Split Geothermal Products RPVS, RPVE Geothermal Heat Pump Installation, Operation & Maintenance Instructions

Form No. 92-103352-01
Split Geothermal Products
RPVS & RPVE Series
Residential Indoor and Outdoor Split
Geothermal Heat Pumps
Installation, Operation &
Maintenance Instructions
97B0077N03
Revised: 06 February, 2016
Table of Contents
Model Nomenclature
3
Electrical - HWG Wiring
29
Safety
4
Low Water Temperature Cutout Selection
30
Storage
5
Electrical - Low Voltage Wiring
30-33
Pre-Installation
5
Water Valve Wiring
31
Equipment Selection
6
Thermostat Wiring
32
Air Handler Match-ups
6
ICC Controls
34-41
Installation
7-9
Water Connections
8
Unit Commissioning
and Operating Conditions
42
Ground-Loop Heat Pump Applications
10-11
Unit Starting and Operating Conditions
43
Unit Start-Up Procedure
44
Ground-Water Heat Pump Applications “Indoor” Compressor Section Only
12
Unit Operating Conditions
45-46
Ground-Water Heat Pump Applications
13
Preventive Maintenance
47
Open Loop - Ground Water Systems
13
Troubleshooting
48-49
Water Quality Standards
14
ICC/Blower Control Troubleshooting Chart
49
Refrigeration Installation
15-22
Functional Troubleshooting
50-51
Lineset Information
15
Troubleshooting Form
52
Hot Water Generator
23-25
Warranty
53-54
HWG Module Refrigeration Installation
For Outdoor Compressor Section Only
Revision History
56
26-27
Electrical - Line Voltage
28
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Model Nomenclature:
General Overview For All RPV V/H/D Series
1
2
3
4
5
6 7 8
9
10
11
12
15
13 14
R P V S C 036 J C 1 C N N S
STANDARD
S = Standard
SUPPLY AIR FLOW &
MOTOR CONFIGURATION
SERIES
N = NOT APPLICABLE
RETURN AIR FLOW CONFIGURATION
EFFICIENCY REFERENCE
N = NOT APPLICABLE
V = 27 EER
HEAT EXCHANGER OPTIONS
CONFIGURATION
C = COPPER HEAT CONTROLLER
N = CUPRO-NICKEL HEAT EXCHANGER
S = SPLIT, INDOOR
E = SPLIT, OUTDOOR
(EXTERIOR)
REV LEVEL
C = CURRENT REVISION
UNIT SIZE
025
036
048
062
WATER CIRCUIT OPTIONS
0 = NONE
1 = HWG w/INTERNAL PUMP (INDOOR UNIT ONLY)
CONTROLS
2
C = COMFORT CONTROL SYSTEMS
VOLTAGE
J = 208-230/60/1
NOTE: Above model nomenclature is a general reference. Consult individual specification sections for detailed information.
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Safety
Safety
Warnings, cautions and notices appear throughout this
manual. Read these items carefully before attempting any
installation, service, or troubleshooting of the equipment.
DANGER: Indicates an immediate hazardous situation, which
if not avoided will result in death or serious injury. DANGER
labels on unit access panels must be observed.
WARNING: Indicates a potentially hazardous situation, which
if not avoided could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation or an
unsafe practice, which if not avoided could result in minor or
moderate injury or product or property damage.
NOTICE: Notification of installation, operation or maintenance
information, which is important, but which is not hazardrelated.
WARNING!
WARNING! To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must be
serviced only by technicians who meet local, state, and
federal proficiency requirements.
4
WARNING!
WARNING! All refrigerant discharged from this unit must
be recovered WITHOUT EXCEPTION. Technicians must
follow industry accepted guidelines and all local, state,
and federal statutes for the recovery and disposal of
refrigerants. If a compressor is removed from this unit,
refrigerant circuit oil will remain in the compressor. To
avoid leakage of compressor oil, refrigerant lines of the
compressor must be sealed after it is removed.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT use
these units as a source of heating or cooling during the
construction process. The mechanical components and
filters will quickly become clogged with construction dirt
and debris, which may cause system damage.
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General Information
Storage
Pre-Installation
Inspection
Upon receipt of the equipment, carefully check the shipment
against the bill of lading. Make sure all units have been
received. Inspect the packaging of each unit, and inspect
each unit for damage. Insure that the carrier makes proper
notation of any shortages or damage on all copies of the
freight bill and completes a common carrier inspection report.
Concealed damage not discovered during unloading must be
reported to the carrier within 15 days of receipt of shipment.
If not 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
your equipment supplier of all damage within fifteen (15) days
of shipment.
Storage
Equipment should be stored in its original packaging in a
clean, dry area. Store units in an upright position at all times.
Stack units a maximum of 3 units high.
7.
compressor rides freely on the grommets.
Locate and verify any hot water generator (HWG), hanger,
or other accessory kit located in the compressor section
or blower section.
CAUTION!
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 and store units in an upright position.
Tilting units on their sides may cause equipment damage.
CAUTION!
Unit Protection
Cover units on the job site with either the original packaging
or an equivalent protective covering. Cap the open ends
of pipes stored on the job site. In areas where painting,
plastering, and/or spraying has not been completed, all due
precautions must be taken to avoid physical damage to the
units and contamination by foreign material. Physical damage
and contamination may prevent proper start-up and may
result in costly equipment clean-up.
CAUTION! CUT HAZARD - Failure to follow this caution
may result in personal injury. Sheet metal parts may have
sharp edges or burrs. Use care and wear appropriate
protective clothing, safety glasses and gloves when
handling parts and servicing heat pumps.
Examine all pipes, fittings, and valves before installing any of
the system components. Remove any dirt or debris found in
or on these components.
WARNING! Polyolester Oil, commonly known as POE oil, is
a synthetic oil used in many refrigeration systems including
those with HFC-410A refrigerant. POE oil, if it ever comes
in contact with PVC or CPVC piping, may cause failure of
the PVC/CPVC. PVC/CPVC piping should never be used
as supply or return water piping with water source heat
pump products containing HFC-410A as system failures and
property damage may result.
Pre-Installation
Installation, Operation, and Maintenance instructions are
provided with each unit. Horizontal equipment is designed for
installation above false ceiling or in a ceiling plenum. Other
unit configurations are typically installed in a mechanical
room. The installation site chosen should include adequate
service clearance around the unit. Before unit start-up,
read all manuals and become familiar with the unit and its
operation. Thoroughly check the system before operation.
WARNING!
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the correct
unit has been shipped.
2. Keep the cabinet covered with the original packaging until
installation is complete and all plastering, painting, etc. is
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.
5. Remove any blower support packaging (water-to-air
units only).
6. Loosen compressor bolts on units equipped with
compressor grommet vibration isolation until the
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Equipment Selection
Air Handler Match-ups
The installation of geothermal heat pump units and all
associated components, parts, and accessories which make
up the installation shall be in accordance with the regulations
of ALL authorities having jurisdiction and MUST conform to
all applicable codes. It is the responsibility of the installing
contractor to determine and comply with ALL applicable
codes and regulations.
General
Proper indoor coil selection is critical to system efficiency.
Using an older-model coil can affect efficiency and may
not provide the customer with rated or advertised EER
and COP. Coil design and technology have dramatically
improved operating efficiency and capacity in the past 20
years. Homeowners using an older coil are not reaping these
cost savings and comfort benefits. NEVER MATCH AN R-22
INDOOR COIL WITH AN HFC-410A COMPRESSOR SECTION.
Newer indoor coils have a larger surface area, enhanced fin
design, and grooved tubing. These features provide a larger
area for heat transfer, improving efficiency and expanding
capacity. Typical older coils may only have one-third to onehalf the face area of these redesigned coils.
Indoor Coil Selection - RPVS and RPVE
Split system heat pumps are rated in the ARI directory with
a specific indoor coil match. Matches with air handlers are
shown in Table 1. An ECM motor and TXV is required. Cap
tubes and fixed orifices are not acceptable.
Table 1: Air Handler Matches for ARI Ratings
Compressor Section
Air Handler Model
025
036
048
062
RHPL-HM2421
RHPL-HM3621
RHPL-HM24
RHPL-HM6024
Refrigerant
HFC-10A
Metering Device
Air Coil
Type
Rows - Fins/in.
Face Area (sq. ft.)
TXV (Non Bleed) required
N Style
2 - 16 fpi
5.7
Cabinet Configuration
ECM Settings
Fan Motor Type - HP
6
N Style
2 - 16 fpi
5.7
N Style
2 - 16 fpi
8.55
N Style
3 - 14 fpi
9.98
Upflow/Downflow/Horizontal (Multiposition)
Comfort Control
System
Comfort Control
System
Comfort Control
System
Comfort Control
System
ECM - 1/3 HP
ECM - 1/2 HP
ECM - 3/4 HP
ECM - 3/4 HP
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Installation
The installation of water source heat pump units and all
associated components, parts and accessories which make
up the installation shall be in accordance with the regulations
of ALL authorities having jurisdiction and MUST conform to
all applicable codes. It is the responsibility of the installing
contractor to determine and comply with ALL applicable
codes and regulations.
Removing Existing Condensing Unit (Where Applicable)
1. Pump down condensing unit. Close the liquid line
service valve of existing condensing unit and start
compressor to pump refrigerant back into compressor
section. Then, close suction service valve while
compressor is still running to trap refrigerant in outdoor
section. Immediately kill power to the condensing unit.
2. Disconnect power and low voltage and remove old
condensing unit. Cut or unbraze line set from unit.
Remove condensing unit.
3. If condensing unit is not operational or will not pump
down, refrigerant should be recovered using appropriate
equipment.
4. Replace line set, especially if upgrading system from
R-22 to HFC-410A refrigerant. If line set cannot be
replaced, it must be thoroughly flushed before installing
new compressor section. HFC-410A compressors use
POE oil instead of mineral oil (R-22 systems). Mineral oil
is not compatible with POE oil, and could cause system
damage if not completely flushed from the line set.
“Indoor” Compressor Section Location
Both “indoor” and “outdoor” versions of the geothermal
split system compressor section are available. “Indoor”
version is not designed for outdoor installation. Locate the
unit in an INDOOR area that allows enough space for service
personnel to perform typical maintenance or repairs without
removing unit. Units are typically installed in a mechanical
room or closet. Never install units in areas subject to freezing
or where humidity levels could cause cabinet condensation
(such as unconditioned spaces subject to 100% outside air).
Consideration should be given to access for easy removal
of service access panels. Provide sufficient room to make
water, electrical, and line set connections.
closet or mechanical room. Space should be sufficient to
allow removal of the unit, if necessary.
5. Provide access to water valves and fittings and
screwdriver access to the unit side panels and all
electrical connections.
“Outdoor” Compressor Section Location
Locate the unit in an outdoor area that allows easy loop
and lineset access and also has enough space for service
personnel to perform typical maintenance or repairs. The
“outdoor” compressor section is usually installed on a
condenser pad directly outside the lineset access into the
building. The loop access end should be located away from
the building. Conform to the following guidelines when
selecting unit location:
1. Provide adequate access for loop trench excavation.
2. Locate unit directly outside lineset penetration if
possible. Utilize existing condensor pad where
possible.
3. Provide access for servicing and maintenance.
“Outdoor” compressor section may be mounted on a
vibration isolation pad with loop access hole as shown
in Figure 2. When mounting on an existing concrete
condenser pad, 3” [76 mm] holes should be bored through
the pad to accomodate the pipe (1-¼” - 32mm) and
insulation (½” [13mm] wall thickness). Figure 2 illustrates
location and dimensions of the holes required.
Air Handler Installation
This manual specifically addresses the compressor section
of the system. Air handler location and installation should
be according to the instructions provided with the air
handling unit.
Figure 1: RPVS Installation
Any access panel screws that would be difficult to remove
after the unit is installed should be removed prior to setting
the unit. Refer to Figure 1 for an illustration of a typical
installation. Refer to “Physical Dimensions” section for
dimensional data. Conform to the following guidelines when
selecting unit location:
1. Install the unit on a piece of rubber, neoprene or other
mounting pad material for sound isolation. The pad should
be at least 3/8” [10mm] to 1/2” [13mm] in thickness.
Extend the pad beyond all four edges of the unit.
2. Provide adequate clearance for maintenance and
service. Do not block access panels with piping, conduit
or other materials.
3. Provide access for servicing the compressor and coils
without removing the unit.
4. Provide an unobstructed path to the unit within the
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Installation
Figure 2: RPVE Installation
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Stainless
Steel
Braided
Connecting
Hoses
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RI8QLW
µ[µ
[FP
µ
>FP@
Air Pad With
Access Hole
µ>FP@
µ
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External Flow Controller Mounting
The Flow Controller can be mounted beside the indoor unit
as shown in Figure 5. Review the Flow Controller installation
manual for more details.
Water Connections-Residential (RPVS)
Residential models utilize swivel piping fittings for water
connections that are rated for 450 psi (3101 kPa) operating
pressure. The connections have a rubber gasket seal
similar to a garden hose gasket, which when mated to the
flush end of most 1” threaded male pipe fittings provides
a leak-free seal without the need for thread sealing tape or
joint compound. Insure that the rubber seal is in the swivel
connector prior to attempting any connection (rubber seals
are shipped attached to the swivel connector). DO NOT
OVER TIGHTEN or leaks may occur.
The female locking ring is threaded onto the pipe threads
which holds the male pipe end against the rubber gasket,
and seals the joint. HAND TIGHTEN ONLY! DO NOT
OVERTIGHTEN!
Internal Flow Controller Connections (RPVE Series)
The RPVE series outdoor compressor section includes a
factory built-in circulator, as shown in Figure 2.
The circulator in the RPVE unit is three speed (shipped on
high speed). Lower circulator speeds may be chosen where
appropriate to lower pumping power and match the flow rate
to the unit’s requirements.
RPVE025 and 036 units come standard with one circulator.
RPVE048 and 062 units come standard with two circulators,
piped in series for greater flow and head capabilities.
8
µ
>FP@
RPVE025 and 036 units are shipped with ¾” stainless steel
braided hoses connected to unit piping. These hoses
terminate in swivel connections.
RPVE048 and 062 units are shipped with 1” stainless steel
braided hoses connected to unit piping. These hoses
terminate in swivel connections.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT allow
system water pressure to exceed 100 psi. when using the
RPVE Outdoor Compressor Section. The expansion tank
in the RPVE has a maximum working water pressure of
100 psi. Any pressure in excess of 100 psi may damage
the expansion tank.
Figure 3: Water Connections (RPVS Series)
Swivel Nut
Stainless steel
snap ring
Hand Tighten
Only!
Do Not
Overtighten!
Gasket
Brass Adaptor
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Installation
Figure 4: Hose Connections (RPVE Series)
CAUTION!
CAUTION! Using check valves in RPVE units will prevent
thermo siphoning of the ground loop. If the unit loses
power this may cause the coaxial heat exchanger to
freeze if the ambient temperature falls below the freeze
point of the ground loop fluid.
6WDLQOHVV6WHHO
%UDLGHG&RQQHFWLQJ
+RVHV
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Figure 6: Pump Curves for RPVE internal pump(s) - Single Pump
35.0
30.0
25.0
Head (ft)
20.0
Speed 3
15.0
Speed 2
10.0
Speed 1
5.0
0.0
0
5
10
15
GPM
20
25
30
35
Figure 6: Pump Curves for RPVE internal pump(s) - Double Pump
70
60
Head (ft)
50
40
Speed 3
30
Speed 2
20
Speed 1
10
0
0
5
10
15
20
GPM
25
30
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Ground-Loop Heat Pump Applications
CAUTION!
CAUTION! The following instructions represent industry
accepted installation practices for closed loop earth
coupled heat pump systems. Instructions are provided
to assist the contractor in installing trouble free ground
loops. These instructions are recommendations only.
State/provincial and local codes MUST be followed and
installation MUST conform to ALL applicable codes. It is
the responsibility of the installing contractor to determine
and comply with ALL applicable codes and regulations.
Pre-Installation
Prior to installation, locate and mark all existing underground
utilities, piping, etc. Install loops for new construction before
sidewalks, patios, driveways, and other construction has
begun. During construction, accurately mark all ground loop
piping on the plot plan as an aid in avoiding potential future
damage to the installation.
Piping Installation
The typical closed loop ground source system is shown in
Figure 5. All earth loop piping materials should be limited
to polyethylene fusion only for in-ground sections of the
loop. Galvanized or steel fittings should not be used at any
time due to their tendency to corrode. All plastic to metal
threaded fittings should be avoided due to their potential to
leak in earth coupled applications. A flanged fitting should
be substituted. P/T plugs should be used so that flow
can be measured using the pressure drop of the unit heat
exchanger.
Earth loop temperatures can range between 25 and
110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm
per ton [2.41 to 3.23 l/m per kW] of cooling capacity is
recommended in these applications.
Test individual horizontal loop circuits before backfilling.
Test vertical U-bends and pond loop assemblies prior to
installation. Pressures of at least 100 psi [689 kPa] should be
used when testing. Do not exceed the pipe pressure rating.
Test entire system when all loops are assembled.
Flushing the Earth Loop
Once piping is completed between the unit, Flow Controller
and the ground loop (Figure 5), the loop is ready for final
purging and charging. A flush cart with at least a 1.5 hp
[1.1 kW] pump is required to achieve enough fluid velocity
in the loop piping system to purge air and dirt particles. An
antifreeze solution is used in most areas to prevent freezing.
All air and debris must be removed from the earth loop
piping before operation. Flush the loop with a high volume
of water at a minimum velocity of 2 fps (0.6 m/s) in all piping.
The steps below must be followed for proper flushing.
1. Fill loop with water from a garden hose through the
flush cart before using the flush cart pump to insure an
even fill.
10
2. Once full, the flushing process can begin. Do not allow
the water level in the flush cart tank to drop below the
pump inlet line to avoid air being pumped back out to
the earth loop.
3. Try to maintain a fluid level in the tank above the return
tee so that air cannot be continuously mixed back into
the fluid. Surges of 50 psi (345 kPa) 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 (345 kPa). To purge, dead head the
pump until maximum pumping pressure is reached.
Open the return valve and a pressure surge will be sent
through the loop to help purge air pockets from the
piping system.
4. Notice the drop in fluid level in the flush cart tank when
the return valve is shut off. If air is adequately purged
from the system, the level will drop only 1-2 inches (2.5 5 cm) in a 10” (25 cm) diameter PVC flush tank (about a
half gallon [2.3 liters]), since liquids are incompressible. If
the level drops more than this, flushing should continue
since air is still being compressed in the loop fluid.
Perform the “dead head” procedure a number of times.
Note: This fluid level drop is your only indication of air in
the loop.
Antifreeze may be added before, during or after the 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,
perform final flush and pressurize the loop to a static
pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi
[241-276 kPa] (summer). After pressurization, be sure to
loosen the plug at the end of the Grundfos loop pump
motor(s) to allow trapped air to be discharged and to insure
the motor housing has been flooded. This is not required
for Taco circulators. Insure that the Flow Controller provides
adequate flow through the unit by checking pressure drop
across the heat exchanger and compare to the pressure
drop tables at the back of the manual.
Antifreeze
In areas where minimum entering loop temperatures drop
below 40°F [5°C] or where piping will be routed through
areas subject to freezing, antifreeze is required. Alcohols
and glycols are commonly used as antifreeze; however your
local sales manager should be consulted for the antifreeze
best suited to your area. Low temperature protection
should be maintained to 15°F [9°C] below the lowest
expected entering loop temperature. For example, if 30°F
[-1°C] is the minimum expected entering loop temperature,
the leaving loop temperature would be 25 to 22°F [-4 to
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Ground-Loop Heat Pump Applications
-6°C] and low temperature protection should be at 15°F
[-10°C]. Calculation is as follows:
30°F - 15°F = 15°F [-1°C - 9°C = -10°C].
CAUTION!
All alcohols should be premixed and pumped from a
reservoir outside of the building when possible or introduced
under the water level to prevent fumes. Calculate the
total volume of fluid in the piping system. Then use the
percentage by volume shown in Table 3 for the amount
of antifreeze needed. Antifreeze concentration should be
checked from a well mixed sample using a hydrometer to
measure specific gravity.
Table 2: Approximate Fluid Volume (U.S. gal. [L]) per
100' of Pipe
Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)
Pipe
Copper
Rubber Hose
Polyethylene
Size
Volume (gal) [liters]
1”
4.1 [15.3]
1.25”
6.4 [23.8]
2.5”
9.2 [34.3]
1”
3.9 [14.6]
3/4” IPS SDR11
2.8 [10.4]
1” iPS SDR11
4.5 [16.7]
1.25” IPS SDR11
8.0 [29.8]
1.5” IPS SDR11
10.9 [40.7]
2” IPS SDR11
18.0 [67.0]
1.25” IPS SCH40
8.3 [30.9]
1.5” IPS SCH40
10.9 [40.7]
2” IPS SCH40
17.0 [63.4]
Unit Heat Exchanger
Typical
1.0 [3.8]
Flush Cart Tank
10” Dia x 3ft tall
[254mm x 91.4cm tall]
10 [37.9]
CAUTION! To avoid equipment damage, DO NOT allow
system water pressure to exceed 100 psi. when using the
RPVE Outdoor Compressor Section. The expansion tank
in the RPVE has a maximum working water pressure of
100 psi. Any pressure in excess of 100 psi may damage
the expansion tank.
Low Water Temperature Cutout Setting - ICC Control
When antifreeze is selected, the FP1 jumper (JW1) should
be clipped to select the low temperature (antifreeze 10°F
[-12.2°C]) set point and avoid nuisance faults (see “Low
Water Temperature Cutout Selection” in this manual). NOTE:
Low water temperature operation requires extended range
equipment.
Figure 5: Loop Connection (Indoor
Compressor Section)
To Loop
Flow
Controller
Unit Power
Disconnect
Insulated
Hose Kit
AH & Thermostat
Wiring
Air Pad or
Extruded
polystyrene
insulation board
P/T Plugs
Table 3: Antifreeze Percentages by Volume
Type
Minimum Temperature for Low Temperature Protection
10°F [-12.2°C]
15°F [-9.4°C]
20°F [-6.7°C]
25°F [-3.9°C]
25%
38%
29%
21%
25%
25%
16%
22%
20%
10%
15%
14%
Methanol
100% USP food grade Propylene Glycol
Ethanol*
* Must not be denatured with any petroleum based product
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Ground-Water Heat Pump Applications “Indoor” Compressor Section Only
Open Loop - Ground Water Systems
Typical open loop piping is shown in Figure 6. Shut off valves
should be included for ease of servicing. Boiler drains or other
valves should be “tee’d” into the lines to allow acid flushing
of the heat exchanger. Shut off valves should be positioned
to allow flow through the coax via the boiler drains without
allowing flow into the piping system. P/T plugs should be
used so that pressure drop and temperature can be measured.
Supply and return water piping should be limited to copper,
HPDE, or other acceptable high temperature material. Note
that PVC or CPVC material is not recommended as they are
not compatible with the polyolester oil used in HFC-410A
products.
Water quantity should be plentiful and of good quality.
Consult Table 4 for water quality guidelines. The unit can
be ordered with either a copper or cupro-nickel water
heat exchanger. Consult Table 4 for recommendations.
Copper is recommended for closed loop systems and open
loop ground water systems that are not high in mineral
content or corrosiveness. In conditions anticipating heavy
scale formation or in brackish water, a cupro-nickel heat
exchanger is recommended. In ground water situations
where scaling could be heavy or where biological growth
such as iron bacteria will be present, an open loop system
is not recommended. Heat exchanger coils may over time
lose heat exchange capabilities due to build up of mineral
deposits. Heat exchangers must only be serviced by a
qualified technician, as acid and special pumping equipment
is required. Desuperheater coils can likewise become scaled
and possibly plugged. In areas with extremely hard water,
the owner should be informed that the heat exchanger
may require occasional acid flushing. In some cases, the
desuperheater option should not be recommended due to
hard water conditions and additional maintenance required.
Water Quality Standards
Table 4 should be consulted for water quality requirements.
Scaling potential should be assessed using the pH/Calcium
hardness method. If the pH <7.5 and the Calcium hardness
is less than 100 ppm, scaling potential is low. If this method
yields numbers out of range of those listed, the Ryznar
Stability and Langelier Saturation indecies should be
calculated. Use the appropriate scaling surface temperature
for the application, 150°F [66°C] for direct use (well water/
open loop) and DHW (desuperheater); 90°F [32°F] for
indirect use. A monitoring plan should be implemented in
these probable scaling situations. Other water quality issues
such as iron fouling, corrosion prevention and erosion and
clogging should be referenced in Table 4.
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to minimize
mineral formation due to air exposure. The expansion tank
should be sized to provide at least one minute continuous
run time of the pump using its drawdown capacity rating to
prevent pump short cycling. Discharge water from the unit
is not contaminated in any manner and can be disposed
12
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 the use of sanitary
sewer for disposal. Consult your local building and zoning
department to assure compliance in your area.
The pump should be sized to handle the home’s domestic
water load (typically 5-9 gpm [23-41 l/m]) plus the flow rate
required for the heat pump. Pump sizing and expansion
tank must be chosen as complimentary items. For example,
an expansion tank that is too small can causing premature
pump failure due to short cycling. Variable speed pumping
applications should be considered for the inherent energy
savings and smaller expansion tank requirements.
Water Control Valve
Note the placement of the water control valve in Figure
6. Always maintain water pressure in the heat exchanger
by placing the water control valve(s) on the discharge line
to prevent mineral precipitation during the off-cycle. Pilot
operated slow closing valves are recommended to reduce
water hammer. If water hammer persists, a mini-expansion
tank can be mounted on the piping to help absorb the
excess hammer shock. Insure that the total ‘VA’ draw of the
valve can be supplied by the unit transformer. For instance,
a slow closing valve can draw up to 35VA. This can overload
smaller 40 or 50 VA transformers depending on the other
controls in the circuit. A typical pilot operated solenoid valve
draws approximately 15VA (see Figure 23). Note the special
wiring diagrams for slow closing valves (Figures 24 & 25).
Flow Regulation
Flow regulation can be accomplished by two methods. One
method of flow regulation involves simply adjusting the ball
valve or water control valve on the discharge line. Measure
the pressure drop through the unit heat exchanger, and
determine flow rate from Table 12. Adjust the valve until the
desired flow of 1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW]
is achieved. A second method of flow control requires a flow
control device mounted on the outlet of the water control
valve. The device is typically a brass fitting with an orifice of
rubber or plastic material that is designed to allow a specified
flow rate. On occasion, flow control devices may produce
velocity noise that can be reduced by applying some back
pressure from the ball valve located on the discharge line.
Slightly closing the valve will spread the pressure drop over
both devices, lessening the velocity noise. NOTE: When
EWT is below 50°F [10°C], a minimum of 2 gpm per ton
(2.6 l/m per kW) is required.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT allow
system water pressure to exceed 100 psi. when using the
RPVE Outdoor Compressor Section. The expansion tank
in the RPVE has a maximum working water pressure of
100 psi. Any pressure in excess of 100 psi may damage
the expansion tank.
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Ground-Water Heat Pump Applications
Open Loop - Ground Water Systems
Water Coil Low Temperature Limit Setting
For all open loop systems the 30°F [-1.1°C] FP1 setting
(factory setting-water) should be used to avoid freeze damage
to the unit. See “Low Water Temperature Cutout Selection” in
this manual for details on the low limit setting.
Figure 6: Water Well Connections
Flow
Water
Regulator
Control
Valve
CAUTION!
CAUTION! Many units are installed with a field supplied
manual or electric shut-off valve. DAMAGE WILL
OCCUR if shut-off valve is closed during unit operation.
A high pressure switch must be installed on the heat
pump side of any field provided shut-off valves and
connected to the heat pump controls in series with
the built-in refrigerant circuit high pressure switch to
disable compressor operation if water pressure exceeds
pressure switch setting. The field installed high pressure
switch shall have a cut-out pressure of 300 psig and a
cut-in pressure of 250 psig. This pressure switch can
be ordered with a 1/4” internal flare connection as part
number 39B0005N02.
Pressure
Tank
Water Out
Water In
Shut-Off
Valve
Optional
Filter
P/T Plugs
Boiler
Drains
CAUTION!
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with this equipment.
13
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Water Quality Standards
Table 3: Water Quality Standards
Water Quality
Parameter
HX
Material
Closed
Recirculating
Open Loop and Recirculating Well
Scaling Potential - Primary Measurement
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below
pH/Calcium Hardness
Method
All
-
pH < 7.5 and Ca Hardness <100ppm
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)
Scaling indexes should be calculated at 66°C for direct use and HWG applications, and at 32°C for indirect HX use.
A monitoring plan should be implemented.
Ryznar
6.0 - 7.5
All
Stability Index
If >7.5 minimize steel pipe use.
-0.5 to +0.5
Langelier
All
If <-0.5 minimize steel pipe use. Based upon 66°C HWG and
Saturation Index
Direct well, 29°C Indirect Well HX
Iron Fouling
Iron Fe 2+ (Ferrous)
(Bacterial Iron potential)
All
Iron Fouling
All
-
<0.2 ppm (Ferrous)
If Fe2+ (ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.
-
<0.5 ppm of Oxygen
Above this level deposition will occur .
Corrosion Prevention
6 - 8.5
pH
All
Hydrogen Sulfide (H2S)
All
Ammonia ion as hydroxide, chloride,
nitrate and sulfate compounds
All
Monitor/treat as
needed
-
6 - 8.5
Minimize steel pipe below 7 and no open tanks with pH <8
<0.5 ppm
At H2S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.
Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.
-
<0.5 ppm
Maximum Allowable at maximum water temperature.
Maximum
Chloride Levels
Copper
Cupronickel
304 SS
316 SS
Titanium
-
10$C
<20ppm
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
24$C
NR
NR
<250 ppm
<550 ppm
>550 ppm
38 C
NR
NR
<150 ppm
< 375 ppm
>375 ppm
Erosion and Clogging
Particulate Size and
Erosion
All
<10 ppm of particles
and a maximum
velocity of 1.8 m/s
Filtered for maximum
841 micron [0.84 mm,
20 mesh] size.
<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum
velocity of 1.8 m/s. Filtered for maximum 841 micron 0.84 mm,
20 mesh] size. Any particulate that is not removed can potentially
clog components.
The Water Quality Table provides water quality requirements for ClimateMaster coaxial heat exchangers. The water should be evaluated by an independent testing
facility comparing to this Table and when properties are outside of these requirements, an external secondary heat exchanger must be used to isolate the heat pump
heat exchanger from the unsuitable water. Failure to do so will void the warranty for the coaxial heat exchanger and any other components damaged by a leak.
Notes:
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‡15$SSOLFDWLRQQRWUHFRPPHQGHG
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14
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Refrigeration Installation
When passing refrigerant lines through a wall, seal
opening with silicon-based caulk. Avoid direct contact
with water pipes, duct work, floor joists, wall studs,
floors or other structural components that could transmit
compressor vibration. Do not suspend refrigerant tubing
from joists with rigid straps. Do not attach line set to the
wall. When necessary, use hanger straps with isolation
sleeves to minimize transmission of line set vibration to
the structure.
CAUTION!
CAUTION! HFC-410A systems operate at higher
pressures than R-22 systems. Be certain that service
equipment (gauges, tools, etc.) is rated for HFC-410A.
Some R-22 service equipment may not be acceptable.
CAUTION!
CAUTION! Installation of a factory supplied liquid line
bi-directional filter drier is required. Never install a suction
line filter in the liquid line.
Line Set Installation
Figures 9a through 9b illustrate typical installations of a
compressor section matched to either an air handler (fan coil) or
add-on furnace coil. Table 5 shows typical line-set diameters at
various lengths. Line set lengths should be kept to a minimum
and should always be installed with care to avoid kinking. Line
sets are limited to 60 feet in length (one way). Line sets over
60 feet void the equipment warranty. If the line set is kinked or
distorted, and it cannot be formed back into its original shape,
the damaged portion of the line should be replaced. A restricted
line set will effect the performance of the system.
Split units are shipped with a filter drier (loose) inside the
cabinet that must be installed in the liquid line at the line set.
All brazing should be performed using nitrogen circulating
at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the
tubing. All line sets should be insulated with a minimum of
1/2” [13mm] thick closed cell insulation. Liquid lines should
be insulated for sound control purposes. All insulation
tubing should be sealed using a UV resistant paint or
covering to prevent deterioration from sunlight.
Installing the Line set at the Compressor Section
Braze the line set to the service valve stubs as shown in Figure
7. Remove the schraeder cores and heat trap the valves to
avoid overheating and damage. On installations with long line
sets, copper adapters may be needed to connect the larger
diameter tube to the stubs. Nitrogen should be circulated
through the system at 2-3 psi [13.8-20.7 kPa] to prevent
oxidation contamination. Use a low silver phos-copper braze
alloy on all brazed connections. Compressor section is
shipped with a factory charge. Therefore, service valves
should not be opened until the line set has been leak
tested, purged and evacuated. See “Charging the System.”
Installing the Indoor Coil and Line set
Figure 8 shows the installation of the line set and TXV to a
typical indoor coil. An indoor coil or air handler (fan coil) with a
TXV is required. Coils with cap tubes may not be used. If coil
includes removable fixed orifice, the orifice must be removed
and a TXV must be installed as shown in Figure 8. Fasten
the copper line set to the coil. Nitrogen should be circulated
through the system at 2-3 psi [13.8-20.7 kPa] to prevent
oxidation inside the refrigerant tubing. Use a low silver phoscopper braze alloy on all brazed connections.
Table 5: Line set Diameters and Charge Information - RPV E/S
Model
Factory†
Charge (oz)
[kg]
Basic**
Charge (oz)
[kg]
20 Feet [6 meters]
40 Feet [12 meters]
Liquid
Liquid
Suction
Suction
60 Feet* [18 meters]
Liquid
Suction
025
93 [2.64]
76 [2.15]
3/8”
3/4”
3/8”
3/4”
3/8”
3/4”
036
120 [3.40]
89 [2.52]
3/8”
7/8”
3/8”
7/8”
3/8”
7/8”
048
137 [3.89]
106 [3.01]
3/8”
7/8”
3/8”
7/8”
3/8”
7/8”
062
212 [6.01]
150 [4.25]
1/2”
7/8”
1/2”
7/8”
1/2”
7/8”
* 60 Feet is the maximum line set length.
**Basic charge includes only the amount required for the condensing unit and the evaporating coil.
An additional amount should be added allowing 0.6oz per ft. for 3/8” [0.6g per cm] and 1.2oz per ft. for 1/2” [1.1g per cm] of line set used.
† Factory charge is preset for 25’ [7.6 meters] line set.
15
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Refrigeration Installation
Figure 7: Braze Instructions
Figure 8: Air Coil Connection
Bulb (Must be
Installed and
Insulated)
Fully Insulated
Vapor Line
Suction
Equalizer
Line
TXV (‘IN’ toward
compressor section)
FP2
Sensor
Suction Line
TXV has internal
check valve
Fully Insulated
Liquid Line
Liquid Line
Nitrogen Braze
Replace Caps after adjusting
service valves
WARNING!
WARNING! If at all possible, it is recommended that a
new line set be used when replacing an existing R-22
system with an HFC-410A system. In rare instances
where replacing the line set is not possible, the line set
must be flushed prior to installation of the HFC-410A
system. It is also important to empty all existing traps.
Polyolester (POE) oils are used in units charged with
HFC-410A refrigerant. Residual mineral oil can act as an
insulator on the wall of the coil tubing, hindering proper
heat transfer and thus reducing system efficiency and
capacity. Another important reason to thoroughly flush
the line set is remove any trash and other contaminants
that may be present which could clog the thermal
expansion valve.
Failure to properly flush the system per the instructions
below will void the warranty.
CCW
CCW
Rev. 05/31/00
Service ports for
gauges
Fully Insulated
Liquid Line
WARNING!
Fully Insulated
Vapor Line
WARNING! The Environmental Protection Agency
prohibits the intentional venting of HCFC and HFC
refrigerants during maintenance, service, repair and
disposal of appliance. Approved methods of recovery,
recycling or reclaiming must be followed.
Nitrogen Braze
Table 6: Service Valve Positions
Position
Description
Operation Position
CCW - Full Out
CCW - Full Out 1/2 turn CW Service Position
CCW - Full In
Shipping Position
System
Open
Open
Closed
Service
Port
Closed
Open
Open
Re-Using Existing Line Set - R-22 to HFC-410A
Conversion
New line sets are always recommended, but are required if;
• The previous system had a compressor burn out.
• The existing line set has oil traps.
• The existing line set is larger or smaller than the
recommended line set for the HFC-410A system.
• The existing line set is damaged, corroded, or shows signs
of abrasion/fatigue
16
CAUTION!
CAUTION! This procedure should not be performed
on systems which contain containments (Example:
compressor burn out).
Required Equipment
The following equipment will be required in order to flush the
indoor coil and existing line set:
• Two R-22 recovery cylinders
• Refrigerant recovery machine with a pump down feature
• Two sets of gauges (one used for R-22 and one used with
the HFC-410A).
• Cylinder of clean R-22 (minimum amount required to
adequately flush shown below)
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Refrigeration Installation
°
°
°
3/4” diameter suction lines: 1/4 lb. per foot of line set +
1 lb. per ton for indoor coil.
7/8” diameter suction lines: 1/3 lb. per foot of line set +
1 lb. per ton for indoor coil
1-1/8” diameter suction lines: 1/2 lb. per foot of line set
+ 1 lb. per ton for indoor coil.
Example: 3-ton system with 40 ft. long line set and 3/4”
suction line.
Line set: 1/4 lb./ft. x 40 ft. = 10 lb.
Indoor coil: 1 lb./ton x 3 tons = 3 lbs. (not required if coil
is removed and lines are connected together)
Total: 10 lbs. + 3 lbs. = 13 lbs. to adequately flush line
set and indoor coil.
The Flushing Procedure
1. Remove the existing R-22 refrigerant by selecting the
appropriate procedure stated below.
If the unit is not operational, follow steps A-E.
• A.) First, disconnect all power supply to the existing
outdoor unit.
• B.) Connect a clean refrigerant recovery cylinder and
the refrigerant recovery machine to the existing unit
according to the instructions provided with the recovery
machine.
• C.) Remove all R-22 refrigerant from the existing system.
• D.) Check the gauges after shutdown to confirm all
refrigerant has been completely removed from the entire
system.
• E.) Disconnect the liquid and vapor lines from the
existing outdoor unit.
2.
3.
4.
5.
If the unit is operational, follow steps F- L.
• F.) First, start the existing R-22 system in the cooling
mode and close the liquid line valve.
• G.) Completely pump all existing R-22 refrigerant into
the outdoor unit. It will be necessary to bypass the low
pressure switch if the unit is so equipped to ensure that
the refrigerant is completely evacuated.)
• H.) The low side system pressures will eventually reach 0
psig. When this happens, close the vapor line valve and
immediately shut the outdoor unit off.
• I.) Check the gauges after shutdown to confirm that the
valves are not allowing refrigerant to leak back into the
low side of the system.
• J.) Disconnect power to the indoor furnace or airhandler to kill low voltage to the outdoor unit.
• K.) Disconnect the power supply wiring from the
existing outdoor unit.
• L.) Unsweat the liquid and vapor lines from the existing
outdoor unit.
Remove the existing outdoor unit.
Set the new HFC-410A unit in place and braze the liquid
and vapor lines to the unit connections. Connect the low
voltage and line voltage to the new outdoor unit. Do not
turn on power supply to the unit and do not open the
outdoor unit service valves at this time.
The indoor coil can be left in place for the flushing process
or removed.
If the indoor coil is removed, the suction and liquid line
must be connected together on the indoor coil end. See
illustration for recommended method for connecting these
together.
17
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Refrigeration Installation
6.
7.
8.
9.
10.
11.
12.
13.
14.
18
If the indoor coil is left in place during flushing, removing
the existing refrigerant flow control orifice or thermal
expansion valve prior to flushing is highly recommended
to assure proper flushing. Use a field-provided fitting or
piece of copper tubing to reconnect the lines where the
thermal expansion valve was removed.
Remove the pressure tap valve cores from the outdoor
unit’s service valves.
Connect an R-22 cylinder of clean R-22 refrigerant to the
vapor service valve. (see “Required Equipment Section”
for minimum required amount of R-22 for adequate
flushing)
Connect the low pressure side of an R-22 gauge set to the
liquid line valve.
Connect a hose from the recovery machine with an empty
recovery drum to the common port of the gauge set.
Set the recovery machine for liquid recovery and start the
machine.
Open the gauge set low side valve. This will allow the
recovery machine to pull a vacuum on the existing system
line set.
Make sure to invert the cylinder of clean R-22 refrigerant
and open the cylinder’s valve to allow liquid refrigerant to
flow into the system through the vapor line valve. (This
should allow the refrigerant to flow from the cylinder and
through the line set before it enters the recovery machine.)
The cylinder should not be inverted if it is the type with
separate liquid and vapor valves. Use the liquid valve on
the cylinder in this case, keeping the cylinder upright.
Once the liquid refrigerant has been completely recovered,
switch the recovery machine to vapor recovery so that the
R-22 vapor can be completely recovered.
IMPORTANT! Always remember, every time the
system is flushed you must always pull a vacuum
with a recovery machine on the system at the
end of each procedure. (If desired, a second flushing
with clean refrigerant may be performed if insufficient
amounts of mineral oil were removed during the initial
flush.)
15. Tightly close the valve on the inverted R-22 cylinder and
the gauge set valves.
16. Completely pump all remaining R22 refrigerant out of the
recovery machine and turn the machine off.
17. Before removing the recovery machine, R-22 refrigerant
cylinder and gauges, break the vacuum on the refrigerant
lines and indoor coil using dry-nitrogen.
18. Unsweat the liquid and vapor lines from the old indoor coil
or from each other and install a new matched HFC-410A
indoor coil, connecting the flushed refrigerant lines to the
new coil using field supplied connectors and tubing.
19. Reinstall pressure tap valve cores into unit service valves.
20. Pressurize the lines and coil and check for leaks in the line
set connection points using a soap solution.
21. Thoroughly evacuate the line set and indoor coil per the
instructions found in this manual.
22. Open the liquid and vapor service valves, releasing the
HFC-410A refrigerant contained in the outdoor unit into
the evacuated line set and indoor coil.
23. Energize the system and adjust the refrigerant charge
according to the charging procedures found in this
manual.
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Refrigeration Installation
FP2 Sensor Installation
An FP2 sensor with violet wiring is shipped loose with the
compressor section. This is the air coil low temperature
protection sensor. Install this sensor on the refrigerant line
between the indoor expansion valve and the air coil using
thermal compound and the supplied mounting clips. Ensure
that the sensor makes good thermal contact with the refrigerant
line and insulate the sensor.
Air coil low temperature protection will not be active if this
sensor is installed incorrectly or is not installed.
Add-On Heat Pump Applications
The indoor coil should be located in the supply side of
the furnace to avoid condensation damage to the furnace
heat exchanger for add-on heat pump applications. A high
temperature limit switch should be installed as shown
in Figure 9b just upstream of the coil to de-energize the
compressor any time the furnace is energized to avoid
blowing hot air directly into the coil, elevating refrigerant
pressures during operation. The heat pump will trip out on
high pressure lockout without some method of disengaging
the compressor during furnace operation. Alternatively, some
thermostats with “dual fuel” mode will automatically deenergize the compressor when second stage (backup) heat
is required.
The TXV should be brazed into place as shown in Figure 8,
keeping the “IN” side toward the compressor section. The
TXV has an internal check valve and must be installed in the
proper direction for operation. Always keep the valve body
cool with a brazing shield and wet rags to prevent damage
to the TXV. Attach the bulb to the suction line using the
supplied hose clamp. Be careful not to overtighten the clamp
and deform the bulb.
NOTICE! The air coil should be thoroughly washed with a
filming agent, (dishwasher detergent like Cascade) to help
condensate drainage. Apply a 20 to 1 solution of detergent
and water. Spray both sides of coil, repeat and rinse
thoroughly with water.
Evacuation and Charging the Unit
LEAK TESTING - The refrigeration line set must be pressurized
and checked for leaks before evacuating and charging the unit.
To pressurize the line set, attach refrigerant gauges to the service
ports and add an inert gas (nitrogen or dry carbon dioxide) until
pressure reaches 60-90 psig [413-620 kPa]. Never use oxygen or
acetylene to pressure test. Use a halogen leak tester or a good
quality bubble solution to detect leaks on all connections made
in the field. Check the service valve ports and stem for leaks. If
a leak is found, repair it and repeat the above steps. For safety
reasons do not pressurize system above 150 psig [1034 kPa].
System is now ready for evacuation and charging.
Turn service valves full out CCW (see Table 6) and then turn
back in one-half turn to open service ports. Add the required
refrigerant so that the total charge calculated for the unit and
line set is now in the system. Open the service valve fully
counter clockwise so that the stem will backseat and prevent
leakage through the schrader port while it is not in use.
Start unit in the heating mode and measure superheat and
subcooling values after 5 minutes of run time. See tables
13a through 13d for superheat and sub-cooling values.
Superheat is measured using suction temperature and
pressure at the compressor suction line. Subcooling should
be measured using the liquid line temperature immediately
outside the compressor section cabinet and either the liquid
line service valve pressure or the compressor discharge
pressure. Note that different values from tables 13a through
13d will be obtained due to the pressure losses through the
condenser heat exchanger. Adding refrigerant will increase
sub-cooling while superheat should remain fairly constant
allowing for a slight amount of hunting in TXV systems.
This increase in subcooling will require 5 minutes or so
of operation before it should be measured. After values
are measured, compare to the chart and go to “FINAL
EVALUATION.”
PARTIAL CHARGE METHOD - Open service valve fully
counterclockwise and then turn back in one-half turn to
open service port. Add vaporized (Gas) into the suction side
of the compressor until the pressure in the system reaches
approximately 100-120 psig. Never add liquid refrigerant into
the suction side of a compressor. Start the unit in heating
and add gas to the suction port at a rate not to exceed
five pounds [2.27 kg] per minute. Keep adding refrigerant
until the complete charge has been entered. Superheat is
measured using suction temperature and pressure at the
compressor suction line. Subcooling should be measured
using the liquid line temperature immediately outside the
compressor section cabinet and either the liquid line service
valve pressure or the compressor discharge pressure. Note
that different values from tables 13a through 13d will be
obtained due to the pressure losses through the condenser
heat exchanger. Adding refrigerant will increase sub-cooling
while superheat should remain fairly constant allowing for
a slight amount of hunting in TXV systems. This increase in
subcooling will require 5 minutes or so of operation before it
should be measured. After values are measured, compare to
the chart and go to “FINAL EVALUATION.”
FINAL EVALUATION -In a split system, cooling subcooling
values can be misleading depending on the location of the
measurement. Therefore, it is recommended that charging
be monitored in the heating mode. Charge should be
evaluated by monitoring the subcooling in the heating mode.
After initial check of heating sub-cooling, shut off unit and
allow to sit 3-5 minutes until pressures equalize. Restart unit
in the cooling mode and check the cooling superheat against
Tables 13a through 13d. If unit runs satisfactorily, charging
is complete. If unit does not perform to specifications the
cooling TXV (air coil side) may need to be readjusted (if
possible) until the cooling superheat values are met.
19
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Refrigeration Installation
Checking Superheat and Subcooling
Determining Superheat:
1. Measure the temperature of the suction line at a point
near the expansion valve bulb.
2. Determine the suction pressure by attaching refrigeration
gauges to the suction schrader connection at the
compressor.
3. Convert the pressure obtained in step 2 to saturation
temperature (boiling point) by using the pressure/
temperature conversion table on the gauge set.
4. Subtract the temperature obtained in step 3 from step
1. The difference will be the superheat of the unit or the
total number of degrees above saturation temperature.
Refer to Tables 13a through 13d for superheat ranges at
specific entering water conditions.
Example:
The temperature of the suction line at the sensing bulb is
50°F. The suction pressure at the compressor is 110 psig
which is equivalent to 36°F saturation temperature from the
HFC-410A press/temp conversion table on the gauge set.
36°F subtracted from 50°F = 14°F Superheat.
Determining Sub-Cooling:
1. Measure the temperature of the liquid line on the smaller
refrigerant line (liquid line) just outside of the cabinet.
This location will be adequate for measurement in both
modes unless a significant temperature drop in the liquid
line is anticipated.
2. Determine the condensor pressure (high side) by
attaching refrigerant gauges to the schrader connection
on the liquid line service valve. If the hot gas discharge
line of the compressor is used, refer to the appropriate
column in Tables 13a through 13d.
3. Convert the pressure obtained in step 2 to the
saturation temperature by using the press/temp
conversion table on the gauge set.
4. Subtract the temperature of Step 3 from the temperature
of Step 1. The difference will be the sub-cooling value for
that unit (total degrees below the saturation temperature).
Refer to Tables 13a through 13d for sub-cooling values at
specific entering water temperatures.
Example:
The condenser pressure at the service port is 335 psig,
which is equivalent to 104°F saturation temperature.
Discharge pressure is 365 psig at the compressor (109°F
saturation temperature). Measured liquid line temperature is
100°F. 100°F subtracted from 104°F = 4 degrees sub-cooling
(9 degrees if using the compressor discharge pressure).
20
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Refrigeration Installation
Figure 9a: Typical Split/Air Handler Installation
Power
Disconnects
TXV 'IN' toward
Compressor
Section
Insulated
Linesets
PVC Condensate
with vented trap
Compressor Section
Low Voltage
Air pad or Extruded
polystryene
Figure 9b: Typical Split/Add-on Coil Fossil Fuel Furnace Installation
TXV 'IN' toward
Compressor
Section
Air Temperature
Limit Switch
PVC Condensate
with vented trap
Compressor Section
Air pad or Extruded
polystyrene
21
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Refrigeration Installation
Evacuation Of The Lineset And Coil
The line set and coil must be evacuated to at least 500
microns to remove any moisture and noncondensables.
Evacuate the system through both service ports in the
shipping position (full CW in - see table 6) to prevent false
readings on the gauge because of pressure drop through
service ports. A vacuum gauge or thermistor capable of
accurately meausuring the vacuum depth is crucial in
determining if the system is ready for charging. If the system
meets the requirements in Figure 10, it is ready for charging.
Figure 10: Evacuation Graph
NOTICE!
NOTICE: Use tables 13a to 13d for superheat/
subcooling values. These tables use discharge pressure
(converted to saturation temperature) and liquid line
temperature for subcooling calculations. If using liquid
line pressure, subtract 3°F from the table values.
22
Charging The System
There are two methods of charging a refrigerant system. One
method is the total charge method, where the volume of the
system is determined and the refrigerant is measured and
added into the evacuated system. The other method is the
partial charge method where a small initial charge is added
to an evacuated system, and remaining refrigerant added
during operation.
Total Charge Method - See Table 5 for the compressor
section basic charge. For line sets with 3/8” liquid lines
add 0.6 ounces of refrigerant to the basic charge for every
installed foot of liquid line [0.6 grams per cm]. Add 1.2 oz.
per foot [1.1 grams per cm] if using l/2” line. Once the total
charge is determined, the factory pre-charge (Table 5) is
subtracted and the remainder is the amount needed to be
added to the system. This method should be used with the
ARI matched air handler.
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Hot Water Generator
Indoor Compressor Section
The HWG (Hot Water Generator) or desuperheater option
provides considerable operating cost savings by utilizing
excess heat energy from the heat pump to help satisfy
domestic hot water requirements. The HWG is active
throughout the year, providing virtually free hot water when
the heat pump operates in the cooling mode or hot water at
the COP of the heat pump during operation in the heating
mode. Actual HWG water heating capacities are provided in
the appropriate heat pump performance data.
Heat pumps equipped with the HWG option include a builtin water to refrigerant heat exchanger that eliminates the
need to tie into the heat pump refrigerant circuit in the field.
The control circuit and pump are also built in for residential
equipment. Figure 11 shows a typical example of HWG water
piping connections on a unit with built-in circulating pump.
This piping layout reduces scaling potential.
The temperature set point of the HWG is field selectable
to 125°F or 150°F . The 150°F set point allows more heat
storage from the HWG. For example, consider the amount
of heat that can be generated by the HWG when using the
125°F set point, versus the amount of heat that can be
generated by the HWG when using the 150°F set point.
In a typical 50 gallon two-element electric water heater
the lower element should be turned down to 100°F, or the
lowest setting, to get the most from the HWG. The tank will
eventually stratify so that the lower 80% of the tank, or 40
gallons, becomes 100°F (controlled by the lower element).
The upper 20% of the tank, or 10 gallons, will be maintained
at 125°F (controlled by the upper element).
Using a 125°F set point, the HWG can heat the lower 40
gallons of water from 100°F to 125°F, providing up to 8,330
btu’s of heat. Using the 150°F set point, the HWG can heat
the same 40 gallons of water from 100°F to 150°F and the
remaining 10 gallons of water from 125°F to 150°F, providing
a total of up to 18,743 btu’s of heat, or more than twice as
much heat as when using the 125°F set point.
This example ignored standby losses of the tank. When
those losses are considered the additional savings are even
greater.
Electric water heaters are recommended. If a gas, propane,
or oil water heater is used, a second preheat tank must be
installed (Figure 12). If the electric water heater has only a
single center element, the dual tank system is recommended
to insure a usable entering water temperature for the HWG.
Typically a single tank of at least 52 gallons (235 liters) is
used to limit installation costs and space. However, a dual
tank, as shown in Figure 12, is the most efficient system,
providing the maximum storage and temperate source water
to the HWG.
It is always advisable to use water softening equipment on
domestic water systems to reduce the scaling potential and
lengthen equipment life. In extreme water conditions, it may
be necessary to avoid the use of the HWG option since the
potential cost of frequent maintenance may offset or exceed
any savings. Consult Table 4 for scaling potential tests.
WARNING!
WARNING! A 150°F SETPOINT MAY LEAD TO
SCALDING OR BURNS. THE 150°F SET POINT MUST
ONLY BE USED ON SYSTEMS THAT EMPLOY AN
APPROVED ANTI-SCALD VALVE.
Figure 12: HWG Double Tank Installation
(Indoor Compressor Section)
Hot Outlet to
house
Figure 11: Typical HWG Installation
(Indoor Compressor Section)
Cold Inlet from
Domestic supply
Hot Outlet
Hot Outlet
to home
Shut-off
Valve #1
Cold
Inlet
Shut Off
Valve #1
Upper
element to
120 - 130°F
[49 - 54°C]
Powered
Water
Heater
Lower
element to
100 - 110°F
[38 - 43°C]
Upper element to 130°F [54°C]
(or owner preference)
Shut-off
Valve #4
Shut Off
Valve #4
Shut-off
Valve #3
Cold Inlet
Powered
Water Heater
Lower element to 120°F [49°C]
Unpowered
Shut-off
Valve #3
Water Heater
Shut Off
Valve #2
Field Supplied 3/4” brass nipple and “T”
Insulated water lines - 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
Shut Off
Valve #2
Field supplied 3/4’ brass nipple and ‘T’
Insulated water lines 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
23
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Hot Water Generator
Installation
The HWG is controlled by two sensors and a microprocessor
control. One sensor is located on the compressor discharge
line to sense the discharge refrigerant temperature. The
other sensor is located on the HWG heat exchanger’s “Water
In” line to sense the potable water temperature.
ANTI-SCALD
VALVE PIPING
CONNECTIONS
ANTI-SCALD
VALVE
WARNING!
The microprocessor control monitors the refrigerant and
water temperatures to determine when to operate the HWG.
The HWG will operate any time the refrigerant temperature
is sufficiently above the water temperature. Once the
HWG has satisfied the water heating demand during a
heat pump run cycle, the controller will cycle the pump at
regular Intervals to determine if an additional HWG cycle
can be utilized. The microprocessor control Includes 3 DIP
switches, SW10 (HWG PUMP TEST), SW11 (HWG TEMP),
and SW12 (HWG STATUS).
SW10 HWG PUMP TEST. When this switch is in the “ON”
position, the HWG pump is forced to operate even if there
is no call for the HWG. This mode may be beneficial to
assist in purging the system of air during Initial start up.
When SW10 is in the “OFF” position, the HWG will operate
normally. This switch is shipped from the factory in the
“OFF” (normal) position. NOTE; If left in the “On” position for
5 minutes, the pump control will revert to normal operation.
SW11 HWG TEMP. The control setpoint of the HWG can
be set to either of two temperatures, 125°F or 150°F. When
SW11 is in the “ON” position the HWG setpoint is 150°F.
When SW11 is in the “OFF” position the HWG setpoint is
WARNING!
WARNING! USING A 150°F SETPOINT ON THE
HWG WILL RESULT IN WATER TEMPERATURES
SUFFICIENT TO CAUSE SEVERE PHYSICAL INJURY
IN THE FORM OF SCALDING OR BURNS, EVEN
WHEN THE HOT WATER TANK TEMPERATURE
SETTING IS VISIBLY SET BELOW 150°F. THE 150°F
HWG SETPOINT MUST ONLY BE USED ON SYSTEMS
THAT EMPLOY AN APPROVED ANTI-SCALD VALVE
(PART NUMBER AVAS4) AT THE HOT WATER
STORAGE TANK WITH SUCH VALVE PROPERLY
SET TO CONTROL WATER TEMPERATURES
DISTRIBUTED TO ALL HOT WATER OUTLETS AT A
TEMPERATURE LEVEL THAT PREVENTS SCALDING
OR BURNS!
24
HOT WATER
TO HOUSE
C
M
H
8” MAX
WARNING! UNDER NO CIRCUMSTANCES SHOULD
THE SENSORS BE DISCONNECTED OR REMOVED
AS FULL LOAD CONDITIONS CAN DRIVE HOT
WATER TANK TEMPERATURES FAR ABOVE SAFE
TEMPERATURE LEVELS IF SENSORS HAVE BEEN
DISCONNECTED OR REMOVED.
CHECK VALVE
COLD WATER
SUPPLY
WATER HEATER
125°F. This switch Is shipped from the factory in the “OFF”
(125°F) position.
SW12 HWG STATUS. This switch controls operation of the
HWG. When SW12 is in the “OFF” position the HWG is
disabled and will not operate. When SW12 is in the “OFF”
position the HWG is in the enabled mode and will operate
normally. This switch is shipped from the factory in the
“ON” (disabled) position. CAUTION: DO NOT PLACE THIS
SWITCH IN THE ENABLED POSITION UNITL THE HWG
PIPING IS CONNECTED, FILLED WITH WATER, AND
PURGED OR PUMP DAMAGE WILL OCCUR.
When the control is powered and the HWG pump output
is not active, the status LED (AN1) will be “On”. When the
HWG pump output is active for water temperature sampling
or HWG operation, the status LED will slowly flash (On 1
second, Off 1 second).
If the control has detected a fault, the status LED will flash a
numeric fault code as follows:
Hot Water Sensor Fault
Compressor Discharge sensor fault
High Water Temperature (>160ºF)
Control Logic Error
1 flash
2 flashes
3 flashes
4 flashes
Fault code flashes have a duration of 0.4 seconds with
a 3 second pause between fault codes. For example, a
“Compressor Discharge sensor fault” will be four flashes
0.4 seconds long, then a 3 second pause, then four flashes
again, etc.
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Hot Water Generator
Warning! The HWG pump Is fully wired from the
factory. Use extreme caution when working around
the microprocessor control as it contains line voltage
connections that presents a shock hazard that can
cause severe injury or death!
The heat pump, water piping, pump, and hot water tank
should be located where the ambient temperature does
not fall below 50°F [10°C]. Keep water piping lengths at a
minimum. DO NOT use a one way length greater than 50 ft.
(one way) [15 m].
All installations must be in accordance with local codes. The
installer is responsible for knowing the local requirements,
and for performing the installation accordingly. DO NOT
connect the pump wiring until “Initial Start-Up” section,
below. Powering the pump before all installation steps are
completed may damage the pump.
Water Tank Preparation
1. Turn off power or fuel supply to the hot water tank.
2. Connect a hose to the drain valve on the water tank.
3. Shut off the cold water supply to the water tank.
4. Open the drain valve and open the pressure relief valve
or a hot water faucet to drain tank.
5. When using an existing tank, it should be flushed with
cold water after it is drained until the water leaving the
drain hose is clear and free of sediment.
6. Close all valves and remove the drain hose.
7. Install HWG water piping.
HWG Water Piping
1. Using at least 5/8” [16mm] O.D. copper, route and install
the water piping and valves as shown in Figures 11 or
12. Install an approved anti-scald valve if the 150°F HWG
setpoint is or will be selected. An appropriate method
must be employed to purge air from the HWG piping.
This may be accomplished by flushing water through the
HWG (as In Figures 11 and 12) or by Installing an air vent
at the high point of the HWG piping system.
2. Insulate all HWG water piping with no less than 3/8”
[10mm] wall closed cell insulation.
3. Open both shut off valves and make sure the tank drain
valve is closed.
On tanks with both upper and lower elements and
thermostats, the lower element should be turned down
to 100°F [38°C] or the lowest setting; the upper element
should be adjusted to 120-130°F [49-54°C]. Depending
upon the specific needs of the customer, you may want
to adjust the upper element differently. On tanks with a
single thermostat, a preheat tank should be used (Fig 12).
6. Replace access cover(s) and restore power or
fuel supply.
Initial Start-Up
1. Make sure all valves in the HWG water circuit are
fully open.
2. Turn on the heat pump and allow it to run for
10-15 minutes.
3. Set SW12 to the “OFF” position (enabled) to engage the
HWG.
4. The HWG pump should not run if the compressor is not
running.
5. The temperature difference between the water entering
and leaving the HWG coil should be approximately
5-10°F [3-6°C].
6. Allow the unit to operate for 20 to 30 minutes to insure
that it is functioning properly.
HWG Water Piping Size and Length
Unit
Nominal
Tonnage
Nominal
HWG Flow
(gpm)
1/2" Copper
(max length*)
3/4" Copper
(max length*)
1.5
0.6
50
-
2.0
0.8
50
-
2.5
1.0
50
-
3.0
1.2
50
-
3.5
1.4
50
-
4.0
1.6
45
50
5.0
2.0
25
50
6.0
2.4
10
50
*Maximum length is equivalent length (in feet) one way of type L
copper.
Water Tank Refill
1. Close valve #4. Ensure that the HWG valves (valves #2
and #3) are open. Open the cold water supply (valve #1)
to fill the tank through the HWG piping. This will purge air
from the HWG piping.
2. Open a hot water faucet to vent air from the system until
water flows from faucet; turn off faucet. Open valve #4.
3. Depress the hot water tank pressure relief valve handle to
ensure that there is no air remaining in the tank.
4. Inspect all work for leaks.
5. Before restoring power or fuel supply to the water heater,
adjust the temperature setting on the tank thermostat(s)
to insure maximum utilization of the heat available from
the refrigeration system and conserve the most energy.
25
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Hot Water Generator Module Refrigeration Installation
For Outdoor Compressor Section Only
General Information
The HWG Module consists of an all-copper, vented doublewall heat exchanger and a water-cooled water circulating
pump. The pump is controlled by a microprocessor in the
HWG module. Power for the pump is provided from a remote
115 vac power source.
Location/Mounting
The HWG module should be mounted as close to the heat
pump outdoor section as possible, in order to minimize
the length of refrigerant run. Indoor mounting is preferred,
where practical, to reduce the likelihood of freezing ambient
temperature. It is recommended that the HWG module be
mounted above the system compressor in order to promote
proper oil movement and drain-down. This means that the
HWG module can be wall mounted in any orientation
except for stubs up. Mounting should be accomplished
by fastening the HWG module cabinet to the wall or other
selected vertical surface. Mounting holes are provided at
the rear of the unit. Any fastener suitable for supporting a 12
pound [5.4] vertical load is acceptable.
SPECIAL NOTE: The selected mounting location and
orientation must allow the circulator pump to be positioned
with the motor shaft horizontal. DO NOT install the Heat
Recovery Unit flat on its back.
Refrigerant Line Installation
Before starting the installation into the refrigerant circuit,
inspect and note the condition and performance of the heat
pump. Disconnect power to the heat pump outdoor unit. Any
system deficiencies must be corrected prior to installing the
HWG module. Addition of the unit will not correct system
problems. Record the suction and discharge pressures and
compressor amperage draw. These will be used for comparison with system operation after the refrigerant line installation is complete and before the water line installation is
performed.
Install the Add-On HWG Kit
Locate the HWG as close to the water heater as possible.
Install the lineset to the desuperheater valves in the outdoor
compressor section and the refrigerant line connections
on the HWG. Maximum length should be 30 feet one way.
Evacuate the lineset to 500 microns through the hot gas
valves in the outdoor unit. Open the HWG valves in the compressor section up fully (and close the desuperheater bypass
valve). See Figures 13a through 13d. Check the lineset for
leaks. Verify that lineset tubing is completely insulated with
a minimum 1/2” thick closed cell and painted to prevent
deterioration of the insulation due to ultra violet light and
weather. Make the connections with high temperature solder
or brazing rod. The recommended line size is dependent on
the one way distance between the Heat Recovery Unit and
the compressor; and the size of the system. Use Figure 14
as a guideline.
26
Initial Start-Up
1. Make sure all valves in the HWG water circuit are fully
open.
2. Turn the heat pump power and remote HWG power “off”
and switch dip switch SW12 on the HWG controller to the
“off” (enabled) position to activate the HWG.
3. The HWG pump should not run if the compressor is not
running.
4. The temperature difference between the water entering
and leaving the HWG should be approximately 5-10 °F
[3-6 °C].
5. Allow the unit to operate for 20 to 30 minutes insure that
it is functioning properly.
6. Always turn dip switch SW12 on the HWG controller to
the “on” (disabled) position to deactivate the HWG when
servicing the outdoor compressor section.
NOTICE! Make sure the compressor discharge line
is connected to the “Hot Gas In” stub on the Heat
Recovery Unit.
WARNING!
WARNING! The HWG module is an appliance that operates
in conjunction with the heat pump system, the hot water
system and the electrical system. Installation should only be
performed by skilled technicians with appropriate training
and experience. The installation must be in compliance with
local codes and ordinances. Local plumbing and electrical
building codes take precedence over instructions contained
herein. The Manufacturer accepts no liability for equipment
damaged and/or personal injury arising from improper
installation of the HWG module.
CAUTION!
CAUTION! The HWG module must be installed in an area
that is not subject to freezing temperatures.
CAUTION!
CAUTION! Locate Refrigerant lines to avoid accidental
damage by lawnmowers or children.
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Hot Water Generator Module Refrigeration Installation
For Outdoor Compressor Section Only
Figure 13a: Outdoor Compressor Section HWG
Installation
Figure 14: HWG Refrigerant Line Sizing
Capacity
Refr to
HWG
Line Set Size
1/2” OD
5/8” OD
3/4” OD
2 Ton
Up to 16 ft.
[4.9m]
Up to 30 ft.
[9.1m]
N/A
3 Ton
Up to 9 ft.
[2.7m]
Up to 25 ft.
[7.6m]
Up to 30 ft.
[9.1m]
4 Ton
Up to 5 ft.
[1.5m]
Up to 13 ft.
[4.0m]
Up to 30 ft.
[9.1m]
5 Ton
N/A
Up to 9 ft.
[2.7m]
Up to 25 ft.
[7.6m]
Refr from
HWG
Figure 13c: HWG Service Valves
Fully Insulated
Lines to the HWG
Figure 13b: Remote HWG Module
Control
Board
HWG
Refr Out
HWG
Water Out
HWG
Refr In
Circulator
High Voltage
HWG
Water In
Refr
to HWG
Refr from
HWG
HWG
Bypass
Valve
HWG
Line Valves
Figure 13d: HWG Bypass Valve
Valve Open
(HWG Bypassed)
Valve Closed
(HWG Activated)
Figure 15: HWG Wiring
TO RELAY R1 IN COMPRESSOR SECTION
CONDENSER
CONDENSER
27
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Electrical - Line Voltage
All final electrical connections must be made with a length of
flexible conduit to minimize vibration and sound transmission
to the building.
WARNING!
WARNING! To avoid possible injury or death due to
electrical shock, open the power supply disconnect switch
and secure it in an open position during installation.
General Line Voltage Wiring
Be sure the available power is the same voltage and phase
shown on the unit serial plate. Line and low voltage wiring
must be done in accordance with local codes or the National
Electric Code, whichever is applicable.
CAUTION!
CAUTION! Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to accept
other types of conductors.
Power Connection
Line voltage connection is made by connecting the incoming
line voltage wires to the “L” side of the contactor as shown
in Figures 16 and 17. Consult Table for correct fuse size.
Electrical - Line Voltage
All field installed wiring, including electrical ground, must
comply with the National Electrical Code as well as all
applicable local codes. Refer to the unit electrical data for fuse
sizes. Consult wiring diagram for field connections that must
be made by the installing (or electrical) contractor.
208-230 Volt Operation
Verify transformer tap with air handler wiring diagram to
insure that the transformer tap is set to the correct voltage,
208V or 230V.
Table 7a: RPVS Series Electrical Data
Compressor
RLA
LRA
Qty
HWG
Pump FLA
External
Pump FLA
Total Unit
FLA
Min Circuit
Amps
Max Fuse/
HACR
026
11.7
58.3
1
0.5
4.0
16.2
19.1
30
038
15.3
83.0
1
0.5
4.0
19.8
23.6
35
049
21.2
104.0
1
0.5
4.0
25.7
31.0
50
064
27.1
152.9
1
0.5
4.0
31.6
38.3
60
Model
Rated Voltage of 208/230/60/1
HACR circuit breaker in USA only
Min/Max Voltage of 197/252
All fuses Class RK-5
Table 7b: RPVE Series Electrical Data
Compressor
RLA
LRA
Qty
Internal Loop
Pump FLA
Total
Unit FLA
Min Circuit
Amps
Max Fuse/
HACR
026
11.7
58.3
1
0.8
11.7
14.6
25
Model
036
15.3
83.0
1
0.8
15.3
19.1
30
048
21.2
104.0
1
1.6
21.2
26.5
45
062
27.1
152.9
1
1.6
27.1
33.9
60
Rated Voltage of 208/230/60/1
HACR circuit breaker in USA only
Remote HWG
Module
28
Min/Max Voltage of 197/254
All fuses Class RK-5
Voltage
Pump
FLA
Total
FLA
Min Circuit
Amps
AHWG1AARS
115/60/1
0.52
0.52
1.20
AHWG1AGRS
208/230/60/1
0.40
0.40
0.90
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Electrical - Line Voltage
Figure 16: Indoor Compressor Section Line Voltage Field Wiring
Unit Power Supply
(see electrical table for wire
and breaker size)
Figure 17: Outdoor Compressor Section Line Voltage Field Wiring
ELECTRICAL - HWG WIRING
208-230 Volt Operation
Verify transformer tap with air handler wiring diagram to
insure that the transformer tap is set to the correct voltage,
208V or 230V.
HWG Module Wiring - For “Outdoor” Compressor
Section
The HWG module should be wired to a 115 vac power
supply as shown in Figure 18. A safety disconnect should
be installed at the HWG module as required by code to allow
servicing of the module. DO NOT energize the pump until all
HWG piping is completed and air is purged from the water
piping to avoid running the pump “dry”.
Figure 18: HWG Module Wiring - For Use with Outdoor Compressor Section
HWG Module
TO RELAY R1 IN COMPRESSOR SECTION
CONDENSER
CONDENSER
29
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Electrical - Low Voltage Wiring
Low Water Temperature Cutout Selection
Thermostat Connections
The thermostat should be wired to the air handler with
appropriate connections also made to the ICC control module
in the compressor section. Typical thermostat wiring is shown
in Figure 20. Note that the air handler or furnace transformer
will be used to power the ICC board in the compressor
section.
Low Air Temperature Sensor Installation
After mounting the FP2 sensor in the air handler connect the
sensor wiring to the violet wires in the compressor section’s
control box as shown in Figure 20. Remove the violet wire
loop from the FP2 connector on the ICC control. Connect
the violet leads from FP2 to the FP2 connection on the ICC
control. FP2 sensor is packed inside the compressor section
control box.
Figure 19: RPVS Low Voltage Field Wiring
To “C” on HWG Controller
To “CC” on HWG Controller
Thermostat Connections
The thermostat should be wired to the air handler with
appropriate connections also made to the ICC control module
in the compressor section. Typical thermostat wiring is shown
in Figure 20. Note that the air handler or furnace transformer
will be used to power the ICC board in the compressor section.
Figure 20: RPVE Low Voltage Field Wiring
30
Low Water Temperature Cutout Selection
The ICC control allows the field selection of low water (or
water-antifreeze solution) temperature limit by clipping jumper
JW1, which changes the sensing temperature associated with
thermistor FP1. Note that the FP1 thermistor is located on
the refrigerant line between the coaxial heat exchanger and
expansion device (TXV). Therefore, FP1 is sensing refrigerant
temperature, not water temperature, which is a better indication
of how water flow rate/temperature is affecting the refrigeration
circuit.
The factory setting for FP1 is for systems using water (30°F
[-1.1°C] refrigerant temperature). In low water temperature
(extended range) applications with antifreeze (most ground
loops), jumper JW1 should be clipped as shown in Figure
22 to change the setting to 10°F [-12.2°C] refrigerant
temperature, a more suitable temperature when using
an antifreeze solution. All residential units include water/
refrigerant circuit insulation to prevent internal condensation,
which is required when operating with entering water
temperatures below 59°F [15°C].
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Electrical - Low Voltage Wiring
Water Valve Wiring
Figure 21: FP1 Limit Setting
control should be in the ON position. When a slow closing
water control valve is used, dipswitch SW1-2 on the ICC
control must be placed in the OFF position. See Figure 23
for the position of dipswitch SW1-2 on the ICC control.
Figure 23: Typical Water Valve Wiring
Figure 22: Two-Stage Piping
Solenoid
Valve
Flow
Regulator
Figure 24: AMV Valve Wiring
Stage 2
To Discharge
OUT
Stage 1
IN
From Water Source
NOTE: Shut-off valves, strainers and
other required components not shown.
Water Solenoid Valves
An external solenoid valve(s) should be used on ground water
installations to shut off flow to the unit when the compressor
is not operating. A slow closing valve may be required to
help reduce water hammer.
RPV split system units should be designed with two parallel
valves for ground water applications to limit water use during
first stage operation. For example, at 1.5 gpm/ton [2.0
l/m per kW], a RPV 048 unit requires 6 gpm [23 l/m] for full
load (2nd stage) operation, but only 4 gpm [15 l/m] during
1st stage operation. Since the unit will operate on first
stage 80-90% of the time, significant water savings can be
realized by using two parallel solenoid valves with two flow
regulators. In the example above, stage one solenoid would
be installed with a 4 gpm [15 l/m] flow regulator on the outlet,
while stage two would utilize a 2 gpm [8 l/m] flow regulator.
When stage one is operating, the second solenoid valve will
be closed. When stage two is operating, both valves will be
open, allowing full load flow rate. Figure 22 illustrates piping
for two-stage solenoid valves. NOTE: when EWT is below
50ºF [10ºC], a minimum of 2 gpm per ton [2.6 l/m per kW] is
required.
Figure 25: Taco SBV Valve Wiring
Figure 23 shows typical wiring for 24 VAC external solenoid
valves. Figures 24 and 25 illustrate typical wiring utilizing
slow closing water control valves. When standard water
solenoid valves are used, dipswitch SW1-2 on the ICC
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Electrical - Low Voltage Wiring
Thermostat Wiring
CAUTION!
CAUTION! Many units are installed with a field supplied
manual or electric shut-off valve. DAMAGE WILL
OCCUR if shut-off valve is closed during unit operation.
A high pressure switch must be installed on the heat
pump side of any field provided shut-off valves and
connected to the heat pump controls in series with
the built-in refrigerant circuit high pressure switch to
disable compressor operation if water pressure exceeds
pressure switch setting. The field installed high pressure
switch shall have a cut-out pressure of 300 psig and a
cut-in pressure of 250 psig. This pressure switch can
be ordered with a 1/4” internal flare connection as part
number 39B0005N02.
ELECTRICAL - THERMOSTAT WIRING
Thermostat Installation
The thermostat should be located on an interior wall in a
larger room, away from supply duct drafts. DO NOT locate
the thermostat in areas subject to sunlight, drafts or on
external walls. The wire access hole behind the thermostat
may in certain cases need to be sealed to prevent erroneous
temperature measurement. Position the thermostat back
plate against the wall so that it appears level and so the
thermostat wires protrude through the middle of the back
plate. Mark the position of the back plate mounting holes
and drill holes with a 3/16” (5mm) bit. Install supplied
anchors and secure plate to the wall. Thermostat wire
must be 18 AWG wire. Wire the appropriate thermostat as
shown in Figures 26 through 30 to the low voltage terminal
strip on the CXM control board. Practically any heat pump
thermostat will work with these units, provided it has the
correct number of heating and cooling stages.
CAUTION!
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with ClimateMaster
equipment.
Figure 26: Typical Comfort Control 2 System™ Wiring Diagram
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Electrical - Low Voltage Wiring
Figure 27: Typical Two-Stage Thermostat: Heat Pump
with Electric Heat
Figure 28: Typical Two-Stage Thermostat: Heat
Pump with Electric Heat Using A Humidistat for
Dehumidification
Figure 29: Typical Two-Stage Thermostat: Heat Pump
with Electric Heat Using A Two-Stage Thermostat with
Dehumidification
Figure 30: (-)PRL Heat Pump with Electric Heat Using
A Two-Stage Thermostat with Dehumidification and A
Malfunction Light
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ICC Controls
ICC Control Description
Dual 7-Segment LED
Displays status and diagnostic codes, for normal operation
and fault recall.
Red LED (Y1)
Displays the status of the Y1 thermostat input.
Caution: UNIT MAY START SUDDENLY AND WITHOUT
WARNING. Solid red light indicates a thermostat call for
operation is present at the ICC control. The ICC control will
attempt to start the unit after the short cycle timer expires if
the control is not locked out.
Green LED (COMM STATUS)
The COMM STATUS LED will flash green in normal
operation. A flashing green light indicates 24VAC is present
and the data wires 1 and 2 are wired properly.
Important: If the COMM STATUS LED is solid green, data
wire 1 and data wire 2 are not properly connected. Typically
the connections are switched. Verify wiring and correct the
polarity at the two wires.
Compressor Control (K2)
Sealed single pole compressor relay switch with optical
feedback feature (arc detection).
Low Voltage Fuse
If necessary replace with 3 A automotive ATC style blade
fuse.
Low Pressure Control (LPC Input)
Low pressure control is automatically resetting factory
installed device.
High Pressure Control (HPC Input)
High pressure control is automatically resetting factory
installed device.
Water Coil Low Temperature (FP1)
Low water coil temperature protection control is a factory
installed temperature sensor.
Air Coil Low Temperature (FP2)
Low air coil temperature protection control is a field installed
temperature sensor.
TEST and SW2 Buttons
The TEST and SW2 buttons are used to enter the Test and
Fault Recall modes.
Test Mode: Test mode allows the service technician to check
the operation of the control system in a timely manner. The
Test mode is activated by pressing the TEST button for 1
second, and will reset any active ICC lockout, reset the
anti-short cycle timer, and activate the compressor output
without a command for unit operation.
If the Test mode is initiated with no command for operation
34
present, and the ICC control will do the following:
1) A steady “t” appears on the ICC diagnostic display.
2) The compressor and low speed pump outputs will be
activated.
3) The compressor and pump outputs will turn off after 5
seconds.
Note: If a command for unit operation is present at the end
of the Test mode, the unit will continue to operate.
If the Test mode is initiated with a command for operation
present, and the ICC control will do the following:
1) A “t” is displayed momentarily on the ICC diagnostic
display.
2) The compressor and low speed pump outputs will be
activated.
3) The ICC diagnostic display will change to “c”, “C”, “h”, or
“H” to show the current command for unit operation.
Fault Recall Mode: The Fault Recall mode is activated by
pressing both the TEST and SW2 buttons for 1 second
If the Fault Recall mode is initiated, the ICC control will do
the following:
1) When entering and exiting the Fault Recall mode, the top
and bottom right hand segments of the dual 7-segment
LEDs will illuminate.
2) When entering the Fault Recall mode, the ICC will
automatically scroll through the stored faults on the dual
7-segment LEDs.
3) Each stored fault is displayed on time with the top right
hand segment of the dual 7-segment display activated
between fault codes.
4) Each fault is displayed with the most recent fault
displayed first.
5) A maximum of six individual faults can be stored.
6) A maximum of three consecutive identical faults may be
stored.
7) A “0” will be displayed when no faults are stored in
memory.
8) The ICC will automatically exit the Fault Recall mode
after displaying stored faults.
Clear Fault History: The stored fault history may be cleared
by pressing both the TEST and SW2 buttons for 5 seconds.
The top and bottom right hand segments of the dual
7-segment LEDs will flash to indicate the fault history has
been cleared.
ICC Control DIP Switches
Note: In the following field configuration options, DIP
switches should only be changed when power is removed
from the ICC control.
DIP switch SW1–1: Factory Setting – Normal position is
“On”. Do not change this selection unless instructed to do
so by the factory.
DIP switch SW1–2: Slow Opening Water Valve – Provides the
selection of the pump (water valve) operation.
On = Normal operation. Off = Slow opening water valve.
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ICC Controls
Field Configuration Jumper
Note: The JW1 field configuration jumper should be clipped
ONLY when power is removed from the ICC control.
Water Coil Low Temperature Limit Setting: Jumper 1 (JW1)
provides field selection of the temperature limit setting for
FP1 of 30ºF or 10ºF [-1ºC or -12ºC] (refrigerant temperature).
Not Clipped = 30ºF [-1ºC]. Clipped = 10ºF [-12ºC].
Diagnostic Port
The diagnostic port E25 is for a diagnostic tool only. Do not
attempt to connect other components or use a telephone
cord. Damage will occur.
Memory Card
The memory card stores all of the unit configuration
data, referred to as shared data. The shared data is the
information required for proper unit operation.
NOTE: The memory card for the unit has specific shared
data for this unit. The memory card is attached to the
control box with a tether.
command for first stage cooling operation, a lower case
“c” is displayed on the dual 7-segment LED.
Lower case “c” indicates first stage cooling operation.
2) Second Stage Cooling Operation – When the ICC
receives a command for second stage cooling operation,
an upper case “C” is displayed on the dual 7-segment
LED.
Upper case “C” indicates second stage cooling operation.
3) First Stage Heating Operation – When the ICC receives a
command for first stage heating operation, a lower case
“h” is displayed on the dual 7-segment LED.
Normal Control System Operation
Lower case “h” indicates first stage heating operation.
Installation Verification:
24VAC power on R & C must be present at the ICC control
and the Blower control for the system to operate properly.
4) Second Stage Heating Operation – When the ICC
receives a command for second stage heating operation,
an upper case “H” is displayed on the dual 7-segment
LED.
Line voltage must be present for the compressor, blower,
and pumps to operate properly.
The ICC control displays a “0” for standby mode. Standby
mode indicates line voltage and 24VAC are present at the
ICC, and there is not a command for unit operation from the
serial communicating thermostat.
Upper case “H” indicates second stage heating operation.
5-Minute Anti-Short Cycle Timer
The ICC has a built in 5-minute time delay between
compressor operations to protect the compressor against
short cycling. The dual 7-segment LEDs will flash “c”,
“C”, “h”, or “H” while the short cycle timer is active and a
command for unit operation is received.
Zero (0) displayed indicates the unit is in standby
Command for Compressor Operation (Y1 LED)
If a command for compressor operation is received by the
ICC (first stage/second stage cooling or first stage/second
stage heating), the LED will illuminate.
The ICC has an on/off pump delay of one (1) second for each
stage of heating or cooling.
The Blower control has an on/off indoor blower delay for
heating and cooling.
The ICC ignores the low pressure control for the first 120
seconds of compressor operation.
The ICC ignores the low temperature protection
temperatures for the first 120 seconds of compressor
operation.
The dual 7-segment LED displays four (4) operational status
codes:
1) First Stage Cooling Operation – When the ICC receives a
Flashing lower case “c” indicates a command for first stage
cooling has been received.
Flashing upper case “C” indicates a command for second
stage cooling has been received.
Flashing lower case “h” indicates a command for first stage
heating has been received.
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ICC Controls
The ICC will display a flashing “L” followed by a flashing “29”
when a high-pressure lockout occurs.
Flashing upper case “H” indicates a command for second
stage heating has been received.
The 5-minute time delay can be bypasses when a command
for compressor operation is present by pressing the TEST
button for 1 second and releasing. The compressor will
begin operation and the dual 7-segment will stop flashing.
30 Second Minimum Run Timer
The ICC has a built in 30 second minimum unit run time. If a
command for compressor operation is received by the ICC
and the command is removed, the compressor will continue
to operate for 30 seconds. The dual 7-segment LEDs will
flash “c”, “C”, “h”, or “H” while the minimum run timer is
active.
1 Second Compressor/Pump Delay
The ICC starts/stops the pump output one (1) second after
the start/stop of the compressor upon a command for
compressor operation to minimize current inrush and/or
voltage drop.
Active Protection – Code L29 – Open High Pressure Control
If the HPC opens three (3) times during the same command
for compressor operation, the ICC will lockout the
compressor to keep it from continuing to operate and flash a
“L” on the dual 7-segment LEDs followed by a “29”.
IMPORTANT: This mode of active protection must be
manually reset.
3) Low Water Coil Temperature Lockout
The ICC will display a flashing “L” followed by a flashing “85”
when a low water coil temperature lockout occurs.
Safety Feature Operation
Active Compressor Protection Modes
The ICC actively protects the system from harmful operation
during a fault condition
When the ICC detects a condition that could damage the
system, the ICC will enter active protection mode and
lockout compressor operation
The condition causing active protection must be resolved
before the ICC will restart the system
There are eight (8) active protection modes:
1) Low Pressure Control Lockout
The ICC will display a flashing “L” followed by a flashing “21”
when a low-pressure lockout occurs.
Active Protection – Code L85 – Low Water Coil Temperature
If the Water Coil Temperature sensor (FP1) measures a
temperature below the currently selected setpoint (JW1) for
thirty (30) continuous seconds during compressor operation,
the ICC will lockout the compressor to keep it from
continuing to operate and flash a “L” on the dual 7-segment
LEDs followed by a “85”.
IMPORTANT: This mode of active protection must be
manually reset.
4) Low Air Coil Temperature Lockout
The ICC will display a flashing “L” followed by a flashing “86”
when a low air coil temperature lockout occurs.
Active Protection – Code L21 – Open Low Pressure Control
If the LPC opens for thirty (30) continuous seconds, three (3)
times during the same command for compressor operation,
the ICC will lockout the compressor to keep it from
continuing to operate and flash a “L” on the dual 7-segment
LEDs followed by a “21”.
IMPORTANT: This mode of active protection must be
manually reset.
2) High Pressure Control Lockout
36
Active Protection – Code L86 – Low Air Coil Temperature
If the Air Coil Temperature sensor (FP2) measures a
temperature below 30ºF [-1ºC] for thirty (30) continuous
seconds during compressor operation, the ICC will lockout
the compressor to keep it from continuing to operate and
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ICC Controls
flash a “L” on the dual 7-segment LEDs followed by a “86”.
when a compressor open run circuit condition occurs.
IMPORTANT: This mode of active protection must be
manually reset.
5) Compressor Locked Rotor Lockout
The ICC will display a flashing “L” followed by a flashing “04”
when a compressor locked rotor condition occurs.
Active Protection – Code L7 – Compressor Open Run Circuit
If the ICC detects current in the start circuit without
current present in the run circuit, the ICC will lockout the
compressor to keep it from continuing to operate and flash a
“L” on the dual 7-segment LEDs followed by a “07”.
Active Protection – Code L4 – Compressor Locked Rotor
If the ICC detects the compressor has run less than 15
seconds for four (4) consecutive starts during the same
command for unit operation, the ICC will lockout the
compressor to keep it from continuing to operate and flash a
“L” on the dual 7-segment LEDs followed by a “04”.
IMPORTANT: This mode of active protection must be
manually reset.
6) Compressor Protector Trip
If the ICC detects a compressor protector trip it will display
a “P”. If the protector doesn’t reset within 4 hours, the ICC
display will change to “5”.
Compressor Protector – Code P – Protector Trip
7) Open Compressor Start Circuit Lockout
The ICC will display a flashing “L” followed by a flashing “06”
when a compressor open start circuit condition occurs.
Active Protection – Code L6 – Compressor Open Start
Circuit
If the ICC detects current in the run circuit without
current present in the start circuit, the ICC will lockout the
compressor to keep it from continuing to operate and flash a
“L” on the dual 7-segment LEDs followed by a “06”.
IMPORTANT: This mode of active protection must be
manually reset.
8) Open Compressor Run Circuit Lockout
The ICC will display a flashing “L” followed by a flashing “07”
IMPORTANT: This mode of active protection must be
manually reset.
Exiting Active Compressor Protection Lockout
There are three methods to reset the ICC after an active
protection lockout:
1) Cycle the line voltage to the unit
2) Cycle 24VAC to the ICC (remove the R or C
connection to the ICC)
3) Push the TEST button down with an insulated probe
for one (1) second and release
Note: The ICC will attempt to start the unit when the TEST
button is pressed and released
Note: The preferred method of resetting the ICC is to push
the TEST button down for one (1) second.
Optional Condensate Overflow Protection
An optional condensate overflow protection float switch may
be connected to the Blower control when using the Comfort
Control2 system.
If the optional float switch is open for thirty (30) consecutive
seconds during compressor operation, the ICC will
shut down the compressor to keep it from continuing to
operate, until the float switch has been closed for thirty (30)
consecutive seconds. The dual 7-segment LEDs will flash
“c”, “C”, “h”, or “H” while the compressor is shut down due
to condensate overflow protection.
ICC Control Diagnostic Codes
The description of ICC diagnostic codes displayed on the
dual 7-segment LEDs are provided below:
Dual 7 Segment
LEDs Display
Code
Diagnostic
Description
Status/Possible
Cause –
Troubleshooting
Information
0 – Standby
No command for
operation
Normal Operation
c – First Stage Cooling
Unit has received a
command for first stage
cooling
Normal Operation
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ICC Controls
Flashing
Dual 7 Segment
LEDs Display
Code
Flashing
Flashing
Flashing
38
c – Anti-short cycle timer
(5 minutes) or Minimum
run timer (30 seconds)
active
• The unit has received a
command for first stage
cooling during an active
anti-short cycle timer or
minimum run timer
• Wait until unit timer
has expired or press the
TEST button to defeat
short cycle delay
Diagnostic
Description
Status/Possible
Cause –
Troubleshooting
Information
C – Second Stage
Cooling
Unit has received a command for second stage
cooling
Normal Operation
C – Anti-short cycle timer
(5 minutes) or Minimum
run timer (30 seconds)
active
• The unit has received
a command for second
stage cooling during an
active anti-short cycle
timer or minimum run
timer
• Wait until unit timer
has expired or press the
TEST button to defeat
short cycle delay
h – First Stage Heating
Unit has received a
command for first stage
heating
Normal Operation
h – Anti-short cycle timer
(5 minutes) or Minimum
run timer (30 seconds)
active
• The unit has received a
command for first stage
heating during an active
anti-short cycle timer or
minimum run timer
• Wait until unit timer
has expired or press the
TEST button to defeat
short cycle delay
H – Second Stage
Heating
Unit has received a command for second stage
heating
Normal Operation
H – Anti-short cycle timer
(5 minutes) or Minimum
run timer (30 seconds)
active
• The unit has received
a command for second
stage heating during an
active anti-short cycle
timer or minimum run
timer
• Wait until unit timer
has expired or press the
TEST button to defeat
short cycle delay
t – Test Mode
The ICC is in the TEST
mode
P – Protector Trip
A command for compressor operation is present
but no current is measured to the compressor
• Motor protector open
Dual 7 Segment
LEDs Display
Code
01 – Long Run Time
(Compressor)
The compressor has
continuously run for
more than 18 hours
• Low refrigerant charge
• Air ducts have substantial leakage
• Dirty air filter or air coil
02 – High Side Fault
Compressor limit has
opened four (4) times
within a call for operation
• Dirty air filter or air coil
• Blower is not running
• Liquid line restriction
• Excessive refrigerant
charge
Diagnostic
Description
Status/Possible
Cause –
Troubleshooting
Information
03 – Short Cycling
the ICC detects the run
time for the past four
(4) compressor cycles
is less than three (3)
minutes each
• Check thermostat wire
connections
• Check thermostat location in zone (too close to
discharge grill)
L4 – Locked Rotor
The ICC detects four (4)
consecutive protector
trips have occurred and
the average run time for
each trip is less than 15
seconds
• Bad run capacitor
• Low line voltage
• Excessive refrigerant in
compressor
• Seized bearings in compressor
05 – Open Run Circuit
(Compressor will not run)
The ICC has had a protector trip for more than
4 hours
• Check for damaged,
miswired, or wrong run
capacitor
• Check for broken wires,
loose connectors, or
miswired compressor
• Check compressor
windings for continuity
• Check for open compressor internal protector
06 – Compressor Open
Start Circuit
The ICC detects current
in the Run circuit but not
in the Start circuit of the
compressor
• Check for damaged,
miswired, or wrong run
capacitor
• Check for broken wires,
loose connectors, or
miswired compressor
• Check compressor
windings for continuity
L6 – Compressor Open
Start Circuit
The ICC detects current
in the Run circuit but
not in the Start circuit of
the compressor four (4)
times in one compressor call
• Check for damaged,
miswired, or wrong run
capacitor
• Check for broken wires,
loose connectors, or
miswired compressor
• Check compressor
windings for continuity
07 – Compressor Open
Run Circuit
The ICC detects current
in the Start circuit but
not the Run circuit of the
compressor
• Check for damaged,
miswired, or wrong run
capacitor
• Check for broken wires,
loose connectors, or
miswired compressor
• Check compressor
windings for continuity
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ICC Controls
L7 – Compressor Open
Run Circuit
The ICC detects current
in the Start circuit but
not the Run circuit of
the compressor four (4)
times in one compressor call
09 – Low Secondary
Voltage
The secondary voltage
at R and C is below
18VAC
Dual 7 Segment
LEDs Display
Code
• Check for damaged,
miswired, or wrong run
capacitor
• Check for broken wires,
loose connectors, or
miswired compressor
• Check compressor
windings for continuity
• Control transformer
overloaded
• Low line voltage
Diagnostic
Description
Status/Possible
Cause –
Troubleshooting
Information
21 – Low Pressure Control Open
The ICC detects the LPC
is open.
Note: The low pressure
control is ignored for
the first 120 seconds of
compressor operation
• Unit has low refrigerant
charge
• Air coil is frozen
• Dirty air filter or air coil
• Blower is not running
• Expansion valve is not
operating properly
L21 – Active Protection
Low Pressure Control
Trip
LPC has opened 3
times in the same compressor operation, the
ICC has locked out the
compressor to protect
it. ICC alternately
flashes L and 21
Flashing
27 – Low Line Voltage
or No Line Voltage
Fault
• Check incoming line
voltage to the disconnect and unit
• Check wiring connections
28 – High Line Voltage
Fault
• Check line voltage
29 – High Pressure
Control Open
The ICC detects the
HPC is open
• Dirty air filter or air coil
• Blower is not running
• Liquid line restriction
• Excessive Refrigerant
charge
L29 – Active Protection
High Pressure Control
Trip
HPC has opened 3
times in the same compressor operation, the
ICC has locked out the
compressor to protect
it. ICC alternately
flashes L and 29
30 – Fuse Open
The ICC detects the
on-board fuse is open
• The 3-amp fuse on
the ICC is open
• Low voltage wiring at
R and C is damaged or
miswired
80 - Low Air Flow
The ICC detects that
the blower is not
providing the minimum
airflow requirements
• Wrong blower motor
configuration
Flashing
85 – Low Water Coil
Temperature
The ICC detects the
water coil temperature
below the selected
setpoint
Dual 7 Segment
LEDs Display
Code
Diagnostic
Description
• Low water flow
• Water pump not running
Status/Possible
Cause –
Troubleshooting
Information
L85 – Active Protection Low Water Coil
Temperature Trip
The water coil temperature has been detected
below the selected
setpoint, the ICC has
locked out the compressor to protect it.
ICC alternately flashes
L and 85
86 – Low Air Coil Temperature
The ICC detects the air
coil temperature below
the setpoint
• Low airflow
• Dirty air filter or air coil
•Blower is not running
L86 – Active Protection
Low Air Coil Temperature Trip
The air coil temperature
has been detected
below the setpoint, the
ICC has locked out the
compressor to protect
it. ICC alternately
flashes L and 86
93 – Internal Control
Fault
The control is not functioning properly
• Check control for
proper system operation
• Replace control
d1 – No Shared Data
The control board does
not have shared data
• Replace memory card
with correct system
information
d3 – Airflow CFM
Mismatch
The blower cannot supply the required airflow
for proper system
operation
• Misapplied/wrong
blower – replace with
properly sized blower
Flashing
d4 – Memory Card
Invalid for Device
The memory card is
missing or the data in
the memory card does
not match the data in
the control
d8 – Old Shared Data
System data is obsolete
• Check memory card
to ensure it matches
device
• Check if memory card
is present
• If system will not operate, order new memory
card to update system
information
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ICC Controls
Figure 31: ICC Control Board
Table 8: Unit Operation
40
Comfort Control2
System Demand
24 VAC Thermostat
Signals
Fan Only
G
Stage 1 Heating
Y1, G
Stage 2 Heating
Y1, Y2, G
Stage 3 Heating
Y1, Y2, W1 (W2), G
Emergency Heat
W1 (W2), G
Stage 1 Cooling
Y1, O, G
Stage 2 Cooling
Y1, Y2, O G
System Operation
Constant Fan
1st Stage Compressor & Fan, 1st Stage Pump
2nd Stage Compressor & Fan, 1st & 2nd Stage Pumps
2nd Stage Compressor & Fan, 1st & 2nd Stage Pumps, Auxiliary Heat
Fan & Auxiliary Heat
1st Stage Compressor & Fan, 1st Stage Pump, Reversing Valve
2nd Stage Compresor & Fan, 1st & 2nd Stage Pumps, Reversing Valve
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ICC Controls
Table 9: Nominal resistance at various temperatures
Temp
(°C)
Temp
(°F)
Resistance
(kOhm)
Temp
(°C)
Temp
(°F)
Resistance
(kOhm)
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Unit Commissioning and Operating Conditions
Operating Limits
Environment – Units are designed for indoor installation only. Never install in areas subject to freezing or where humidity levels
could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Power Supply – A voltage
variation of +/– 10% of nameplate utilization voltage is acceptable.
Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature,
and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should
be at normal levels to insure proper unit operation. Extreme variations in temperature and humidity and/or corrosive water or
air will adversely affect unit performance, reliability, and service life. Consult 10a for operating limits.
Table 10a: Building Operating Limits
Operating Limits
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
Rated entering air, DB/WB
Max. entering air, DB/WB
Water Limits
Min. entering water
Normal entering water
Max. entering water
Normal Water Flow
RPVS
Cooling
Heating
RPVE
Operating Limits
Air Limits
45ºF [7ºC]
39ºF [4ºC]
Min. ambient air, DB
80.6ºF [27ºC]
68ºF [20ºC]
Rated ambient air, DB
110ºF [43ºC]
85ºF [29ºC]
Max. ambient air, DB
60/45ºF [16/7ºC]
40ºF [4.4ºC]
Min. entering air, DB/WB
80.6/66.2ºF [27/19ºC]
68ºF [20ºC]
Rated entering air, DB/WB
100/75ºF [38/24ºC]
80ºF [27ºC]
Max. entering air, DB/WB
Water Limits
30ºF [-1ºC]
20ºF [-6.7ºC]
Min. entering water
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC] Normal entering water
120ºF [49ºC]
90ºF [32ºC]
Max. entering water
1.5 to 3.0 gpm / ton
Normal Water Flow
[1.6 to 3.2 l/m per kW]
Cooling
Heating
-10ºF [-23ºC]
80.6ºF [27ºC]
110ºF [43ºC]
60/45ºF [16/7ºC]
80.6/66.2ºF [27/19ºC]
100/75ºF [38/24ºC]
-10ºF [-23ºC]
68ºF [20ºC]
85ºF [29ºC]
40ºF [4.4ºC]
68ºF [20ºC]
80ºF [27ºC]
30ºF [-1ºC]
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
90ºF [32ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Created: 27 August, 2009B
Commissioning Limits
Consult Table 10b for the particular model. Starting conditions vary depending upon model and are based upon the following
notes:
Notes:
1.
Commissioning limits in Table 10b are not normal or continuous operating conditions. Minimum/maximum limits are
start-up conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under
these conditions on a regular basis.
2.
Voltage utilization range complies with ARI Standard 110.
Table 10b: Building Commissioning Limits
Commissioning Limits
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
Rated entering air, DB/WB
Max. entering air, DB/WB
Water Limits
Min. entering water
Normal entering water
Max. entering water
Normal Water Flow
42
RPVS
Cooling
Heating
Commissioning Limits
Air Limits
45ºF [7ºC]
39ºF [4ºC]
Min. ambient air, DB
80.6ºF [27ºC]
68ºF [20ºC]
Rated ambient air, DB
110ºF [43ºC]
85ºF [29ºC]
Max. ambient air, DB
50ºF [10ºC]
40ºF [4.5ºC]
Min. entering air, DB/WB
80.6/66.2ºF [27/19ºC]
68ºF [20ºC]
Rated entering air, DB/WB
110/83ºF [43/28ºC]
80ºF [27ºC]
Max. entering air, DB/WB
Water Limits
30ºF [-1ºC]
20ºF [-6.7ºC]
Min. entering water
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC] Normal entering water
120ºF [49ºC]
90ºF [32ºC]
Max. entering water
1.5 to 3.0 gpm / ton
Normal Water Flow
[1.6 to 3.2 l/m per kW]
RPVE
Cooling
Heating
-10ºF [-23ºC]
80.6ºF [27ºC]
110ºF [43ºC]
50ºF [10ºC]
80.6/66.2ºF [27/19ºC]
110/83ºF [43/28ºC]
-10ºF [-23ºC]
68ºF [20ºC]
85ºF [29ºC]
40ºF [4.5ºC]
68ºF [20ºC]
80ºF [27ºC]
30ºF [-1ºC]
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
90ºF [32ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Created: 27 August, 2009B
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Unit Starting and Operating Conditions
Unit and System Checkout
BEFORE POWERING SYSTEM, please check the following:
UNIT CHECKOUT
Balancing/shutoff valves: Insure that all isolation valves
are open and water control valves are wired.
Line voltage and wiring: Verify that voltage is within
an acceptable range for the unit and wiring and fuses/
breakers are properly sized. Verify that low voltage wiring
is complete.
Unit control transformer: Insure that transformer has the
properly selected voltage tap. Residential 208-230V units
are factory wired for 230V operation unless specified
otherwise.
Loop/water piping is complete and purged of air. Water/
piping is clean.
Antifreeze has been added if necessary.
Entering water and air: Insure that entering water and air
temperatures are within operating limits of Table 10b.
Low water temperature cutout: Verify that low water
temperature cut-out on the ICC control is properly set.
Unit fan: Manually rotate fan to verify free rotation and
insure that blower wheel is secured to the motor shaft.
Be sure to remove any shipping supports if needed.
DO NOT oil motors upon start-up. Fan motors are preoiled at the factory. Check unit fan speed selection and
compare to design requirements.
Condensate line: Verify that condensate line is open and
properly pitched toward drain.
HWG pump is disconnected unless piping is completed
and air has been purged from the system.
Water flow balancing: Record inlet and outlet water
temperatures for each heat pump upon startup. This
check can eliminate nuisance trip outs and high velocity
water flow that could erode heat exchangers.
Unit air coil and filters: Insure that filter is clean and
accessible. Clean air coil of all manufacturing oils.
Unit controls: Verify that ICC field selection options are
properly set. Low voltage wiring is complete.
Blower speed is set.
Service/access panels are in place.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT allow
system water pressure to exceed 100 psi. when using the
RPVE Outdoor Compressor Section. The expansion tank
in the RPVE has a maximum working water pressure of
100 psi. Any pressure in excess of 100 psi may damage
the expansion tank.
SYSTEM CHECKOUT
System water temperature: Check water temperature
for proper range and also verify heating and cooling set
points for proper operation.
System pH: Check and adjust water pH if necessary to
maintain a level between 6 and 8.5. Proper pH promotes
longevity of hoses and fittings (see Table 4).
System flushing: Verify that all air is purged from the
system. Air in the system can cause poor operation or
system corrosion. Water used in the system must be
potable quality initially and clean of dirt, piping slag,
and strong chemical cleaning agents. Some antifreeze
solutions may require distilled water.
Flow Controller pump(s): Verify that the pump(s) is wired,
purged of air, and in operating condition.
System controls: Verify that system controls function and
operate in the proper sequence.
Low water temperature cutout: Verify that low water
temperature cut-out controls are set properly
(FP1 - JW1).
Miscellaneous: Note any questionable aspects of
the installation.
CAUTION!
CAUTION! Verify that ALL water control valves are open
and allow water flow prior to engaging the compressor.
Freezing of the coax or water lines can permanently
damage the heat pump.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT
leave system filled in a building without heat during the
winter unless antifreeze is added to the water loop. Heat
exchangers never fully drain by themselves and will freeze
unless winterized with antifreeze.
Unit Start-up Procedure
1. Always deactivate the HWG (on units equipped with an
HWG) before completing the following steps.
2. Turn the thermostat fan position to “ON.” Blower should
start.
3. Balance air flow at registers.
4. Adjust all valves to their full open position. Turn on the
line power to all heat pump units.
5. Room temperature should be within the minimummaximum ranges of Table 10b. During start-up checks,
loop water temperature entering the heat pump should
be between 30°F [-1°C] and 95°F [35°C].
6. Two factors determine the operating limits of water
source heat pumps, (a) return air temperature, and (b)
water temperature. When any one of these factors is at a
minimum or maximum level, the other factor must be at
normal level to insure proper unit operation.
a. Adjust the unit thermostat to the warmest setting.
Place the thermostat mode switch in the “COOL”
position. Slowly reduce thermostat setting until the
compressor activates.
b. Check for cool air delivery at the unit grille within a
few minutes after the unit has begun to operate.
43
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Unit Start-Up Procedure
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 P/T plugs and
comparing to Table 11.
d. Check the elevation and cleanliness of the
condensate lines. Dripping may be a sign of a
blocked line. Check that the condensate trap is filled
to provide a water seal.
e. Refer to Table 12a. Check the temperature of both
entering and leaving water. If temperature is within
range, proceed with the test. If temperature is
outside of the operating range, check refrigerant
pressures and compare to Tables 13a through 13d.
Verify correct water flow by comparing unit pressure
drop across the heat exchanger versus the data in
Table 11. Heat of rejection (HR) can be calculated
and compared to catalog data capacity pages. The
formula for HR for systems with water is as follows:
HR = TD x GPM x 500, where TD is the temperature
difference between the entering and leaving water,
and GPM is the flow rate in U.S. GPM, determined
by comparing the pressure drop across the heat
exchanger to Table 11.
f. Check air temperature drop across the air coil when
compressor is operating. Air temperature drop should
be between 15°F and 25°F [8°C and 14°C].
g. Turn thermostat to “OFF” position. A hissing noise
indicates proper functioning of the reversing valve.
7. Allow five (5) minutes between tests for pressure to
equalize before beginning heating test.
a. Adjust the thermostat to the lowest setting. Place the
thermostat mode switch in the “HEAT” position.
b. Slowly raise the thermostat to a higher temperature
until the compressor activates.
c. Check for warm air delivery within a few minutes after
the unit has begun to operate.
d. Refer to Table 12a. Check the temperature of both
entering and leaving water. If temperature is within
range, proceed with the test. If temperature is
outside of the operating range, check refrigerant
pressures and compare to Tables 13a through 13d
Verify correct water flow by comparing unit pressure
drop across the heat exchanger versus the data in
Table 11. Heat of extraction (HE) can be calculated
and compared to submittal data capacity pages. The
formula for HE for systems with water is as follows:
HE = TD x GPM x 500, where TD is the temperature
difference between the entering and leaving water,
and GPM is the flow rate in U.S. GPM, determined
by comparing the pressure drop across the heat
exchanger to Table 11.
e. Check air temperature rise across the air coil when
compressor is operating. Air temperature rise should
be between 20°F and 30°F [11°C and 17°C].
f. Check for vibration, noise, and water leaks.
8. If unit fails to operate, perform troubleshooting analysis
(see troubleshooting section). If the check described
fails to reveal the problem and the unit still does not
operate, contact a trained service technician to insure
44
proper diagnosis and repair of the equipment.
9. When testing is complete, set system to maintain
desired comfort level.
10. BE CERTAIN TO FILL OUT AND RETURN ALL
WARRANTY REGISTRATION PAPERWORK.
Note: If performance during any mode appears abnormal,
refer to the ICC section or troubleshooting section of this
manual.
WARNING!
WARNING! When the disconnect switch is closed, high
voltage is present in some areas of the electrical panel.
Exercise caution when working with energized equipment.
CAUTION!
CAUTION! Verify that ALL water control valves are open
and allow water flow prior to engaging the compressor.
Freezing of the coax or water lines can permanently
damage the heat pump.
Table 11: Two-Stage HFC-410A Compressor Section
Coax Water Pressure Drop
Model
025
036
048
062
GPM
2.3
3.0
3.4
4.5
6.0
3.0
4.5
6.0
6.8
9.0
4.5
6.0
6.8
9.0
12.0
6.0
7.5
9.0
11.3
12.0
15.0
Pressure Drop (psi)
30°F
0.7
1.1
1.3
2.0
3.1
0.7
1.1
1.3
2.0
6.9
0.7
1.1
1.3
2.0
4.6
0.9
1.7
2.5
3.7
4.1
6.1
50°F
0.4
0.7
0.9
1.4
2.3
0.9
1.7
2.7
3.2
5.2
0.6
1.1
1.4
2.5
4.2
0.2
0.9
1.5
2.6
3.0
4.7
70°F
0.4
0.6
0.8
1.2
1.9
0.8
1.5
2.3
2.7
4.4
0.5
1.0
1.3
2.3
3.8
0.2
0.7
1.3
2.3
2.6
4.1
90°F
0.5
0.7
0.8
1.2
1.8
0.9
1.5
2.2
2.6
4.1
0.3
0.9
1.2
2.2
3.5
0.3
0.8
1.4
2.3
2.6
4.0
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Unit Operating Conditions
Antifreeze Correction Table
Table 12a: Water Temperature Change Through
Heat Exchanger
Antifreeze
%
Antifreeze Type
Water
Propylene Glycol
Methanol
Ethanol
Ethylene Glycol
Cooling
Heating
EWT 90°F
EWT 30°F
Total
Cap
Sens
Cap
0
1.000
1.000
5
0.995
15
WPD
Corr. Fct.
EWT 30°F
Power
Htg
Cap
Power
1.000
1.000
1.000
0.995
1.003
0.989
0.997
1.070
0.986
0.986
1.009
0.968
0.990
1.210
25
0.978
0.978
1.014
0.947
0.983
1.360
5
0.997
0.997
1.002
0.989
0.997
1.070
15
0.990
0.990
1.007
0.968
0.990
1.160
25
0.982
0.982
1.012
0.949
0.984
1.220
5
0.998
0.998
1.002
0.981
0.994
1.140
15
0.994
0.994
1.005
0.944
0.983
1.300
25
0.986
0.986
1.009
0.917
0.974
1.360
5
0.998
0.998
1.002
0.993
0.998
1.040
15
0.994
0.994
1.004
0.980
0.994
1.120
25
0.988
0.988
1.008
0.966
0.990
1.200
1.000
Table 12b: RPV E/S Heat of Rejection/ Heat of Extraction
Model
Stage GPM CFM
Heat of Rejection
Heat of Extraction
30°F 50°F
70°F 90°F
30°F 50°F 70°F
90°F
600
24.4
24.6
24.7
24.1
24.4
24.5
23.1
23.3
23.4
22.0
22.3
22.4
21.5
21.7
21.8
9.5
10.0
10.2
13.5
14.2
14.4
17.2
18.1
18.4
20.8
21.9
22.2
4.0
6.0
8.0
500
32.8
33.3
33.3
31.6
32.9
32.9
31.0
31.5
31.5
29.6
30.0
30.0
28.9
29.3
29.3
13.6
14.2
14.5
17.7
18.4
18.8
21.6
22.5
23.0
25.4
26.5
27.1
1
4.0
6.0
8.0
800
31.6
31.9
32.1
31.3
31.6
31.8
29.4
29.6
29.8
28.2
28.4
28.6
27.8
28.1
28.3
11.4
12.1
12.4
17.7
18.6
19.2
21.8
23.0
23.7
26.7
28.2
29.1
2
4.5
6.8
9.0
1100
47.9
48.4
48.7
47.5
47.9
48.2
45.9
46.3
46.6
44.3
44.7
45.0
43.5
43.9
44.1
19.4
20.5
21.1
26.5
28.0
28.8
31.1
32.9
33.9
38.2
40.4
41.6
1
5.5
8.3
11.0
1050
43.1
43.8
44.2
42.7
43.4
43.8
41.9
42.6
43.0
40.8
41.5
41.9
40.2
40.8
41.2
17.4
18.3
18.9
24.0
25.2
26.1
30.2
31.8
32.9
37.1
39.0
40.4
2
6.0
9.0
12.0
1650
62.4
63.4
64.0
61.8
62.8
63.4
59.9
61.0
61.5
58.1
59.1
59.7
57.2
58.2
58.7
23.7
24.9
25.7
33.6
35.3
36.5
39.7
41.8
43.2
48.7
51.3
53.0
1
7.0
10.5
14.0
1400
58.7
59.3
59.6
58.1
58.7
59.0
56.5
57.1
57.4
54.0
54.6
54.9
52.4
53.0
53.3
20.4
21.4
22.0
30.4
31.9
32.8
39.9
42.0
43.1
49.0
51.5
52.9
2
7.5
11.3
15.0
1550
79.8
80.6
81.1
79.0
79.8
80.3
76.5
77.3
77.7
74.0
74.8
75.2
72.8
73.5
73.9
27.8
29.2
30.0
39.1
41.1
42.1
49.7
52.2
53.6
61.0
64.1
65.8
1
3.5
5.8
7.0
2
025
036
048
062
100°F
Table 13a: Size 025 Two-Stage HFC-410A Typical Unit Operating Pressures and Temperatures
Full Load Cooling - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/
ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
30
1.5
2.25
3
122-132
122-132
122-132
159-179
146-166
132-152
13-18
13-18
14-19
50
1.5
2.25
3
132-142
132-142
132-142
186-206
172-192
158-178
70
1.5
2.25
3
139-149
139-149
139-149
90
1.5
2.25
3
110
1.5
2.25
3
Full Load Heating - without HWG active
Water Temp
Rise °F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Drop °F
Air Temp
Rise °F
DB
9-14
7-12
7-12
16.7-18.7
12.3-14.3
7.9-9.9
18-24
19-25
19-25
77-87
79-89
82-92
278-298
280-300
282-302
4-9
4-9
4-9
10-15
10-15
10-15
5.9-7.9
4.2-6.2
2.7-4.7
18-24
19-25
20-26
8-13
8-13
8-13
8-13
6-11
6-11
16.3-18.3
12.1-14.1
7.8-9.8
18-24
19-25
19-25
107-117
111-121
115-125
314-334
315-335
317-337
6-11
6-11
6-11
13-18
13-18
13-18
8.9-10.9
6.7-8.7
4.5-6.5
25-31
26-32
26-32
281-301
267-287
253-273
7-12
7-12
7-12
8-13
8-13
7-12
15.7-17.7
11.6-13.6
7.6-9.6
18-24
18-24
18-24
139-149
145-155
152-162
350-370
352-372
354-374
7-12
7-12
7-12
15-20
15-20
15-20
11.3-13.3
8.5-10.5
5.8-7.8
31-38
32-39
32-39
141-151
141-151
141-151
374-394
360-380
346-366
7-12
7-12
7-12
9-14
9-14
8-13
14.6-16.6
10.7-12.7
6.9-8.9
17-23
17-23
17-23
177-187
181-191
186-196
392-412
397-417
402-422
9-14
10-15
11-16
17-22
17-22
17-22
14.4-16.4
10.8-12.8
7.1-9.1
37-45
38-46
38-46
145-155
145-155
145-155
473-493
458-478
441-461
7-12
7-12
7-12
10-15
10-15
9-14
13.6-15.6
9.9-11.9
6.2-8.2
16-22
16-22
16-22
Operation Not Recommended
45
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Unit Operating Conditions
Table 13b: Size 036 Two-Stage HFC-410A Typical Unit Operating Pressures and Temperatures
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/
ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Rise °F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Drop °F
Air Temp
Rise °F
DB
30
1.5
2.25
3
122-132
121-131
121-131
153-173
145-165
135-155
18-23
18-23
18-23
9-14
8-13
8-13
22.1-24.1
16.8-18.8
10.5-12.5
19-25
20-26
20-26
71-81
75-85
78-88
263-283
267-287
270-290
5-10
5-10
5-10
2-5
2-5
2-5
8.1-10.1
5.9-7.9
3.7-5.7
17-23
18-24
19-25
50
1.5
2.25
3
131-141
130-140
130-140
222-242
208-228
194-214
13-18
13-18
14-19
10-15
9-14
9-14
21.9-23.9
16.1-18.1
10.3-12.3
19-25
20-26
20-26
103-113
107-117
112-122
292-312
296-316
301-321
6-11
6-11
6-11
2.5-7
2.5-7
2.5-7
11.5-13.5
8.6-10.6
5.7-7.7
23-29
24-30
24-30
70
1.5
2.25
3
138-148
137-147
137-147
299-319
280-300
263-283
8-13
8-13
8-13
13-18
12-17
12-17
21.5-23.5
15.8-17.8
10-12
19-25
20-26
20-26
134-144
140-150
146-156
322-342
328-358
334-354
7-12
7-12
7-12
2.5-7
2.5-7
2.5-7
14.5-16.5
11.1-13.1
7.7-9.7
28-35
29-36
30-37
90
1.5
2.25
3
142-152
142-152
142-152
388-408
367-387
347-367
6-11
7-12
7-12
13-18
8-13
8-13
20.5-22.5
14.9-16.9
9.3-11.3
18-24
18-24
18-24
172-182
184-194
196-206
360-380
369-389
378-398
8-13
8-13
8-13
2.5-7
2.5-7
2.5-7
20.5-22.5
15-17
10-12
36-44
37-45
39-47
110
1.5
2.25
3
147-157
147-157
147-157
486-506
465-475
444-464
6-11
7-12
7-12
13-18
8-13
8-13
19-21
14-16
9-11
18-24
18-24
18-24
Operation Not Recommended
Table 13c: Size 048 Two-Stage HFC-410A Typical Unit Operating Pressures and Temperatures
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/
ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Rise °F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Drop °F
Air Temp
Rise °F
DB
30
30
30
1.5
2.25
3
112-122
111-121
111-121
187-207
167-187
147-167
18-23
18-23
18-23
23-28
21-26
20-25
20.7-22.7
15.5-17.5
10.2-12.2
19-25
19-25
19-25
66-76
69-79
72-82
261-281
264-284
267-287
8-13
8-13
8-13
5-10
5-10
5-10
8-10
6-8
4-6
18-24
19-25
19-25
50
50
50
1.5
2.25
3
125-135
123-133
122-132
245-265
227-247
208-228
13-18
13-18
14-19
19-24
18-23
16-21
20.9-22.9
15.6-17.6
10.2-12.2
20-26
20-26
20-26
93-103
98-108
103-113
289-309
295-315
301-321
7-12
7-12
7-12
5-10
5-10
5-10
11.5-13.5
8.7-10.7
5.9-7.9
23-29
24-30
25-31
70
70
70
1.5
2.25
3
133-143
132-142
131-141
314-334
294-314
274-294
9-14
9-14
10-15
17-22
16-21
14-19
20.5-22.5
15.2-17.2
9.9-11.9
20-26
20-26
20-26
123-133
130-140
137-147
319-339
329-349
336-356
7-12
7-12
7-12
5-10
5-10
5-10
15-17
11.5-13.5
7.9-9.9
28-35
29-36
30-37
90
90
90
1.5
2.25
3
138-148
137-147
136-146
401-421
379-399
357-377
8-13
8-13
9-14
16-21
15-20
13-18
19.2-21.2
14.3-16.3
9.3-11.3
19-25
19-25
19-25
167-177
177-187
187-197
365-385
374-394
388-408
7-12
7-12
7-12
5-10
5-10
5-10
19.6-21.6
15-17
10.3-12.3
37-45
38-46
39-47
110
110
110
1.5
2.25
3
144-154
143-153
142-152
502-522
477-497
452-472
8-13
8-13
9-14
14-19
13-18
12-17
18-20
13.3-15.3
8.5-10.5
18-24
18-24
18-24
Operation Not Recommended
Table 13d: Size 062 Two-Stage HFC-410A Typical Unit Operating Pressures and Temperatures
46
Full Load Cooling - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/
ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
30
1.5
2.25
3
117-127
116-126
115-125
160-180
133-153
125-145
16-21
17-22
18-23
50
1.5
2.25
3
126-136
124-134
123-133
228-248
212-232
195-215
70
1.5
2.25
3
130-140
129-139
128-138
90
1.5
2.25
3
110
1.5
2.25
3
Full Load Heating - without HWG active
Water Temp
Rise °F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Superheat
Subcooling
Water Temp
Drop °F
Air Temp
Rise °F
DB
8-13
6-11
5-10
17.5-19.5
11.9-13.9
6.3-8.3
16-22
16-22
16-22
66-76
69-79
72-82
282-302
285-305
289-309
9-15
9-15
9-15
8-13
8-13
9-14
8-10
6-8
4-6
21-27
21-27
22-28
8-13
11-16
14-19
8-13
6-11
5-10
19.8-21.8
14.2-16.2
8.5-10.5
20-26
20-26
20-26
95-105
100-110
105-115
318-338
321-341
324-344
9-15
9-15
9-15
12-17
12-17
12-17
11.3-13.3
8.5-10.5
5.7-7.7
27-33
28-34
30-36
305-325
286-306
266-286
8-13
9-14
11-16
10-15
9-14
7-12
20.3-22.3
14.8-16.8
9.3-11.3
21-27
21-27
21-27
128-138
133-143
139-149
360-380
364-384
368-388
8-14
8-14
8-14
12-17
12-17
12-17
14-16
10.6-12.6
7.3-9.3
33-38
34-40
35-41
133-143
132-142
132-142
398-418
376-396
354-374
8-13
8-13
8-13
10-15
9-14
7-12
19.4-21.4
14.1-16.1
8.8-10.8
20-26
20-26
20-26
173-183
177-187
182-192
407-427
411-431
415-435
8-14
8-14
8-14
13-18
13-18
14-19
18.2-20.2
13.9-15.9
9.6-11.6
42-50
43-51
44-52
138-148
137-147
136-146
505-525
483-503
459-479
6-11
6-11
6-11
10-15
9-14
8-13
18.3-20.3
13.3-15.3
8.3-10.3
19-25
19-25
19-25
Operation Not Recommended
Residential Split
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Preventive Maintenance
Water Coil Maintenance
(Direct ground water applications only)
If the system is installed in an area with a known high mineral
content (125 P.P.M. or greater) in the water, it is best to
establish a periodic maintenance schedule with the owner
so the coil can be checked regularly. Consult the well water
applications section of this manual for a more detailed water
coil material selection. Should periodic coil cleaning be
necessary, use standard coil cleaning procedures, which are
compatible with the heat exchanger material and copper
water lines. Generally, the more water flowing through the
unit, the less chance for scaling. Therefore, 1.5 gpm per
ton [2.0 l/m per kW] is recommended as a minimum flow.
Minimum flow rate for entering water temperatures below
50°F [10°C] is 2.0 gpm per ton [2.6 l/m per kW].
Water Coil Maintenance
(All other water loop applications)
Generally water coil maintenance is not needed for closed
loop systems. However, if the piping is known to have
high dirt or debris content, it is best to establish a periodic
maintenance schedule with the owner so the water coil
can be checked regularly. Dirty installations are typically
the result of deterioration of iron or galvanized piping or
components in the system. Open cooling towers requiring
heavy chemical treatment and mineral buildup through water
use can also contribute to higher maintenance. Should
periodic coil cleaning be necessary, use standard coil
cleaning procedures, which are compatible with both the
heat exchanger material and copper water lines. Generally,
the more water flowing through the unit, the less chance for
scaling. However, flow rates over 3 gpm per ton (3.9 l/m per
kW) can produce water (or debris) velocities that can erode
the heat exchanger wall and ultimately produce leaks.
Hot Water Generator Coils
See water coil maintenance for ground water units. If the
potable water is hard or not chemically softened, the high
temperatures of the desuperheater will tend to scale even
quicker than the water coil and may need more frequent
inspections. In areas with extremely hard water, a HWG is
not recommended.
Condensate Drain
In areas where airborne bacteria may produce a “slimy”
substance in the drain pan, it may be necessary to treat the
drain pan chemically with an algaecide approximately every
three months to minimize the problem. The condensate pan
may also need to be cleaned periodically to insure indoor
air quality. The condensate drain can pick up lint and dirt,
especially with dirty filters. Inspect the drain twice a year to
avoid the possibility of plugging and eventual overflow.
Compressor
Conduct annual amperage checks to insure that amp draw is
no more than 10% greater than indicated on the serial plate
data.
Fan Motors
Consult air handler I.O.M. for maintenance requirements.
Air Coil
The air coil must be cleaned to obtain maximum
performance. Check once a year under normal operating
conditions and, if dirty, brush or vacuum clean. Care must
be taken not to damage the aluminum fins while cleaning.
CAUTION: Fin edges are sharp.
Cabinet - “Indoor” Compressor Section
Do not allow water to stay in contact with the cabinet for
long periods of time to prevent corrosion of the cabinet sheet
metal. Generally, cabinets are set up from the floor a few
inches [7 - 8 cm] to prevent water from entering the cabinet.
The cabinet can be cleaned using a mild detergent.
Refrigerant System
To maintain sealed circuit integrity, do not install service
gauges unless unit operation appears abnormal. Reference
the operating charts for pressures and temperatures. Verify
that air and water flow rates are at proper levels before
servicing the refrigerant circuit.
Filters
Filters must be clean to obtain maximum performance.
Filters should be inspected every month under normal
operating conditions and be replaced when necessary. Units
should never be operated without a filter.
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. It is especially
important to provide consistent washing of these filters (in
the opposite direction of the normal air flow) once per month
using a high pressure wash similar to those found at selfserve car washes.
47
Residential Split
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Troubleshooting
General
If operational difficulties are encountered, perform
the preliminary checks below before referring to the
troubleshooting charts.
• Verify that the unit is receiving electrical supply power.
• Make sure the fuses in the fused disconnect switches
are intact.
After completing the preliminary checks described above,
inspect for other obvious problems such as leaking
connections, broken or disconnected wires, etc. If
everything appears to be in order, but the unit still fails to
operate properly, refer to the “ICC Troubleshooting Process
Flowchart” or “Functional Troubleshooting Chart.”
ICC Control System
The ICC control provide status and diagnostic information
that greatly enhances the ability to quickly diagnose system
faults.
NOTE In diagnosing common faults in the system
develop a logical thought pattern as used by experienced
technicians. The charts which follow are not intended to be
an answer to all problems but only to guide the technician’s
troubleshooting.
Comfort Control2 System Startup
If the communications wires are wired backwards at any
point the green LED (COMM STATUS) will always be on. If
this happens check the wires at each point to ensure they
are not reversed
Once all devices are connected power up the line and
low voltage system. When all devices are powered the
thermostat should detect the ICC control within 45 seconds.
The control has a set of bias dipswitches set at a factory
default to the ON position. These dipswitches are for future
use. DO NOT CHANGE THESE DIPSWITCHES.
Once the system is powered the airflow settings will be
configured for all devices. The ICC will send information to
configure airflow to the Blower control. If the Blower control
is incapable of supplying the required airflow a d3 fault will
be displayed on the thermostat and ICC.
All devices have a LEARN button. This button is for future
use and has no function at this time.
All airflow adjustments are made at the thermostat.
Items that can be changed are Airflow trim adjustment,
Dehumidification Setpoint, and mode of operation. The
thermostat also has a wide range of fault and history
information.
Sensor Inputs
All sensor inputs are ‘paired wires’ connecting each component
to the board. Therefore, continuity on pressure switches, for
example can be checked at the board connector.
48
The thermistor resistance should be measured with the
connector removed so that only the impedance of the
thermistor is measured. If desired, this reading can be
compared to the thermistor resistance chart shown in
Table 9. An ice bath can be used to check calibration of the
thermistor.
ICC Control System Troubleshooting Flowchart/
Functional Troubleshooting Chart
The “ICC Control System Troubleshooting Flowchart” is
a quick overview of how to start diagnosing a suspected
problem, using the fault recognition features of the ICC
control board. The “Functional Troubleshooting Chart” on
the following page is a more comprehensive method for
identifying a number of malfunctions that may occur, and is
not limited to just the ICC control.
Comfort Control2 System Board Replacement
Verification of a Comfort Control2 failure is required before
replacement.
WARNING!
WARNING! HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING REMOTE
DISCONNECTS BEFORE SERVICING.
Failure to disconnect power before servicing can cause
severe personal injury or death.
Each control board in the Comfort Control2 System needs
information specific to the unit the control is installed
in. This information is called shared data because it is
distributed (shared) on the HVAC network. The shared data
for a unit contains information that allows the unit to operate
correctly.
When a control board requires replacement, it is important
that the replacement control gets the shared data from the
old control. The primary way the replacement control gets
this information is by the memory card that is installed in
the old control. Remove the memory card from the old
control, but leave it attached to the unit by the plastic tether,
replace the control and reinstall the memory card on the new
control. Never remove the memory card from the unit or cut
the tether of a memory card as it is the most effective way
to transfer the shared data. The unit will operate without a
memory card, but a D3 error will be displayed on the ICC
7-segment LEDs.
The memory card from a different unit should never be used.
Residential Split
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ICC Control System
Troubleshooting Chart
Troubleshooting
Control
Flowchart
Thermostat cool/
Heat call, but no
cooling/heating
Compressor
running?
No
Check fault history
Refer to mechanical
troubleshooting.
Yes
Compressor
control 7segment lit?
No
Check control voltage to
control
Yes
Y1 LED lit?
No
Check thermostat wiring
Yes
Waiting for anti-short cycle
delay
Yes
Control in lockout
mode. Refer to IOM
diagnostic chard
Yes
Refer to IOM diagnostic
chart
Yes
Flashing “c” on
display?
No
Alternating “L”
and “###” on
display?
No
Other fault
displayed?
No
Replace control
49
Residential Split
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Functional Troubleshooting
Fault
Main power Problems
Fault Code 27
Htg Clg Possible Cause
X
HP Fault-Code 29
High pressure
Solution
X
Low or no line voltage
Check Line Voltage circuit breaker and disconnect
Check for line voltage between L1 and L2 on the control
board
X
Reduced or no water flow
in cooling
Check pump operation or valve operation/setting
Check water flow adjust to proper flow rate
X
Water Temperature out of range in
Bring water temp within design parameters
cooling
X
Reduced or no Air flow
in heating
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Dirty Air Coil- construction dust etc.
Too high of external static. Check static vs blower table
X
X
X
Air Temperature out of range in
heating
Bring return air temp within design parameters
Overcharged with refrigerant
Check superheat/subcooling vs typical operating condition
table
Bad HP Switch
Insufficient charge
Check switch continuity and operation. Replace
Check for refrigerant leaks
X
X
LP/LOC Fault-Code 21
X
X
Low Pressure/Loss of Charge
X
Compressor pump down at startup
Check charge and start-up water flow
FP1 Fault - Code 85
X
Reduced or no water flow
Check pump operation or water valve operation/setting
in heating
Plugged strainer or filter. Clean or replace.
X
Inadequate anti-freeze level
Check antifreeze density with hydrometer
X
Improper temperature limit setting
(30°F vs 10°F [-1°C vs -12°C])
Clip JW1 jumper for antifreeze (10°F [-12°C]) use
Water Coil low
temperature limit
Check water flow adjust to proper flow rate
X
X
FP2 fault - Code 86
Water Temperature out of range
Bring water temp within design parameters
X
X
Bad thermistor
Reduced or no Air flow
in cooling
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
X
Air Temperature out of range
X
Improper temperature limit setting
(30°F vs 10°F [-1°C vs -12°C])
Normal airside applications will require 30°F [-1°C] only
X
Bad thermistor
Check temp and impedance correlation per chart
Air Coil low
temperature limit
X
Condensate Fault-Code 25
Under Voltage- Code 09
(Auto resetting)
Too much cold vent air? Bring entering air temp within
design parameters
X
X
Blocked Drain
Check for blockage and clean drain
X
X
X
Improper trap
Poor Drainage
X
Moisture on sensor
X
Under Voltage
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?
X
Check 24VAC and unit transformer tap for correct power
supply voltage
Unit Short Cycles
Only Fan Runs
50
X
X
X
X
Dirty Air Filter
Unit in "Test Mode"
X
X
Unit selection
X
X
Compressor Overload
Check and Clean air filter
Reset power or wait 20 minutes for auto exit.
Unit may be oversized for space. Check sizing for actual
load of space.
Check and Replace if necessary
X
X
Thermostat position
Insure thermostat set for heating or cooling operation
X
X
Unit locked out
Check for lockout codes. Reset power.
X
X
Compressor Overload
Check compressor overload. Replace if necessary.
X
X
Thermostat wiring
Check thermostat wiring at heat pump. Jumper Y and R
for compressor operation in test mode.
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Functional Troubleshooting
Only Compressor Runs
X
X
X
X
Fan Motor
X
Reversing Valve
X
Thermostat setup
X
Thermostat wiring
X
Thermostat wiring
Unit Doesn't Operate in
Cooling
Thermostat wiring
Check G wiring at heat pump. Jumper G and R for fan
operation.
Check for line voltage at motor. Check capacitor.
Set for cooling demand and check 24VAC on RV coil and at
ICC board.
If RV is stuck, run high pressure up by reducing water flow
and while operating engage and disengage RV coil voltage
to push valve.
Check for 'O' RV setup not 'B'
Check O wiring at heat pump. Jumper O and R for RV coil
'Click'.
Put thermostat in cooling mode. Check for 24VAC on O
(check between C and O); check for 24VAC on W (check
between W and C). There should be voltage on O, but not
on W. If voltage is present on W, thermostat may be bad
or wired incorrectly.
Performance Troubleshooting
Performance
Troubleshooting
Insufficient capacity/
Not cooling or heating
Htg Clg Possible Cause
X
X
X
properly
High Head Pressure
Solution
Dirty Filter
Replace or clean
Reduced or no Air flow
Check for dirty air filter and clean or replace
in heating
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
Reduced or no Air flow
in cooling
X
X
Leaky duct work
X
X
X
X
X
X
X
Low refrigerant charge
Restricted metering device
Defective Reversing Valve
Thermostat improperly located
X
X
Unit undersized
X
X
Scaling in water heat exchanger
Perform Scaling check and clean if necessary
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
X
Too high of external static. Check static vs blower table
X
X
X
Low Suction Pressure
X
X
X
X
X
X
X
X
X
High humidity
Check pump operation or valve operation/setting
Check water flow adjust to proper flow rate
Check load, loop sizing, loop backfill, ground moisture.
Scaling in water heat exchanger
Unit Overcharged
Non-condensables insystem
Restricted metering device
Reduced water flow
in heating
Perform Scaling check and clean if necessary
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
Bring return air temp within design parameters
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
X
Too high of air flow
Check fan motor speed selection and airflow chart
X
X
Poor Performance
Too high of air flow
X
Unit oversized
See 'Insufficient Capacity'
Check fan motor speed selection and airflow chart
Recheck loads & sizing check sensible clg load and heat
pump capacity
X
Low discharge air
temperature in heating
Reduced or no water flow
in cooling
Inlet Water too Hot
Air Temperature out of range in
heating
51
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Troubleshooting Form
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Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Optional Warranty
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Notes:
55
Residential Split
R e v. : 0 6 F e b r u a r y, 2 0 1 6
Revision History
Date
Page #
Description
13 March, 15
15
11 Sept., 14
5, 12
7 April, 14
All
19 April, 11
27, 29
31 Jan, 11
15
Refrigerant Charge Information Updated
13 Jan, 11
8
Circulator Check Valve Removed
29 July, 10
5
Compressor isolation upgrade from Springs to grommets
7 May, 10
53-54
3 May, 10
23
HWG Piping Drawings Revised
12 Oct., 09
All
First Published
Update Text and Table
Update Text POE Oil
Updated to Rev. C
Updated all HWG wiring diagrams
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Updated Warranties
IS
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ARD 1
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25
6
*97B0077N03*
97B0077N03
5600 Old Greenwood Road
Ft. Smith, AR 72908
(405) 357-0409
The Manufacturer 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 the Manufacturer’s Customer Service Department at
1-405-357-0409 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 Manufacturer’s opinion or commendation of
its products.
The management system governing the manufacture of Manufacturer’s products is ISO 9001:2000 certified.
© LSB, Inc. 2009
56
Revised: 06 February, 2016