/RPM
Configures the control to monitor the RPM output of an
ECM/ECM2 blower motor. When using IntelliZone with a
PSC fan motor, the control should be configured for “NO
RPM” sensing.
PSC Fan/RPM
Monitoring
Disabled
ECM2 Fan/RPM
Monitoring
Enabled
SW 3-
4
AT EH Board / Premium EH Board.
Configures the control to operate with the Premium electric
heat control board (17P514A01) or with the Premium electric heat control board (17P501A01).
Electric Heat Control 17P501A01
Electric Heat Control 17P514A01
SW 3-
5
Future Use
Future Use
Future Use
Configures the control to operate with the ECM blower Operation
motor (motor with square control on end) or with the
ECM2 blower motor.
21
PREMIUM INSTALLATION MANUAL
FX10 Control Operation
(Optional Microprocessor)
FX10 Advanced Control
The Johnson Controls FX10 board is specifically designed for commercial heat pumps and provides control of
the entire unit as well as input ports for Open N2, LonTalk,
BacNet communication protocols as well as an input port
for a user interface. The user interface is an accessory
item that can be used to aid in diagnostics and unit setup.
A 16-pin low voltage terminal board provides terminals for
common field connections. The FX10 Control provides:
•
•
•
•
•
•
•
•
Operational sequencing
High and low-pressure switch monitoring
General lockout
Freeze protection
Condensate overflow sensing
Lockout mode control
Emergency shutdown mode
Random start and short cycle protection
Short Cycle Protection
Allows a minimum compressor “off” time of four minutes and a minimum “on” time of two minutes.
Random Start
A delay of 1 to 120 seconds is generated
after each power-up to prevent simultaneous startup of all
units within a building after the release from an unoccupied
cycle or power loss.
Emergency Shutdown
A field-applied dry contact can be used to place the
control into emergency shutdown mode. During this
mode, all outputs on the board are disabled.
Freeze Protection
Field selectable for 15° or 30°F (-9° or -1°C)
Installation Options
• Stand-alone controlled by standard room thermostat
• Stand-alone with a Zone Temperature Sensor (must
have user interface to change set points beyond the
allowed +/- 5°F)
• Integrated into BAS by adding communication module
Inputs/Outputs
• 6 Analog Inputs
• 12 Digital Inputs
• 9 Digital Output Relays (or 7 relays & 2 triacs)
Accessory Outputs
Quantity 2. One cycled with fan, other with compressor.
Main FX10 Board
(Shown with optional communication card)
User Interface
4 x 20 backlit LCD.
Optional Plug-in Communication Modules (compatible with standard BAS protocols)
• Open N2
• LonTalk
• BacNet
Display
Requires DLI Card/Kit. Up to 2 displays, either 1 local
and 1 remote, or 2 remote. (A 2-display configuration
requires identical displays.) Local display can be up to 3
meters from the controller, power supply, and data communication. Remote display can be up to 300 meters from the
controller. Remote display must be independently powered
with data communication done via 3 pole shielded cable.
Control Timing & Fault Recognition Delays
Lead compressor “ON” delay
30 seconds
Lag compressor “ON” delay
60 seconds
(not applicable for single compressor models)
Minimum compressor “ON” time
2 minutes
(except for fault condition)
Short cycle delay
4 minutes
Random start delay
0-120 seconds
High pressure fault
<1 second
Low pressure fault
30 seconds
Freeze protection fault
30 seconds
Condensate overflow fault
30 seconds
Low pressure fault bypass
2 minutes
Freeze protection fault bypass
2 minutes
Note: Refer to Submittal Data SD1981 or Application
Guide AGFX10 for more information.
22
PREMIUM INSTALLATION MANUAL
Startup Procedures
Before Powering Unit, Check The Following :
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
High Voltage is correct and matches nameplate.
Fuses, breakers and wire size correct.
Low voltage wiring complete.
Piping completed and water system cleaned and flushed.
Air is purged from closed loop system.
Isolation valves are open, water control valves or loop pumps wired.
Condensate line open and correctly pitched.
Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been installed in models
019-066.
Dip switches are set correctly.
DHW pump switch is “OFF” unless piping is completed and air has been purged.
Blower rotates freely – foam shipping support has been removed.
Blower speed correct (DIP switch setting ECM blowers only).
Air filter/cleaner is clean and in position.
Service/access panels are in place.
Return air temperature is between 50-80ºF heating and 60-95ºF cooling.
Air coil is clean.
Startup Steps
Note: Complete the Equipment Startup/Commissioning Check Sheet during this procedure. Refer to thermostat operating
instructions and complete the startup procedure.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
15.
16.
17.
18.
19.
Initiate a control signal to energize the blower motor. Check blower operation. Desuperheater pump should be deenergized.
Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.
First stage cooling will energize after a time delay.
Be sure that the compressor and water control valve or loop pump(s) are activated.
Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T
plugs and comparing to unit capacity data in specification catalog.
Check the temperature of both the supply and discharge water. (Refer to the table on page 25.)
Check for an air temperature drop of 15°F to 20°F across the air coil, depending on the fan speed and entering water
temperature.
Decrease the cooling set point several degrees and verify high-speed blower operation.
Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps
deactivate.
Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set above room temperature.
First stage heating will energize after a time delay.
Check the temperature of both the supply and discharge water. (Refer to the table on page 25.)
Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the fan speed and entering water
temperature.
If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on
when the thermostat is in the Emergency Heat mode. Check amperage of each element.
Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps
deactivate.
During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.
Set system to desired normal operating mode and set temperature to maintain desired comfort level.
Instruct the owner/operator in the proper operation of the thermostat and system maintenance.
23
PREMIUM INSTALLATION MANUAL
Description of Unit Operation
Note: Fan speed operation below applies only to units equiped with ECM blower motors.
Heating Operation
Heat, 1st Stage (Y1)
The fan motor is started on low speed immediately, the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the “Y1” input. The fan is switched to medium
speed 15 seconds after “Y1” input. The hot water pump is cycled 30 seconds after the “Y1” input.
Heat, 2nd Stage (Y1, Y2)
The hot water pump is de-energized, which directs all heat to satisfying the thermostat, and the fan changes to high
speed 15 seconds after the “Y2”input.
Heat, 3rd Stage (Y1, Y2, W)
The first stage of resistance heat is energized 10 seconds after “W” input, and with continuous 3rd stage demand, the
additional stages of resistance heat engage sequentially every 5 minutes.
Emergency Heat
The fan is started on high speed, and the first stage of resistance heat is energized 10 seconds after the “W” input.
Continuing demand will engage the additional stages of resistance heat sequentially every 2 minutes.
Cooling Operation
In all cooling operations, the reversing valve directly tracks the “O” input. Thus, anytime the “O” input is present, the
reversing valve will be energized.
Cool, 1st Stage (Y1,O)
The fan motor is started on low speed immediately, the loop pump is energized 5 seconds after the “Y1” input is
received, and the compressor is energized 10 seconds after the “Y1” input. In the ECM2 version, the fan is switched to medium speed 15 seconds after “Y1” input (remains in low speed if in dehumidification mode). The hot water pump is cycled
30 seconds after the “Y1” input.
Cool, 2nd Stage (Y1, Y2, O)
The fan changes to high speed (85% of high speed if in dehumidification mode) 15 seconds after the “Y2” input.
Fan (G only)
The fan starts on low speed. Regardless of fan input “G” from thermostat, the fan will remain on low speed for 30
seconds at the end of each heating, cooling or emergency heat cycle.
Lockout Conditions
During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The compressor, loop pump, hot
water pump, and accessory outputs are de-energized. Unless the lockout is caused by an ECM2 low RPM fault, the fan will
continue to run on low speed. If the thermostat calls for heating, emergency heat operation will occur.
Lockout modes of any kind can be reset at the thermostat after a 5-second waitinng perioud, which restores normal
operation but keeeps the unit lockout LED illuminated. Interruption of power to the unit will reset a lockout without a waiting
period and clear all lockout LEDs.
High Pressure
This lockout mode occurs when the normally closed safety switch is opened momentarily.
Low Pressure
This lockout mode occurs when the normally closed low pressure switch is opened for 30 continuous seconds.
Freeze Protection (Water Flow)
This lockout mode occurs when the freeze thermistor temperature is at or below the selected freeze protection point
(well 30°F or loop 15°F) for 30 continuous seconds.
Condensate Overflow
This lockout mode occurs when the condensate overflow level has been reached for 30 continuous seconds.
Fan RPM
When equipped with an ECM2 fan motor, the Premium control board monitors fan RPM to sense operation. This
lockout mode occurs if the fan RPM falls below the low RPM limit (100 RPM) for 30 continuous seconds.
24
PREMIUM INSTALLATION MANUAL
Operation Logic
HEATING
OPERATION LOGIC
DATA
STG1
STG2
COOLING
STG3
EMERG
STG1
STG2
FAN ON
SL1 - IN ON
Compressor
On
On
On
Off
On
On
–
–
ECM2 Normal
Med
High
High
High
Med
High
Low
–
ECM2 Dehumidify
Med
High
High
High
Low
Med
Low
–
PSC
Low
High
High
High
Low
High
–
–
Rev Valve
Off
Off
Off
Off
On
On
–
–
Loop Pump
On
On
On
Off
On
On
–
On
DHW Pump
On
Off
Off
Off
On
On
–
–
Aux Heater
Off
Off
Staged
Staged
Off
Off
–
–
SL 1- Out
On
On
On
Off
On
On
–
–
Emerg LED
On
Off
Off
On
Off
Off
Off
–
T-Stat Signal
Y1
Y1, Y2
Y1, Y2, W
W
Y1, O
Y1, Y2, O
G
–
Typical Water and Air Temperature Changes
WATER
WATER TEMPERATURE CHANGE
FLOW RATE
RISE (CLG)
DROP (HTG)
3 GPM/TON
9-12
4-8
1.5 GPM/TON
20-26
10-17
AIR TEMPERATURE CHANGE
DROP (CLG)
RISE (HTG)
15-20
20-35
Water Pressure Drop
UNIT
P010
P013
P019
P022
P028
P034
P040
P046
P056
P066
GPM
1.5
2.0
2.5
1.5
2.5
3.5
3.0
4.0
5.0
3.0
4.5
6.0
4.0
5.5
7.0
5.0
7.0
9.0
5.0
8.0
11.0
6.0
9.0
12.0
8.0
11.0
14.0
10.0
13.0
16.0
PRESSURE DROP (PSI)
30° EWT
50° EWT
70° EWT
90° EWT
110° EWT
2.1
3.4
5.2
2.0
4.6
8.1
1.2
2.1
3.5
1.5
3.2
6.0
1.2
2.1
3.2
2.4
3.9
6.2
1.7
3.5
6.2
2.2
4.5
7.2
2.6
4.8
7.5
3.7
6.1
9.3
2.0
3.2
4.9
1.9
4.4
7.7
1.2
2.0
3.3
1.4
3.1
5.8
1.2
2.0
3.1
2.2
3.7
5.9
1.6
3.3
5.9
2.1
4.3
6.8
2.5
4.6
7.2
3.5
5.8
8.9
2.0
3.1
4.7
1.9
4.2
7.4
1.1
2.0
3.2
1.3
3.0
5.6
1.1
2.0
3.0
2.2
3.6
5.7
1.5
3.2
5.7
2.1
4.1
6.6
2.4
4.4
6.9
3.4
5.6
8.6
1.9
3.0
4.6
1.8
4.1
7.2
1.1
1.9
3.1
1.3
2.9
5.4
1.1
1.9
2.9
2.1
3.5
5.5
1.5
3.1
5.5
2.0
4.0
6.4
2.4
4.3
6.7
3.3
5.5
8.3
1.8
2.9
4.5
1.7
4.0
7.0
1.1
1.8
3.0
1.3
2.8
5.2
1.1
1.8
2.8
2.0
3.4
5.3
1.5
3.0
5.3
1.9
3.9
6.2
2.3
4.1
6.5
3.2
5.3
8.1
25
PREMIUM INSTALLATION MANUAL
Troubleshooting
To check the unit control board for proper operation:
1. Disconnect thermostat wires at the control board.
2. Jumper the desired test input (Y1, Y2, W, O, or G) to the R terminal with the SW2-8 in the “OFF” position to simulate a
thermostat signal.
3. If control functions properly:
- Check for thermostat and field control wiring (use the diagnostic inputs mode).
4. If control responds improperly:
- Ensure that component being controlled is functioning (Compressor, Blower, Reversing Valve, etc.)
- Ensure that wiring from control to the component is functioning (use the diagnostic outputs mode).
- If steps above check properly, replace unit control.
Note: Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.
LED Definition Table
DIAGNOSTIC MODES
NORMAL DISPLAY
MODE
LED
CURRENT FAULT
STATUS
INPUTS
OUTPUTS 1
OUTPUTS 2
1-Off, 6-On, 7-On
1-N/A, 6-Off,
7-On
1-N/A, 6-On,
7-Off
1-N/A, 6-Off,
7-Off
Drain Pan Overflow
Y1
Compressor
Blower Low
FP Thermistor
(Loop<15°F, Well<30°F)
Y2
Not Used
Blower Med
High Pressure >380 PSI
O
RV
Blower High
Low Pressure <15 PSI
G
Fan
Aux Heat #1
ECM2 RPM <100 RPM
W
DHW Pump
Aux Heat #2
Not Used
SL1
Loop Pump
Aux Heat #3
DHW Limit
Field Selection DIPs:
1-On, 6-On, 7-On
Drain Pan Overflow
Lockout
FP Thermistor
(Loop <15°F Well<30°F)
Lockout
High Pressure >380 PSI
Lockout
Low Pressure <15 PSI
Lockout
ECM2 RPM<100 RPM
Lockout
Microprocessor
Malfunction
HWL Thermistor >130°F
HWL Thermistor >130°F
Not Used
Not Used
Aux Heat #4
DHW Off
DHW Pump Switch Off
DHW Pump Switch Off
–
–
–
Drain
Water Flow
High
Pressure
Low
Pressure
Airflow
Status
Typical Superheat/Subcooling
HEATING
COOLING
ENTERING WATER
TEMPERATURE
SUPERHEAT
SUBCOOLING
SUPERHEAT
SUBCOOLING
30
9 - 14
5-9
25 - 35
15 - 25
50
10 - 14
5-9
10 - 18
15 - 25
70
12 - 16
5-8
9 - 14
13 - 18
90
N/A
N/A
8 - 13
13 - 18
Typical Suction & Discharge Pressures
HEATING
COOLING
ENTERING WATER
TEMPERATURE
SUCTION
DISCHARGE
SUCTION
DISCHARGE
30
35 - 45
170 - 200
62 - 77
95 - 125
50
55 - 65
185 - 220
70 - 83
125 - 165
70
70 - 90
200 - 240
73 - 86
170 - 210
90
90 - 110
220 - 260
75 - 88
220 - 260
26
PREMIUM INSTALLATION MANUAL
Preventive Maintenance
Water Coil Maintenance
1. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to
infiltrate the water line. Lines should always be airtight.
2. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be
placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static
pressure.
Note: On open loop systems, if the installation is in an area with a known high mineral content (125 PPM or greater) in
the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should
periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel
or copper water lines. Generally, the more water flowing through the unit the less chance for scaling.
Other Maintenance
Air Coil
To obtain maximum performance, the air coil should be cleaned before startup. A 10% solution of dishwasher detergent
and water is recommended for both sides of coil; a thorough water rinse should follow.
CAUTION: Fin edges are sharp.
Fan Motors (ECM & PSC)
Blower Motors are equipped with sealed ball bearings and require no periodic oiling.
Desuperheater Coils
See Water Coil Maintenance section.
Filters
Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.
Condensate Drain
In areas where airborne bacteria produce a sludge in the drain pan, it may be necessary to treat chemically to minimize
the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the
possibility of overflow.
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.
Replacement Procedures
Obtaining Parts
When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the
serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of
failure, along with an explanation of the malfunctions and a description of the replacement parts required.
In-warranty Material Return
Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for
warranty return authorization and assistance.
27
Manufactured by WFI
GeoSmart Energy Inc.
290 Pinebush Road
Cambridge, ON N1T 1Z6
1.866.310.6690
www.geosmartenergy.com
WFI has a policy of continuous product research and
development and reserves the right to change design
and specifications without notice.
©2004 WFI.
Product:
Type:
Size:
Premium
Geothermal/Water Source Heat Pumps
3/4 thru 6 Tons
Document Type:
Part Number:
Release Date:
Supercedes:
Installation Manual
IM1555
02/05
IM1555 07/04