Johnson Controls JRC Series Installation Operation & Maintenance
Johnson Controls JRC Series Water Source Heat Pumps are designed for energy efficiency. This manual provides installation, operation, and maintenance instructions for various JRC models, including 0.75-1.5 ton units with different water circuit, voltage, and control options. It covers topics such as wiring diagrams, piping connections, safety features, unit commissioning, troubleshooting, and preventive maintenance.
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Water Source Heat Pumps Installation, Operation, Maintenance Supersedes: 14805-NOM1-0521 Form: 14805-NOM1-1221 JRC-Series Water Source Heat Pump MODELS JRC 0.75-1.5 Tons 97B0035N10 Issue Date: December 8, 2021 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Table of Contents Model Nomenclature 3 General Information 4 Unit Physical Data 6 Installation 7 Piping Connections - JRC Size 06-15 2 9 Piping Connections - JRC Size 18 10 Piping Connections 11 Water-Loop Heat Pump Applications 12 Ground-Loop Heat Pump Applications 13 Ground-Water Heat Pump Applications 14 Water Quality Standards 16 Electrical - Line Voltage 20 Electrical 21 JRC Series Wiring Diagram Matrix 24 CXM Controls 25 DXM Controls 26 Safety Features - CXM/DXM Controls 28 Unit Commissioning and Operating Conditions 30 Piping System Cleaning and Flushing 31 Unit and System Checkout Procedure 32 Unit Start-Up Procedure 33 Unit Operating Conditions 34 Start-Up Log Sheet 36 Preventive Maintenance 37 Functional Troubleshooting 38 Performance Troubleshooting 39 Troubleshooting Form 40 Revision History 44 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Model Nomenclature 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 J RC 0 9 B G C A S S C S R B Model Type R = Right Piping L = Left Piping V = Left Piping w/SS Drain Pan W = Right Piping w/SS Drain Pan Unit Size 09, 12, 15, 18 Revision Level Water Circuit Options B = Current Revision Voltage Controls A = Copper Water Coil w/ e-Coated Air Coil C = Copper Water Coil J = Cupro-nickel Water Coil w/ e-Coated Air Coil N = Cupro-nickel Water Coil V = Copper Water Coil w/ e-Coated Air Coil & Extended Range Insulation E = Copper Water Coil w/Extended Range Insulation M = Cupro-nickel Water Coil w/ e-Coated Air Coil & Extended Range Insulation F = Cupro-nickel Water Coil w/Extended Range Insulation Subbase POWER TERMINATION & OPTIONS A B D F K X X DISCONNECT BREAKER SWITCH X X X - F G H J K L V Heat Exchanger Options R = Remote Mounted Tstat w/CXM S = Remote Mounted Tstat w/DXM N = Remote Mounted w/CXM & MPC P = Remote Mounted w/DXM & MPC 20 Amp PLUG & CORD FPT None Motorized Water Valve Autoflow (2.25 Gpm/Ton) Autoflow (3.0 Gpm/Ton) Motorized Water Valve & Afr (2.25) Motorized Water Valve & Afr (3.0) Secondary Circulation Pump G = 208-230/60/1 A = 115/60/1 E = 265/60/1 OPTION B = Standard Piping Connections JRC = Console FIELD CONNECTED (HARD WIRE) X - Standard RECEPTACLE X S = 5” Subbase H = 5” Subbase w/Motorized Damper N = None 1 = 5” Subbase for Chassis Only Options 2 = 5” Subbase w/Motorized Damper for Chassis Only Options 3 = 5” Subbase for Extended Length Cabinets 4 = 5" Subbase w/Motorized Damper for Extended Length Cabinets Cabinet Construction With Sound Attenuation Package M = Bottom Return D = Bottom Return w/Locking Control Door B = Front Return E = Front Return w/Locking Control Door C = No Cabinet BR Chassis Only J = No Cabinet FR Chassis Only A = Bottom Return w/Extended Cabinet K = Bottom Return w/Locking Control Door w/Extended Cabinet P = Front Return w/Extended Cabinet Q = Front Return w/Locking Control Door w/Extended Cabinet Installation, Operation, Maintenance Without Sound Attenuation Package S = Bottom Return L = Bottom Return w/Locking Control Door F = Front Return G = Front Return w/Locking Control Door N = No Cabinet BR Chassis Only H = No Cabinet FR Chassis Only R = Bottom Return w/Extended Cabinet T = Bottom Return w/Locking Control Door w/Extended Cabinet U = Front Return w/Extended Cabinet V = Front Return w/Locking Control Door w/Extended Cabinet 3 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 General Information 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. ⚠ 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. ⚠ WARNING! ⚠ WARNING! The installation of water-source heat pumps 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. 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 hazard-related. ⚠ 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 can quickly become clogged with construction dirt and debris, which may cause system damage and void product warranty. ⚠ WARNING! ⚠ WARNING! This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. ⚠ WARNING! ⚠ WARNING! This product can expose you to chemicals including formaldehyde, which is known to the state of California to cause cancer. For more information, go to www.P65Warnings.ca.gov. 4 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 General Information, Cont’d. 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. 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. 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. ⚠ 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 will cause equipment damage. ⚠ CAUTION! ⚠ 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. 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. Make sure wall behind the unit is flat and smooth. Installation, Operation, Maintenance 5 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit Physical Data Model 09 12 15 Compressor (1 Each) 18 Rotary Factory Charge HFC-410A (oz) [kg] 28 [0.794] 29 [0.822] 33 [0.907] 39 [1.105] Blower Wheel Blower Wheel Size (dia x w) (in) [mm] - Qty 2 5.25 x 6.25 [133 x 159] Water Connection Size FPT Fittings (in) 1/2 3/4 Coax Volume Volume US Gal [Liters] .09 [.34] .09 [.34] .23 [.87] .26 [.98] Condensate Connection Size I.D. Vinyl Hose (In) [mm] 5/8 [15.9] Air Coil Size 8 x 26 [203 x 660] Dimensions (h x w) - (in) [mm] 10 x 26 [254 x 660] 10 x 32 [254 x 812] Filter Size Bottom Return (in) [mm] Front Return (In) [mm] 1 - 10 x 30 x 1 [254 x 762 x 25] 1 - 10 x 36 x 1 [254 x 914 x 25] 1 - 7 x 29.5 x 1/8 [178 x 749 x 3.2] 1 - 7 x 35.5 x 1/8 [178 x 902 x 3.2] 48 x 26 x 12 [1219 x 660 x 305] 54 x 26 x 12 [1372 x 660 x 305] 48 x 21 x 12 [1219 x 533 x 305] 54 x 21 x 12 [1372 x 533 x 305] Unit Size Bottom Return (Std. 5” Base) (W x H x D) - (In) [mm] Front Return (No Subbase) (W x H x D) - (In) [mm] Unit Weight Weight - Operating, (lbs) [kg] 175 [79] 180 [82] 190 [86.2] 220 [99.8] Weight - Packaged, (lbs) [kg] 185 [83.9] 190 [86] 200 [90.8] 232 [105.2] All units have rubber grommet compressor mountings and TXV expansion devices. Unit Maximum Water Working Pressure Options Max Pressure PSIG [kPa] Base Unit 500 [3,445] Internal Secondary Pump (ISP) 145 [999] Internal Motorized Water Valve (MWV) 300 [2,068] Internal Auto Flow Valve 500 [3,445] Use the lowest maximum pressure rating when multiple options are combined. Optional hoses have pressure rating of 400 PSIG (2758 (kPa) Optional Factory Installed Auto Flow Regulator GPM [LPS] Model 2.25 GPM/Ton 3 GPM/Ton 9 2.0 [.126] 2.5 [.158] 12 2.5 [.158] 3.0 [.189] 15 3.0 [.189] 3.5 [.221] 18 3.5 [.221] 4.0 [.252] 6 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Installation The installation of Console Water-Source Heat Pumps and all associated components, parts and accessories that 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. 9. Before making the final water connections, flush the system as described in the Start Up section of this manual. After flushing the system, connect piping and hoses to the proper supply, return and condensate connections of the unit. Note: An Installation Checklist is provided in this manual. Complete this checklist after all installation procedures are completed. A periodic maintenance checklist provided in the Maintenance section outlines recommended maintenance schedules. A Start-Up Inspection Log is also included at the end of this manual to encourage thorough unit checkout at initial start-up. These checklists are not a substitute for the detailed information found in the Installation section of this manual. 10. Install any other system components as required following manufacturer’s instructions. 1. Console units are typically installed along an outside wall of the room. Provide adequate space in front of the unit for service and maintenance. Locate the Console Unit so that it provides adequate air circulation throughout the room. 1. Install supply and return hoses fitted with swivel-joint fittings at one end to prevent the hose from twisting. 2. Unpack the Console Unit from the shipping carton. Remove the front cabinet by lifting up and away from the backplate. Protect the cabinet from damage during installation by returning it to its original packaging until required. 3. Using a carpenter’s square and a level, ensure the unit is level. Shim the unit if necessary to assure proper installation. 4. Select the proper fasteners to connect the backplate securely to the wall. 5. Fasten the backplate onto the wall through the screw holes located in the back flange. Secure the subbase in place. 6. Remove subbase shipping support bracket and discard. 7. Make all necessary electrical connections as described in the Electrical Wiring section of this manual. Consult the wiring diagram to ensure proper hook-up. 8. Connect the final piping as described in the Supply and Return Piping and Condensate Piping section of the manual. Install shut-off valves, piping and/or hoses and other accessories as specified. Note: When necessary, use adapters to connect hoses. 11. After Start-up, reinstall the front cabinet by carefully lowering the front cabinet over the chassis onto the backplate. Supply and Return Hoses - Optional pressure-rated hose assemblies 400 psi [2758 kPa] are available for use with Console Units. Use the following guidelines when installing supply and return hose assemblies. 2. Use adapters to secure the hose assembly to the unit and the riser. 3. Do not allow the hose to twist during installation. Twisting may damage the hose wall or the interior rubber compound. 4. Use pipe joint compound sparingly on the pipe threads of the fitting adapters. 5. Prevent sealant from reaching the flared surfaces of the joint. 6. Do not use pipe joint compound when teflon thread tape is pre-applied to hose assemblies or when flared-end connections are used. 7. Maximum torque which may be applied to brass fittings is 30 ft-lbs [41 N-m]. When a torque wrench is not used, tighten brass fittings finger-tight plus one quarter turn. 8. Tighten steel fittings as necessary. 9. Shut-off/balancing valves, flow indicators, and drain tees in the supply runout and return at each floor to aid in loop balancing and servicing. ⚠ CAUTION! ⚠ CAUTION! Poor or inadequate installation may result in noisy unit operation or unattractive installation. Installation, Operation, Maintenance 7 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Installation, Cont’d. ⚠ CAUTION! ⚠ CAUTION! Loop Fluids should be of good quality with no more than 0.50 ppm of chlorides w/copper heat exchangers (125 ppm w/ Cupro-nickel) to prevent corrosion and should also be filtered to a maximum 800 micron [0.8mm particle size to prevent erosion of the heat exchangers. Condensate Piping - Unit is supplied with condensate drain hose, 5/8 inch [16 mm] I.D. flexible plastic nonpressure-rated, protruding from piping side of unit. Connect this hose to building drain. Avoid making kinks in hose to ensure an unobstructed flow of condensate from the unit to the drain. DO NOT twist, pull hose out, or push excess hose into unit. If hose will not connect to your building drain several options include, relocate end of building drain, add to or cut hose, use hard plastic or copper elbow fittings for tight radii (put inside hose). Keep hose positioned within or over subbase area so hose does not interfere with front cabinet. Cabinet should not push or reroute hose. Clamp all joints watertight. Check for leaks. Internally the drain hose is clamped to drain pan and pitched correctly. Horizontal runs of condensate hose should be pitched downward 1/4 inch minimum for every foot [10 mm per 46 cm] of hose. Avoid low points because dirt collects in these areas and may cause blockage. If blocked the condensate level in drain pan increases. When the level gets too high, the Console unit has sensor switch that will shut unit off. Overflow may still occur. 8 If the building drain connection is parallel with floor, the height can be up to 1-1/2 inches [38 mm] above the subbase for proper pitch and correct drainage. Up to 5 inches [127 mm] above the subbase is allowable, but drainage will be slower. When the drain connection is 2-1/2 to 5 inches [64 to 127 mm] above, the hose inside the unit will act as a trap. Heights of more than 5 inches [127 mm] above the subbase are NOT allowable (condensate overflow may occur). If the unit has a disconnect option, drain locations are limited. See unit configuration pages for details. Field installation of a trap or vent is not required unless specified by local codes. Console units are designed in a blow-through configuration. The condensate drain pan is located on the outlet side of the blower so that the pressure in the drain pan is higher than atmospheric pressures. When drain connection is completed check for proper drainage and leaks. Correct if necessary. If trap is used, check and clean often. See Preventive Maintenance Instructions. Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Piping Connections – JRC Size 09-15 40.98 40.98 (1040) (1040) Control Box Control Box Optional Flow Optional Flow Regulator Regulator Out Out In In Optional Optional Motorized Motorized Water Valve Water Valve 1.62 (41) 1.62 (41) 2.00 2.00 (51) (51) Water Out Water Out ower Deck Deck Compressor Access Compressor Panel Access Panel r Access Panel ss Panel Water In Water In Water Water Connections Connections 1/2” FPT 1/2” FPT 2.25 2.25 (57) (57) *11.25 (286) *11.25 (286) 8.00 Min 8.00 Min(203) (203) 1.75 (44) 1.75 (44) Condensate 5/8" (15.9) ID Condensate 1.84 1.84 (47) (47) Vinyl Hose 5/8" (15.9) ID Vinyl Hose RightHand HandConfiguration Configuration Right Water Out Water Water Out In Water In Out Out In Optional In Autoflow OptionalValve Autoflow Valve Optional Motorized Optional Water Valve Motorized Water Valve Optional Optional Autoflow Autoflow Valve Valve Optional Motorized Optional Water Valve Motorized Water Valve Water Connections 5/8"Connections (15.9) Water Copper, 5/8"OD (15.9) FPT or OD1/2" Copper, MPT 1/2"1/2" FPT or 1/2" MPT Optional Fused Disconnect Optional FusedBo (mounted Box to cab Disconnect not chassis) (mounted to cabin Available in notAlso chassis) Also Available in N Water Connections 1/2” FPT Water Connections 1/2” FPT 2.25 1.50 (38) 2.25 (57) Water Connections (57) 5/8" (15.9AA) *11.25 (286) WaterOD Connections Copper, 5/8" (15.9AA) *11.25 (286) 1/2" FPT or OD Copper, 1/2" MPT 1/2" FPT or 2.25 (57) 1/2" MPT 2.25 Optional (57) Disconnect Box Condensate Optional (mounted to cabinet 5/8" (15.9) ID Disconnect notBox chassis) 2.72 Condensate Vinyl Hose unted to cabinet (96) 5/8" (15.9) ID not chassis) 2.72 Vinyl Hose (96) 2.00 (51) 2.00 (51) 1.50 (38) 8.00 Min (203) 8.00 Min (203) Left Hand Configuration Left * Hand Configuration Notes: Notes: Dimension reduced by FPT fitting * Dimension reduced by FPT fitting ⚠ CAUTION! ⚠ CAUTION! Corrosive system water requires corrosion resistant fittings and hoses, and may require water treatment. � CAUTION! � ⚠ CAUTION! ⚠ CAUTION! Piping must comply with all applicable codes. � CAUTION! � Installation, Operation, Maintenance CAUTION! Corrosive system water requires corrosion 9 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Piping Connections, Cont’d. – JRC Size 18 40.98 (1040) Optional Motorized Water Valve 1.62 (41) 2.00 (51) Control Box Out In Optional Flow Regulator Water Out eck Compressor Access Panel Water In Water Connections 1/2” FPT 2.25 (57) Optional Motorized Water Valve *11.25 (286) 8.00 Min (203) ss Panel Optional Autoflow Valve 1.75 (44) Condensate 1.84 (47) 5/8" (15.9) ID Vinyl Hose Right Hand Configuration Water Out Optional Autoflow Valve Water In Out In Water Connections 1/2” FPT Optional Motorized Water Valve 1.50 (38) 2.25 (57) Water Connections 5/8" (15.9AA) OD Copper, 1/2" FPT or 1/2" MPT Optional isconnect Box unted to cabinet not chassis) Water Connections 5/8" (15.9) OD Copper, 1/2" FPT or 1/2" MPT Optional Fused Disconnect Box (mounted to cabinet not chassis) Also Available in Non-Fused *11.25 (286) 2.25 (57) 2.00 (51) 8.00 Min (203) Condensate 5/8" (15.9) ID Vinyl Hose 2.72 (96) Left Hand Configuration Notes: * Dimension reduced by FPT fitting ⚠ CAUTION! ⚠ CAUTION! Corrosive system water requires corrosion resistant fittings and hoses, and may require water treatment. � CAUTION! � ⚠ CAUTION! ⚠ CAUTION! Piping must comply with all applicable codes. � CAUTION! � tion, Operation, Maintenance 10 TION! Corrosive system water requires corrosion I n s t a l l aCAUTION! Piping must comply with all applicable codes. THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Piping Connections, Cont’d. ⚠ WARNING! ⚠ Installation of Supply and Return Piping - Follow these piping guidelines. 1. Install a drain valve at the base of each supply and return riser to facilitate system flushing. 2. Install shut-off / balancing valves and unions at each unit to permit unit removal for servicing. 3. Place strainers at the inlet of each system circulating pump. 4. Select the proper hose length to allow slack between connection points. Hoses may vary in length by +2% to -4% under pressure. 5. Refer to Table 1. Do not exceed the minimum bend radius for the hose selected. Exceeding the minimum bend radius may cause the hose to collapse, which reduces water flow rate. Install an angle adapter to avoid sharp bends in the hose when the radius falls below the required minimum. Insulation is not required on loop water piping except where the piping runs through unheated areas, outside the building or when the loop water temperature is below the minimum expected dew point of the pipe ambient conditions. Insulation is required if loop water temperature drops below the dew point (insulation is required for ground loop applications in most climates). 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. ⚠ CAUTION! ⚠ CAUTION! Do not bend or kink supply lines or hoses. Table 1: Metal Hose Minimum Bend Radii Hose Diameter Minimum Bend Radii 1/2" [12.7mm] 2-1/2" [6.4cm] 3/4" [19.1mm] 4" [10.2cm] 1" [25.4mm] 5-1/2" [14cm] NOTICE! Do not allow hoses to rest against structural building components. Compressor vibration may be transmitted through the hoses to the structure, causing unnecessary noise complaints. Pipe joint compound is not necessary when Teflon® thread tape is pre-applied to hose assemblies or when flared-end connections are used. If pipe joint compound is preferred, use compound only in small amounts on the external pipe threads of the fitting adapters. Prevent sealant from reaching the flared surfaces of the joint. Figure 2: Supply/Return Hose Kit Note: When antifreeze is used in the loop, insure that it is compatible with the Teflon tape or pipe joint compound that is applied. MPT Rib Crimped Maximum allowable torque for brass fittings is 30 ft-lbs [41 N-m]. If a torque wrench is not available, tighten finger-tight plus one quarter turn. Tighten steel fittings as necessary. Optional pressure-rated hose assemblies designed specifically for use with console water source heat pump units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses are fitted with swivel-joint fittings at one end to prevent kinking during installation. Refer to Figure 2 for an illustration of a typical supply/ return hose kit. Adapters secure hose assemblies to the unit and risers. Install hose assemblies properly and check regularly to avoid system failure and reduced service life. Installation, Operation, Maintenance MPT Swivel Brass Fitting Length (2 ft [0.6m] Length Standard) Reborde Acanalado MPT Brass Fitting Length (0.6m Length Standard) Rib Crimped MPT Swivel Brass Fitting Longitud (Long. Estándar de 2 pies) Brass Fitting MPT Accesorio Giratorio de Bronce Accesorio de Bronce MPT 11 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Water-Loop Heat Pump Applications Commercial Water Loop Applications - Commercial systems typically include a number of units connected to a common piping system. Any unit plumbing maintenance work can introduce air into the piping system; therefore air elimination equipment is a major portion of the mechanical room plumbing. In piping systems expected to utilize water temperatures below 50°F [10°C], 1/2” (13mm) closed cell insulation is required on all piping surfaces to eliminate condensation (extended range units required). Metal to plastic threaded joints should never be used due to their tendency to leak over time. Teflon tape thread sealant is recommended to minimize internal fouling of the heat exchanger. Do not over tighten connections and route piping so as not to interfere with service or maintenance access. Hose kits are available from the manufacturer in different configurations for connection between the unit and the piping system. Depending upon selection, hose kits may include shut off valves, P/T plugs for performance measurement, high pressure stainless steel braided hose, “Y” type strainer with blow down valve, and/or “J” type swivel connection. Balancing valves and an external low pressure drop solenoid valve for use in variable speed pumping systems may also be included in the hose kit. The piping system should be flushed to remove dirt, piping chips, and other foreign material prior to operation (see “Piping System Cleaning and Flushing Procedures” in this manual). The flow rate is usually set between 2.25 and 3.5 gpm per ton [2.9 and 4.5 l/m per kW] of cooling capacity. The manufacturer recommends 3 gpm per ton [3.9 l/m per kW] for most applications of water loop heat pumps. To insure proper maintenance and servicing, P/T ports are imperative for temperature and flow verification, as well as performance checks. Water loop heat pump (cooling tower/boiler) systems typically utilize a common loop, maintained between 60 90°F [16 - 32°C]. The use of a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary. Low Water Temperature Cutout Setting - CXM Control When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature (antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment. Table 2: Antifreeze Percentages by Volume Type Minimum Temperature for Freeze Protection 10ºF [-12.2ºC] 15ºF [-9.4ºC] 20ºF [6.7ºC] 25ºF [-3.9ºC] Methanol - 100% USP food grade 25% 21% 16% 10% Propylene Glycol 38% 30% 22% 15% 12 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 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. ⚠ CAUTION! ⚠ CAUTION! Ground loop applications require extended range equipment and optional refrigerant/water circuit insulation. 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 - 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. Antifreeze - If any liquid fluid or piping is exposed to unconditioned ambient below 42°F (5.5 C), antifreeze must be added. If the liquid fluid entering the heat pump is 50°F (10°C) or below, calculate the leaving heat pump temperature (shown in submittal on performance data selection notes section). Using the lowest temperature leaving the heat pump, must protect system 15°F (8°C) lower. IE: if temperature leaving the heat pump is 35°F subtract 15°F = 20°F protection required, if Methanol is used the system would require 16% mix by volume. Antifreeze is available in alcohol and glycols, contact local sales office for the best type for your system and area. Following must be considered safety, thermal performance, corrosiveness, local codes, stability, convenience, and cost. 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 2 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity. Low Water Temperature Cutout Setting - CXM Control When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature (antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment. 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 - Upon completion of system installation and testing, flush the system to remove all foreign objects and purge to remove all air. Installation, Operation, Maintenance 13 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Ground-Water Heat Pump Applications Open Loop - Ground Water Systems - 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 materials should be limited to copper, PE, or similar material. PVC or CPVC should never be used as they are incompatible with the POE oils used in HFC-410A products and piping system failure and property damage may result. ⚠ WARNING! ⚠ 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. Water quantity should be plentiful and of good quality. Consult table 3 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 3 for recommendations. Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a 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. Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F [66°C] for direct use (well water/open loop) and DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3. Expansion Tank and Pump - Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain 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. Water Control Valve - 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.. Water Quality Standards - Table 3 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and 14 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Ground-Water Heat Pump Applications, Cont’d. 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. Since the pressure is constantly varying, two pressure gauges may be needed. 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], 2 gpm per ton (2.6 l/m per kW) is required. Notice! Ground-water applications for commercial buildings with more than 2-3 units should include a plate frame heat-exchanger to isolate the heat pumps from the ground-water and confine heat exchanger cleanings to one location and lessen maintenance. Direct use of ground-water may increase the frequency of heat pump maintenance and may shorten life expectancy. Water Coil Low Temperature Limit Setting - For all open loop systems the 30°F [-1.1°C] LT1 setting (factory settingwater) 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. Installation, Operation, Maintenance 15 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Water Quality Standard Table 2: Water Quality Standards Clean water is essential to the performance and life span of water source heat pumps. Contaminants, chemicals, and minerals all have the potential to cause damage to the water heat heat exchanger if not treated properly. All closed water loop systems should undergo water quality testing and be maintained to the water quality standards listed in this table. WATER QUALITY STANDARDS Electrolysis All HX types Fouling & Biological Corrosion Preven�on Scaling Poten�al For Closed-Loop and Open-Loop Systems 16 Descrip�on pH - Chilled Water <85°F pH - Heated Water >85°F Alkalinity Calcium Magnesium Total Hardness Langelier Satura�on Index Ryznar Stability Index Total Dissolved Solids Sulfate Nitrate Chlorine (free) Chloride (water < 80°F) Chloride (water > 120°F) Hydrogen Sulfideα Symbol (HCO3-) ppm - CaCO3 equiv. (Ca) ppm (Mg) ppm (CaCO3) ppm - CaCO3 equiv. LSI RSI ppm - CaCO3 equiv. (TDS) (SO42-) ppm (NO3-) ppm (Cl) ppm ppm (Cl ) ppm (H2S) ppb Carbon Dioxide Iron Oxide Manganese Ammonia Chloramine (Fe) (Mn) (NH3) (NH2CL) ppm ppm ppm ppm ppm (TSS) cells/mL cells/mL cells/mL ppm (CO2) Iron Bacteria Slime Forming Bacteria Sulfate reducing bacteria Suspended Solidsβ Units Earth Ground Resistanceχ Ohms Electrolysis Voltage Leakage Currentδ mV mA δ Heat Exchanger Type Closed Loop Open Loop, Tower, Ground Source Well Recircula�ng All Heat Exchanger COAXIAL HX Copper COAXIAL HX Brazed Plate HX Types Tube in Tube Cupronickel 316 SS 7.0 to 9.0 7.0 to 9.0 7.0 to 9.0 7.0 to 9.0 8.0 to 10.0 8.0 to 10.0 8.0 to 10.0 8.0 to 10.0 50 to 500 50 to 500 50 to 500 50 to 500 <100 <100 <100 <100 <100 <100 <100 <100 30 to 150 150 to 450 150 to 450 150 to 450 -0.5 to +0.5 -0.5 to +0.5 -0.5 to +0.5 -0.5 to +0.5 6.5 to 8.0 6.5 to 8.0 6.5 to 8.0 6.5 to 8.0 <1000 <1000 <1000 <1500 <200 <200 <200 <200 <100 <100 <100 <100 <0.5 <0.5 <0.5 <0.5 <20 <20 <150 <150 <20 <20 <125 <125 <0.5 <0.5 <0.5 <0.5 0 <1.0 < 0.4 <0.05 0 <50 <1.0 <0.4 <0.1 0 10 to 50 <1.0 <0.4 <0.1 0 10 to 50 <0.2 <0.4 <0.1 0 0 0 0 <10 0 0 0 <10 0 0 0 <10 0 0 0 <10 0 <300 <15 Consult NEC & local electrical codes for grounding requirements Measure voltage internal water loop to HP ground Measure current in water loop pipe Building Primary Electrical Ground to unit, must meet local diameter and penetra�on length requirements Do not connect heat pump to steel pipe unless dissimilar materials are separated by using Di-electric unions. Galvanic corrosion of heat pump water pipe will occur. Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Water Quality Standards, Cont’d. 1. The Water Quality Table provides water quality requirements for coaxial & brazed plate heat exchangers. 2. The water must be evaluated by an independent testing facility comparing site samples against this Table. When water properties are outside of these parameters, the water must either be treated by a professional water treatment specialist to bring the water quality within the boundaries of this specification, or an external secondary heat exchanger must be used to isolate the heat pump water system from the unsuitable water. Failure to do so will void the warranty of the heat pump system and will limit liability for damage caused by leaks or system failure. 3. Regular sampling, testing and treatment of the water is necessary to assure that the water quality remains within acceptable levels thereby allowing the heat pump to operate at optimum levels. 4. If closed‐loop systems are turned off for extended periods, water samples must be tested prior to operating the system. 5. For optimal performance, it is recommended that the closed‐loop piping systems are initially filled with de‐ ionized water. 6. Well water with chemistry outside of these boundaries, and salt water or brackish water requires an external secondary heat exchanger. Surface/Pond water should not be used. 7. If water temperature is expected to fall below 40°F, antifreeze is required. Refer to the heat pump IOM for the correct solution ratios to prevent freezing. α β χ δ Hydrogen Sulfide has an odor of rotten eggs. If one detects this smell, a test for H2S must be performed. If H2S is detected above the limit indicated, remediation is necessary (Consult with your Water Testing/Treatment Professional) or a secondary heat exchanger is required using appropriate materials as recommended by the heat exchanger supplier. Suspended solids and particulates must be filtered to prevent fouling and failure of heat exchangers. Strainers or particulate filters must be installed to provide a maximum particle size of 600 micron (0.60 mm, 0.023 in.) using a 20 to 30 mesh screen size. When a loop is installed in areas with fine material such as sand or clay, further filtration is required to a maximum of 100 micron. Refer to the Strainer / Filter Sizing Chart to capture the particle sizes encountered on the site. An electrical grounding system using a dedicated ground rod meeting NEC and Local Electrical codes must be installed. Building Ground must not be connected the WSHP piping system or other plumbing pipes. Refer to IOM for instructions on measuring resistance and leakage currents within water loops. Do not use PVC pipe for water loop (compressor POE oil and glycols damage PVC) use of HDPE pipe is recommended. Strainer / Filter Sizing Mesh Size Particle Size Microns MM Inch 20 840 0.840 0.0340 30 533 0.533 0.0210 60 250 0.250 0.0100 100 149 0.149 0.0060 150 100 0.100 0.0040 200 74 0.074 0.0029 ppm = parts per million ppb = parts per billion Installation, Operation, Maintenance 17 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Water Quality Standards, Cont’d. Measuring Earth Ground Resistance 0.02� Well Casing Building Ground Rod OHM meter Measure the earth ground bond using an Ohm meter between the building's ground rod and the steel well casing. The resistance measured should be zero Ohms. The NEC allows a resistance to ground up to 20 Ohms. Any resistance above zero, indicates a poor earth ground which may be the result of a hot neutral line or that conduc�ve water is present. Both of these may lead to electrolysis and corrosion of the heat pump piping. A check for both should be performed and resolved. Note if the well casing is plas�c, a conduc�ve path can be achieved by inser�ng a #6 AWG bare copper wire into the well water. Remove the temporary conductor when finished. 18 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Water Quality Standards, Cont’d. Measuring Electrolysis Voltage and Current 300mV Heat Pump Volt Meter Wire Electrode inserted into port for Voltage measurement Pete's Port Water-in Water-out Amp Sensor to VOM for Current HP Piping Measure the electrolysis voltage using a volt meter between the heat pump ground and a #14 AWG solid copper wire electrode inserted into the water using a Pete's style access port. The HP must be opera�ng and the water stream flowing. The voltage measured should be less than 300mV (0.300 V). If higher than 500mV electrolysis will occur and corrosion will result. If voltage is measured, the cause is a high resistance earth ground or current on the neutral conductor. Remedial measures should be performed. Measure the current flowing through the piping system by using an amp clamp probe on the water-in line. The HP must be opera�ng and the water stream flowing. There should be zero amps measured. If current is present, there is leakage current to the plumbing system and it must be rec�fied to prevent pipe corrosion. Installation, Operation, Maintenance 19 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Electrical – Line Voltage ⚠ 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! 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. Consult Tables 4 through 5 for correct fuse size. ⚠ CAUTION! ⚠ 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. All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building. 20 Transformer - All commercial dual voltage units are factory wired for 208/60/1. If supply voltage is 230/60/1, installer must rewire transformer. See wire diagram for connections. Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Electrical Table 4: JRC Electrical Data (60Hz) Model JRC09 JRC12 Voltage Code Voltage Min/Max Voltage A 115/60/1 104-126 RLA LRA Fan Motor FLA 8.0 50.0 0.6 Compressor G 208-230/60/1 197-254 3.7 22.0 0.5 E 265/60/1 239-292 3.5 22.0 0.4 A 115/60/1 104-126 9.5 50.0 1.0 G 208-230/60/1 197-254 4.7 25.0 0.6 E 265/60/1 239-292 4.2 22.0 0.4 G 208-230/60/1 197-254 5.6 29.0 0.7 JRC15 E 265/60/1 239-292 5.0 28.0 0.6 G 208-230/60/1 197-254 6.6 33.0 0.7 JRC18 E 265/60/1 239-292 5.6 28.0 0.6 Pump Option FLA Total Unit FLA Min Circuit Amps Max Fuse Amps N/A 8.60 10.60 15 1.0 9.60 11.60 15 N/A 4.20 5.13 15 0.8 5.00 5.93 15 N/A 3.90 4.78 15 0.7 4.60 5.48 15 N/A 10.50 12.88 20 1.4 11.90 14.28 20 N/A 5.30 6.48 15 1.07 6.37 7.55 15 N/A 4.60 5.65 15 1.3 5.90 6.95 15 N/A 6.30 7.70 15 1.07 7.37 8.77 15 N/A 5.60 6.85 15 1.3 6.90 8.15 15 N/A 7.30 8.95 15 1.07 8.37 10.02 15 N/A 6.20 7.60 15 1.3 7.50 8.90 15 Installation, Operation, Maintenance 21 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Electrical, Cont’d. ⚠ WARNING! ⚠ Figure 3: Typical Field Installed Wiring A Heat Pump Field Supplied Disconnect Switch B Room Thermostat A= Two power wires on single-phase units: three power wires on three-phase units. B= 1 heat /1 cool /manual or Auto Change-over remote 24V thermostat. Note: All customer-supplied wiring to be copper only and must conform to NEC and local electrical codes. Wiring shown with dashed lines must be field-supplied and field-installed. "B" only required with systems employing remote mounted thermostats. Low Water Temperature Cutout Setting - CXM Control When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature (antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment. 22 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. ⚠ CAUTION! ⚠ CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors. Figure 4: LT1 Limit Setting LT1 LT2 CXM PCB Installation, Operation, Maintenance JW3-LT1 jumper should be clipped for low temperature operation LT1 LT1 LT2 LT2 THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Electrical, Cont’d. Table 6: Recommended Thermostat Wire Sizes Wire Size Maximum Wire Length* 18-Gauge 75 feet [22m] 16-Gauge 125 feet [38m] 14-Gauge 200 feet [60 m] *Length = Physical distance from thermostat to unit. Thermostat Installation - The thermostat should be located on an interior wall in a larger room, away from supply air 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 Figure 7 to the low voltage terminal strip on the CXM or DXM control board. Practically any heat pump thermostat will work with JRC WSHP units, provided it has the correct number of heating and cooling stages. Figure 7: Typical Remote Thermostat Wiring Connection to CXM Control Thermostat CXM Compressor Y Y Reversing Valve Fan 24Vac Hot 24Vac Common Fault LED O O R R G G C C L AL1 Figure 7a: Wiring for multiple units to be controlled from 1 thermostat Thermostat Zone integrity must be maintained to efficiently control units or groups of units. Unless zones of control are considered and accounted for, adjacent units may operate in heating and cooling modes simultaneously. To prevent this problem, multiple units configured with the DXM controller can be controlled by one thermostat as shown in figure 7A. CS DXM Unit 1 CS DXM Unit 2-6 Connect thermostat to Unit 1 then jumper Com 1 (S to S and C to C) up to 6 units with twisted pair. Installation, Operation, Maintenance 23 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 JRC Series Wiring Diagram Matrix Model Wiring Diagram Electrical Part Number V-Hz-Ph 115-60-1, 96B0292N02 JRC09 JRC18 96B0292N04 Control REM 208/230-60-1, CXM 265-60-1 96B0293N02 115-60-1, 96B0293N04 208/230-60-1, DXM MPC REM MPC DIP Setting for Board JRC DIGIT 8 = C,R + CXM Standard OFF ON 1 JRC DIGIT 8 = D,S + DXM Standard OFF ON OFF ON 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 7 7 S1 8 8 S1 JRC DIGIT 8 = L,N + CXM w/MPC OFF ON 1 S2 JRC DIGIT 8 = M,P + DXM w/MPC OFF ON OFF 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 7 7 8 8 S1 S1 24 ON 1 Installation, Operation, Maintenance S2 THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 CXM Controls CXM Control - For detailed control information, see CXM Application, Operation and Maintenance (AOM) manual. Field Selectable Inputs - Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. At board, momentarily shorting the test terminals or externally, momentarily push test button (See Fig 22), the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals or holding button for 3 seconds. Retry Mode: If the control is attempting a retry of a fault, the status LED will slow flash (slow flash = one flash every 2 seconds) to indicate the control is in the process of retrying. Field Configuration Options - Note: In the following field configuration options, jumper wires should be clipped ONLY when power is removed from the CXM control. Water coil low temperature limit setting: Jumper 3 (JW3LT1 Low Temp) provides field selection of temperature limit setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Air coil low temperature limit setting: Jumper 2 (JW2-LT2 Low Temp) provides field selection of temperature limit setting for LT2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory. Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides field selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection). Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection). DIP Switches - Note: In the following field configuration options, DIP switches should only be changed when power is removed from the CXM control. DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will NOT cycle during test mode. On = Stage 1. Off = Stage 2 DIP switch 3: Not Used. DIP switch 4: DDC Output at EH2 - provides selection for DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output. On = EH2 Normal. Off = DDC Output at EH2. Note: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1. Jumper not clipped = EH2 Normal. Jumper clipped = DDC Output at EH2. DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory. Table 7a: LED And Alarm Relay Operations Description of Operation Normal Mode Normal Mode w/UPS Warning LED ON Open Flashing Code 1 Flashing Code 2 Flashing Code 3 Flashing Code 4 Flashing Code 5 Flashing Code 6 Cycle (Closed 5 seconds, Open 25 seconds) Open Open Closed Open (Closed after 15 Minutes) Cycling Code 1 Cycling Code 2 Cycling Code 3 Cycling Code 4 Cycling Code 5 Cycling Code 6 Flashing Code 7 Cycling Code 7 Flashing Code 8 Flashing Code 9 Cycling Code 8 Cycling Code 9 ON CXM is non-functional Fault Retry Lockout OFF Slow Flash Fast Flash Over/Under Voltage Shutdown Slow Flash Test Mode - No Fault in Memory Test Mode - HP Fault in Memory Test Mode - LP Fault in Memory Test Mode - LT1 Fault in Memory Test Mode - LT2 Fault in Memory Test Mode - CO Fault in Memory Test Mode - Over/Under Shutdown in Memory Test Mode - UPS in Memory Test Mode - Swapped Thermistor Alarm - Slow Flash = 1 flash every 2 seconds - Fast Flash = 2 flashes every 1 second - Flash code 2 = 2 quick flashes, 10 second pause, 2 quick flashes, 10 second pause, etc. - On pulse 1/3 second; off pulse 1/3 second DIP switch 1: Not Applicable.. On = Enabled. Off = Disabled. Installation, Operation, Maintenance 25 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 DXM Controls DXM Control - For detailed control information, see DXM AOM (part #97B0003N13), Lon controller AOM (part #97B0013N01) or MPC AOM (part # 97B0031N01). Table 7b: DXM LED And Alarm Relay Operations Description of Operation Status LED (green) Test LED (yellow) Fault LED (red) Normal mode On - Off Normal mode with UPS On - Flashing Code 8 DXM is non-functional Fault Retry Lockout Test Mode Night Setback ESD Invalid T-stat Inputs Off Slow Flash Fast Flash Flashing Code 2 Flashing Code 3 Flashing Code 4 Off On - Off Flashing fault code Flashing fault code - HP Fault LP Fault LT1 Fault LT2 Fault CO Fault Slow Flash Slow Flash Slow Flash Slow Flash Slow Flash - Flashing Code 2 Flashing Code 3 Flashing Code 4 Flashing Code 5 Flashing Code 6 Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Air coil low temperature limit setting: Jumper 2 (JW2-LT2 Low Temp) provides field selection of temperature limit setting for LT2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, Alarm Relay as recommended by Enertech technical Open services. Cycle (closed 5 sec, open 25 sec) Not Clipped = 30°F [-1°C]. Open Clipped = 10°F [-12°C]. Open Closed Open Open Open Open Open Alarm relay setting: Jumper 4 (JW4-AL2 Dry) provides field selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection). Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection). Open (closed after 15 minutes) Low pressure normally open: Jumper 1 (JW1LP norm open) provides field selection for low Notes: -a) Codes Slow = 1with flash every pressure input to be normally closed or normally open. will Flash be displayed a 10 second LED2offseconds period. For example: Code 3 times, every off for 10 seconds, flash 3 times, off for 10 seconds, etc… Not Clipped = LP normally closed. -b) Slow Fast Flash =3=2flash flashes 1 second flash will be 1 flash per every 2 seconds. -c) Fast Flash code 2 = 2perquick second Clipped = LP normally open. flash will be 2 flashes every 1 flashes, second (same10 as currently is). pause, 2 quick flashes, 10 second pause, etc. - On pulse 1/3 second; off pulse 1/3 second DIP Switches - Note: In the following field configuration options, DIP switches should only be Field Selectable Inputs - Test mode: Test mode allows changed when power is removed from the DXM the service technician to check the operation of the control. control in a timely manner. By momentarily shorting the test terminals, the DXM control enters a 20 minute test DIP Package #1 (S1) - DIP Package #1 has 8 switches mode period in which all time delays are sped up 15 and provides the following setup selections: times. Upon entering test mode, the status LED will flash 1.1 - Not Applicable. a code representing the last fault. For diagnostic ease at On = Enabled. Off = Disabled. the thermostat, the alarm relay will also cycle during test 1.2 - Compressor relay staging operation: DIP 1.2 mode. The alarm relay will cycle on and off similar to the provides selection of compressor relay staging operation. status LED to indicate a code representing the last fault, at The compressor relay can be selected to turn on with a the thermostat. Test mode can be exited by shorting the stage 1 or stage 2 call from the thermostat. This is used test terminals for 3 seconds. with dual stage units (2 compressors where 2 DXM controls are being used) or with master/subordinate Retry mode: If the control is attempting a retry of a fault, applications. In master/subordinate applications, each the status LED will slow flash (slow flash = one flash compressor and fan will stage according to its appropriate every 2 seconds) to indicate the control is in the process DIP 1.2 setting. If set to stage 2, the compressor will have of retrying. a 3 second on-delay before energizing during a Stage 2 demand. Also, if set for stage 2, the alarm relay will NOT Field Configuration Options - Note: In the following cycle during test mode. field configuration options, jumper wires should be clipped On = Stage 1. Off = Stage 2. ONLY when power is removed from the DXM control. Over/Under Voltages Slow Flash - Flashing Code 7 Water coil low temperature limit setting: Jumper 3 (JW3-LT1 Low Temp) provides field selection of temperature limit setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). 26 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 DXM Controls, Cont’d. 1.3 - Thermostat type (heat pump or heat/cool): DIP 1.3 provides selection of thermostat type. Heat pump or heat/cool thermostats can be selected. When in heat/ cool mode, Y1 is the input call for cooling stage 1; Y2 is the input call for cooling stage 2; W1 is the input call for heating stage 1; and O/W2 is the input call for heating stage 2. In heat pump mode, Y1 is the input call for compressor stage 1; Y2 is the input call for compressor stage 2; W1 is the input call for heating stage 3 or emergency heat; and O/W2 is the input call for reversing valve (heating or cooling, depending upon DIP 1.4). On = Heat Pump. Off = Heat/Cool. 1.4 - Thermostat type (O/B): DIP 1.4 provides selection of thermostat type for reversing valve activation. Heat pump thermostats with “O” output (reversing valve energized for cooling) or “B” output (reversing valve energized for heating) can be selected with DIP 1.4. On = HP stat with “O” output for cooling. Off = HP stat with “B” output for heating. 1.5 - Dehumidification mode: DIP 1.5 provides selection of normal or dehumidification fan mode. In dehumidification mode, the fan speed relay will remain off during cooling stage 2. In normal mode, the fan speed relay will turn on during cooling stage 2. On = Normal fan mode. Off = Dehumidification mode. 1.6 - DDC output at EH2: DIP 1.6 provides selection for DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output. On = EH2 Normal. Off = DDC Output at EH2. 1.7 - Boilerless operation: DIP 1.7 provides selection of boilerless operation. In boilerless mode, the compressor is only used for heating when LT1 is above the temperature specified by the setting of DIP 1.8. Below DIP 1.8 setting, the compressor is not used and the control goes into emergency heat mode, staging on EH1 and EH2 to provide heating. On = normal. Off = Boilerless operation. 1.8 - Boilerless changeover temperature: DIP 1.8 provides selection of boilerless changeover temperature setpoint. Note that the LT1 thermistor is sensing refrigerant temperature between the coaxial heat exchanger and the expansion device (TXV). Therefore, the 50°F [10°C] setting is not 50°F [10°C] water, but approximately 60°F [16°C] EWT. On = 50°F [10°C]. Off = 40°F [16°C]. DIP Package #2 (S2) - DIP Package #2 has 8 switches and provides the following setup selections: 2.1 - Accessory1 relay personality: DIP 2.1 provides selection of ACC1 relay personality (relay operation/ characteristics). See table 5c for description of functionality. 2.2 - Accessory1 relay personality: DIP 2.2 provides selection of ACC 1 relay personality (relay operation/ characteristics). See table 5c for description of functionality. 2.3 - Accessory1 relay personality: DIP 2.3 provides selection of ACC 1 relay options. See table 5c for description of functionality. 2.4 - Accessory2 relay personality: DIP 2.4 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table 5c for description of functionality. 2.5 - Accessory2 relay personality: DIP 2.5 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table 5c for description of functionality. 2.6 - Accessory2 relay personality: DIP 2.6 provides selection of ACC 2 relay options. See table 5c for description of functionality. 2.7 - Auto dehumidification fan mode or high fan mode: DIP 2.7 provides selection of auto dehumidification fan mode or high fan mode. In auto dehumidification mode, the fan speed relay will remain off during cooling stage 2 IF the H input is active. In high fan mode, the fan enable and fan speed relays will turn on when the H input is active. On = Auto dehumidification mode. Off = High fan mode. 2.8 - Special factory selection: DIP 2.8 provides special factory selection. Normal position is “On”. Do not change selection unless instructed to do so by the factory. Table 7c: Accessory DIP Switch Settings DIP 2.1 DIP 2.2 DIP 2.3 ACC1 Relay Option On On On Cycle with fan Off On On Digital NSB On Off On Water Valve - slow opening On On Off OAD Off Off Off Reheat Option - Humidistat Off On Off Reheat Option - Dehumidistat DIP 2.4 DIP 2.5 DIP 2.6 ACC2 Relay Option On On On Cycle with compressor Off On On Digital NSB On Off On Water Valve - slow opening On On Off OAD All other DIP combinations are invalid Installation, Operation, Maintenance 27 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Safety Features – CXM/DXM Controls Safety Features – CXM/DXM Control - The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor. Note: The 5 minute anti-short cycle also occurs at power up. Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 120 seconds of a compressor run cycle. Low pressure lockout code = 3 Random start: The control features a random start upon power up of 5-80 seconds. Water coil low temperature (LT1): The LT1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a LT1 fault. The LT1 input is bypassed for the initial 120 seconds of a compressor run cycle. LT1 is set at the factory for one try. Therefore, the control will go into lockout mode once the LT1 fault has occurred. LT1 lockout code = 4 Fault Retry: In Fault Retry mode, the Status LED begins slowly flashing to signal that the control is trying to recover from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the thermostat input call is satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into “lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed at the “fault” LED (DXM board) or by going into test mode (CXM board). Note: LT1/LT2 faults are factory set at only one try. Lockout: In lockout mode, the status LED will begin fast flashing. The compressor relay is turned off immediately. Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault memory. Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur. If DXM is configured for heat pump thermostat type (DIP 1.3), emergency heat will become active if O/ W2 is energized. High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before de-energizing the compressor). High pressure lockout code = 2 Air coil low temperature (LT2): The LT2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a LT2 fault. The LT2 input is bypassed for the initial 60 seconds of a compressor run cycle. LT2 is set at the factory for one try. Therefore, the control will go into lockout mode once the LT2 fault has occurred. LT2 lockout code = 5 Condensate overflow: The condensate overflow sensor must sense overflow level for 30 continuous seconds to be recognized as a CO fault. Condensate overflow will be monitored at all times. CO lockout code = 6 Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC. Over/under voltage shut down is a self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM/DXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close. Over/under voltage shut down code = 7 Example: 2 quick flashes, 10 sec pause, 2 quick flashes, 10 sec. pause, etc. 28 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Safety Features – CXM/DXM Controls, Cont’d. Unit Performance-UPS: The UPS feature indicates when the heat pump is operating inefficiently. A UPS condition exists when: a. b. c. In heating mode with compressor energized, LT2 is greater than 125°F [52°C] for 30 continuous seconds, or: In cooling mode with compressor energized, LT1 is greater than 125°F [52°C] for 30 continuous seconds, or: In cooling mode with compressor energized, LT2 is less than 40°F [4.5°C] for 30 continuous seconds. If a UPS condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for 5 seconds, “off” for 25 seconds, etc. UPS warning code = 8 Swapped LT1/LT2 thermistors: During test mode, the control monitors to see if the LT1 and LT2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout with code 9 after 30 seconds if: a. The compressor is on in the cooling mode and the LT1 sensor is colder than the LT2 sensor, or: b. The compressor is on in the heating mode and the LT2 sensor is colder than the LT1 sensor. Swapped LT1/LT2 thermistor code = 9. CXM/DXM CONTROLS Diagnostic Features - The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory, the LED will flash Code 1 (when in test mode). The green status LED and red fault LED on the DXM board advise the technician of the current status of the DXM control. The status LED will indicate the current mode that the DXM control is in. The fault LED will ALWAYS flash a code representing the LAST fault in memory. If there is no fault in memory, the fault LED will flash Code 1. The yellow test LED will turn on when in test mode. CAUTION: Do not restart units without inspection and remedy of faulting condition. Damage may occur. CXM/DXM Control Start-up Operation - The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a 5 minute anti-short cycle delay at power-up. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted. ESD (DXM only): The ESD (Emergency Shut Down) mode can be enabled from an external common signal to terminal ESD to shut down the unit. The green status light will flash code 3 when the unit is in ESD mode. ESD mode = code 3 (green “status” LED) Installation, Operation, Maintenance 29 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit Commissioning and Operating Conditions Environment - This unit is designed for indoor installation only. Do not install in an area subject to freezing or where humidity levels can cause cabinet condensation. Power Supply - A voltage variation of +/- 10% of nameplate utilization voltage is acceptable. The commissioning table indicates air and water temperatures which are suitable for initial unit commissioning in an environment where the flow rate and water temperature is not yet stable and to avoid nuisance shut down of the units freeze and refrigerant pressure safeties. Operation and performance is primarily dependent upon return air temperature, airflow, water temperature, water flow rate and ambient air temperature. This water to air heat pump is capable of operating over a wide temperature range and with flow rates of between 1.5 GPM (.1 l/s) and 3 GPM (.19 l/s) per ton, however usually no more than one of these factors may be at a minimum or maximum level at a time. The operating table indicates the maximum and minimum ranges of the unit. Table 8: Building Commissioning Table 9: Water Temperature Change Through Heat Exchanger BUILDING COMMISSIONING For more specific unit performance reference the product catalog, the submittal data sheets or contact your supplier for assistance. This is used in the TRW IOM-option for open loop is deleted ALL JRC MODELS Cooling °F [°C] Heating °F [°C] AMBIENT MIN - MAX DB 45-110 [7-43] 40-85 [4.5-29] RETURN AIR MIN DB/WB 60/45 [16/7] 40 [4.5] RETURN AIR MAX DB/WB 110/83 [43/28] 80 [27] STANDARD UNIT ENTERING WATER MIN* - MAX 40-120 [4.5-49] 60-90 [16-43] EXTENDED RANGE UNIT** ENTERING WATER MIN* - MAX 30-120 [-1-49] 20-90 [-6.7-32] *- Requires optional insulation package when operating below the dew point **- Requires antifreeze, optional insulation package and jumper clipped. Table 8A: Unit Operating Limits UNIT OPERATING LIMITS All JRC Models Cooling °F [°C] Heating °F [°C] AMBIENT MIN - MAX DB 50-100 [10-38] 50-85 [10-29] RETURN AIR MIN DB/WB 65/60 [18/15.5] 50 [10] RETURN AIR MAX DB/WB 95/75 [35/24] 80 [27] STANDARD UNIT ENTERING WATER MIN* - MAX 50-120 [10-49] 60-90 [16-43] EXTENDED RANGE UNIT** ENTERING WATER MIN* - MAX 30-120 [-1-49] 20-90 [-6.7-32] *- Requires optional insulation package when operating below the dew point **- Requires antifreeze, optional insulation package and jumper clipped. 30 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Piping System Cleaning and Flushing Piping System Cleaning and Flushing - Cleaning and flushing the WLHP piping system is the single most important step to ensure proper start-up and continued efficient operation of the system. Follow the instructions below to properly clean and flush the system: 1. Ensure that electrical power to the unit is disconnected. 2. Install the system with the supply hose connected directly to the return riser valve. Use a single length of flexible hose. 3. Open all air vents. Fill the system with water. DO NOT allow system to overflow. Bleed all air from the system. Pressurize and check the system for leaks and repair as appropriate. 4. Verify that all strainers are in place (the manufacturer recommends a strainer with a #20 stainless steel wire mesh). Start the pumps, and systematically check each vent to ensure that all air is bled from the system. 5. Verify that make-up water is available. Adjust makeup water as required to replace the air which was bled from the system. Check and adjust the water/air level in the expansion tank. 6. Set the boiler to raise the loop temperature to approximately 86°F [30°C]. Open a drain at the lowest point in the system. Adjust the make-up water replacement rate to equal the rate of bleed. 7. Refill the system and add trisodium phosphate in a proportion of approximately one pound per 150 gallons [1/2 kg per 750 l] of water (or other equivalent approved cleaning agent). Reset the boiler to raise the loop temperature to 100°F [38°C]. Circulate the solution for a minimum of 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning if desired. 8. When the cleaning process is complete, remove the short-circuited hoses. Reconnect the hoses to the proper supply, and return the connections to each of the units. Refill the system and bleed off all air. 9. Test the system pH with litmus paper. The system water should be in the range of pH 6.0 - 8.5 (see table 3). Add chemicals, as appropriate to maintain neutral pH levels. 10. When the system is successfully cleaned, flushed, refilled and bled, check the main system panels, safety cutouts and alarms. Set the controls to properly maintain loop temperatures. ⚠ CAUTION! ⚠ CAUTION! To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 110ºF (43ºC). Note: The manufacturer strongly recommends all piping connections, both internal and external to the unit, be pressure tested by an appropriate method prior to any finishing of the interior space or before access to all connections is limited. Test pressure may not exceed the maximum allowable pressure for the unit and all components within the water system. The manufacturer will not be responsible or liable for damages from water leaks due to inadequate or lack of a pressurized leak test, or damages caused by exceeding the maximum pressure rating during installation. DO NOT use “Stop Leak” or similar chemical agent in this system. Addition of chemicals of this type to the loop water will foul the heat exchanger and inhibit unit operation. Installation, Operation, Maintenance 31 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit and System Checkout Procedure ⚠ WARNING! ⚠ 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. 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. Commercial 208230V units are factory wired for 208V operation unless specified otherwise. Entering water and air: Insure that entering water and air temperatures are within operating limits of Table 8. Low water temperature cutout: Verify that low water temperature cut-out on the CXM/DXM 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. 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 CXM or DXM field selection options are properly set. 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 3). System flushing: Verify that all hoses are connected end to end when flushing to insure that debris bypasses the unit heat exchanger, water valves and other components. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify that all air is purged from the system. Air in the system can cause poor operation or system corrosion. Cooling tower/boiler: Check equipment for proper set points and operation. Standby pumps: Verify that the standby pump is properly installed 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 provided for the outdoor portion of the loop. Otherwise, operating problems may occur. System control center: Verify that the control center and alarm panel have appropriate set points and are operating as designed. 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. NOTICE! Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration. 32 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit Start-Up Procedure Unit Start-up Procedure 1. Turn the thermostat fan position to “ON”. Blower should start. 2. Balance air flow at registers. 3. Adjust all valves to their full open positions. Turn on the line power to all heat pumps. 4. Room temperature should be within the minimummaximum ranges of table 8. During start-up checks, loop water temperature entering the heat pump should be between 60°F [16°C] and 95°F [35°C]. 5. Two factors determine the operating limits of JRC heat pumps, (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal level to insure proper unit operation. a. Adjust the unit thermostat to the warmest setting. Place the thermostat mode switch in the “COOL” position. Slowly reduce thermostat setting until the compressor activates. b. Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate. Note: Units have a five minute time delay in the control circuit that can be eliminated on the CXM/ DXM control board as shown below in Figure 8. See controls description for details. c. 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. d. Refer to Table 9. 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. e. 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]. f. Turn thermostat to “OFF” position. A hissing noise indicates proper functioning of the reversing valve. 6. 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 9. 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. e. Check air temperature rise across the air coil when compressor is operating. Air temperature rise should be between 20°F and 30°F [11°C and 17°C]. f. Check for vibration, noise, and water leaks. 7. If unit fails to operate, perform troubleshooting analysis (see troubleshooting section). If the check described fails to reveal the problem and the unit still does not operate, contact a trained service technician to insure proper diagnosis and repair of the equipment. 8. When testing is complete, set system to maintain desired comfort level. Note: If performance during any mode appears abnormal, refer to the CXM/DXM section or troubleshooting section of this manual. To obtain maximum performance, the air coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended. ⚠ 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. Figure 8: Test Mode Pins Installation, Operation, Maintenance Short test pins together to enter Test Mode and speed-up timing and delays for 20 minutes. LT1 LT2 LT1 LT1 LT2 LT2 33 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit Operating Conditions NOTE: Table 10 includes the following notes: • Airflow is at nominal (rated) conditions; • Entering air is based upon 70°F [21°C] DB in heating and 80/67°F [27/19°C] in cooling; • Subcooling is based upon head pressure at compressor service port; • Cooling air and water values can vary greatly with changes in humidity level. Table: 10 JRC Series Typical Operating Pressures and Temperatures (60 Hz I-P Units) JRC09 Entering Water Temp °F 30 Water Flow GPM/ Ton 1.4 2 2.75 Cooling 126-136 126-136 126-136 161-181 146-166 131-151 17-22 17-22 17-22 8-13 7-12 6-11 19.8-21.8 14.9-16.9 9.9-11.9 21-27 21-27 21-27 74-84 77-87 79-89 278-298 280-300 283-303 6-11 6-11 6-11 4-9 4-9 3-8 6.1-8.1 4.5-6.5 2.8-4.8 Air Temp Rise °F DB 18-24 18-24 19-25 Suction Discharge Pressure Pressure PSIG PSIG SuperSubheat cooling Water Temp Rise °F Air Temp Suction Discharge Super- SubDrop °F Pressure Pressure heat cooling DB PSIG PSIG Water Temp Drop °F 50 1.4 2 2.75 132-142 132-142 132-142 215-235 200-220 185-205 10-15 10-15 10-15 8-13 7-12 6-11 18.8-20.8 14.4-16.1 9.4-11.4 20-26 20-26 20-26 104-114 106-116 108-118 309-329 312-332 315-335 8-12 8-12 8-12 7-12 7-12 7-12 9.6-11.6 7-9 4.5-6.5 24-30 24-30 25-31 70 1.4 2 2.75 138-148 138-148 137-147 278-298 263-283 248-268 8-13 8-13 8-13 9-14 8-13 7-12 17.7-19.7 13.1-15.1 8.5-10.5 19-25 19-25 19-25 127-137 132-142 138-148 332-352 340-360 341-367 10-15 11-16 13-18 10-15 10-15 10-15 12-14 9-10 6.1-8.1 29-35 29-35 30-36 1.4 2 2.75 1.4 2 2.75 142-152 142-152 142-152 150-160 150-160 150-160 365-385 351-371 337-357 439-459 439-459 439-459 8-13 8-13 8-13 7-12 7-12 7-12 9-14 8-13 7-12 9-14 8-13 7-12 16-18 12-14 8-10 14.2-16.2 10.6-12.6 6.9-8.9 18-24 18-24 18-24 17-23 17-23 17-23 164-174 165-175 167-177 372-392 375-395 379-399 17-22 18-23 19-24 13-18 13-18 13-18 14.5-16.5 11.2-13.2 7.9-9.9 35-41 35-41 36-42 90 110 JRC12 Entering Water Temp °F 30 Water Flow GPM/ Ton 1.75 2.6 3.5 Cooling Heating 98-108 98-108 99-109 140-160 135-155 127-148 36-41 36-41 36-41 14-19 12-17 10-15 17.1-19.1 12.5-14.5 7.9-9.9 19-25 19-25 19-25 72-82 85-95 78-88 301-321 304-324 308-328 9-14 9-14 9-14 12-17 12-17 12-17 6.5-8.5 4.7-6.7 2.9-4.9 Air Temp Rise °F DB 21-27 21-27 22-28 Suction Discharge Pressure Pressure PSIG PSIG SuperSubheat cooling Water Temp Rise °F Air Temp Suction Discharge Super- SubDrop °F Pressure Pressure heat cooling DB PSIG PSIG Water Temp Drop °F 50 1.75 2.6 3.5 118-128 118-128 118-128 215-235 200-220 185-205 22-27 22-27 22-27 14-19 12-17 10-15 18.1-20.1 13.1-15.1 8.1-10.1 20-26 20-26 19-25 100-110 98-108 95-105 337-357 334-354 332-352 10-15 10-15 11-16 15-20 15-20 15-20 9.5-11.5 6.6-8.6 3.8-5.8 26-32 26-32 26-32 70 1.75 2.6 3.5 132-142 132-142 132-142 300-320 263-282 245-265 11-16 11-16 12-17 12-17 10-15 7-12 17-19 12.6-14.6 8.2-10.2 19-25 19-25 19-25 115-125 112-122 110-120 361-381 360-380 356-376 19-24 20-25 21-26 18-23 18-23 18-23 11.1-13.1 8-10 4.8-6.8 29-35 29-35 29-35 1.75 2.6 3.5 1.75 2.6 3.5 138-148 138-148 138-148 145-155 145-155 145-155 366-386 353-373 340-360 453-473 442-462 431-451 9-14 9-14 9-14 9-14 9-14 9-14 11-16 9-14 6-11 9-14 7-12 5-10 15.8-17.8 14.9-16.9 14-16 14.7-16.7 10.8-12.8 6.8-8.8 18-24 18-24 18-24 16-22 16-22 17-23 122-132 123-133 124-134 376-396 378-398 380-400 34-39 36-41 38-43 22-27 22-27 23-28 12.1-14.1 9-11 5.8-7.8 32-38 32-38 32-38 90 110 34 Heating Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Unit Operating Conditions, Cont’d. Table: 10 JRC Series Typical Operating Pressures and Temperatures (60 Hz I-P Units) JRC15 Cooling Heating Air Temp Rise °F DB 4-9 4-9 3-8 6.1-8.1 4.5-6.5 2.8-4.8 18-24 18-24 19-25 8-12 8-12 8-12 7-12 7-12 7-12 9.6-11.6 7-9 4.5-6.5 24-30 24-30 25-31 332-352 340-360 347-367 10-15 11-16 13-18 10-15 10-15 10-15 12-14 9-10 6.1-8.1 29-35 29-35 30-36 372-392 375-395 379-399 17-22 18-23 19-24 13-18 13-18 13-18 14.5-16.5 11.2-13.2 7.9-9.9 35-41 35-41 36-42 Water Temp Drop °F Air Temp Rise °F DB Water Flow GPM/ ton 30 2.1 3.15 4.2 98-108 98-108 99-109 140-160 135-155 127-148 36-41 36-41 36-41 14-19 12-17 10-15 17.1-19.1 12.5-14.5 7.9-9.9 19-25 19-25 19-25 74-84 77-87 79-89 278-298 280-300 283-303 6-11 6-11 6-11 50 2.1 3.15 4.2 118-128 118-128 118-128 215-235 200-220 185-205 22-27 22-27 22-27 14-19 12-17 10-15 18.1-20.1 13.1-15.1 8.1-10.1 20-26 20-26 19-25 104-114 106-116 108-118 309-329 312-332 315-335 70 2.1 3.15 4.2 132-142 132-142 132-142 300-320 263-282 245-265 11-16 11-16 12-17 12-17 10-15 7-12 17-19 12.6-14.6 8.2-10.2 19-25 19-25 19-25 127-137 132-142 138-148 90 2.1 3.15 4.2 138-148 138-148 138-148 366-386 353-373 340-360 9-14 9-14 9-14 11-16 9-14 6-11 15.8-17.8 14.9-16.9 14-16 18-24 18-24 18-24 164-174 165-175 167-177 110 2.1 3.15 4.2 145-155 145-155 145-155 453-473 442-462 431-451 9-14 9-14 9-14 9-14 7-12 5-10 14.7-16.7 10.8-12.8 6.8-8.8 16-22 16-22 17-23 Suction Discharge SuperSubPressure Pressure heat cooling PSIG PSIG JRC18 Entering Water Temp °F 30 50 70 90 110 Water Flow GPM/ ton Water Temp Rise °F Water Temp Drop °F Entering Water Temp °F Air Temp Suction Discharge Super- SubDrop °F Pressure Pressure heat cooling DB PSIG PSIG Cooling Suction Discharge Pressure Pressure PSIG PSIG Heating Super- Subheat cooling Water Temp Rise °F Air Temp Suction Discharge Super- SubDrop °F Pressure Pressure heat cooling DB PSIG PSIG 2.5 3.75 5 98-108 98-108 99-109 140-160 135-155 127-148 36-41 36-41 36-41 14-19 12-17 10-15 17.1-19.1 12.5-14.5 7.9-9.9 19-25 19-25 19-25 74-84 77-87 79-89 278-298 280-300 283-303 6-11 6-11 6-11 4-9 4-9 3-8 6.1-8.1 4.5-6.5 2.8-4.8 18-24 18-24 19-25 2.5 3.75 5 118-128 118-128 118-128 215-235 200-220 185-205 22-27 22-27 22-27 14-19 12-17 10-15 18.1-20.1 13.1-15.1 8.1-10.1 20-26 20-26 19-25 104-114 106-116 108-118 309-329 312-332 315-335 8-12 8-12 8-12 7-12 7-12 7-12 9.6-11.6 7-9 4.5-6.5 24-30 24-30 25-31 2.5 3.75 5 132-142 132-142 132-142 300-320 263-282 245-265 11-16 11-16 12-17 12-17 10-15 7-12 17-19 12.6-14.6 8.2-10.2 19-25 19-25 19-25 127-137 132-142 138-148 332-352 340-360 347-367 10-15 11-16 13-18 10-15 10-15 10-15 12-14 9-10 6.1-8.1 29-35 29-35 30-36 2.5 3.75 5 138-148 138-148 138-148 366-386 353-373 340-360 9-14 9-14 9-14 11-16 9-14 6-11 15.8-17.8 14.9-16.9 14-16 18-24 18-24 18-24 164-174 165-175 167-177 372-392 375-395 379-399 17-22 18-23 19-24 13-18 13-18 13-18 14.5-16.5 11.2-13.2 7.9-9.9 35-41 35-41 36-42 2.5 3.75 5 145-155 145-155 145-155 453-473 442-462 431-451 9-14 9-14 9-14 9-14 7-12 5-10 14.7-16.7 10.8-12.8 6.8-8.8 16-22 16-22 17-23 Table 11: Coax Water Pressure Drop Model JRC09 JRC12 JRC15 JRC18 GPM 1.1 1.6 2.3 1.5 2.3 3 1.9 2.8 3.7 2.3 3.4 4.5 30°F 1.6 2.6 4.5 2.1 4.5 6.8 1.5 3 4.7 2.2 4.4 6.9 Pressure Drop, PSI 50°F 70°F 1.2 1.0 2.2 2.0 3.8 3.5 1.8 1.5 3.8 3.5 5.8 4.9 1 0.9 2.3 2 3.9 3.3 1.8 1.5 3.8 3.4 6 5.2 90°F 0.9 1.9 3 1.3 3 4.5 0.8 1.7 2.9 1.3 3 4.8 PD Added for Motorized Water Valve 0.3 0.6 1.2 0.5 1.2 2.2 0.7 1.7 3.3 0.2 0.6 1.1 Installation, Operation, Maintenance 35 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Start-Up Log Sheet Installer: Complete unit and system checkout and follow unit start-up procedures in the IOM. Use this form to record unit information, temperatures and pressures during start-up. Keep this form for future reference. Job Name: Street Address: Model Number: Serial Number: Unit Location in Building: Date: Sales Order No: In order to minimize troubleshooting and costly system failures, complete the following checks and data entries before the system is put into full operation. Temperatures: F or C Pressures: PSIG or kPa Antifreeze: __________________% Type __________________ Cooling Mode Heating Mode Return-Air Temperature DB Supply-Air Temperature DB Temperature Differential Entering Fluid Temperature Leaving Fluid Temperature Temperature Differential Water Coil Heat Exchanger (Water Pressure IN) Water Coil Heat Exchanger (Water Pressure OUT) Pressure Differential Flow Rate GPM (l/s) Supply Voltage at Contactor Transformer Low Side Volts Compressor Amps Motor Amps Allow unit to run 15 minutes in each mode before taking data. Do not connect service manifold gauges during start up unless instructed by the manufacturer service tech. 36 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 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. 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. 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 - All units have lubricated fan motors. Fan motors should never be lubricated unless obvious, dry operation is suspected. Periodic maintenance oiling is not recommended, as it will result in dirt accumulating in the excess oil and cause eventual motor failure. Conduct annual dry operation check and amperage check to insure amp draw is no more than 10% greater than indicated on serial plate data. 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 - Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. 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. 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 self-serve car washes. Installation, Operation, Maintenance 37 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Functional Troubleshooting Fault Main power problems HP Fault Code 2 Htg Clg X X Green Status LED Off X Reduced or no water flow in cooling X Water Temperature out of range in cooling X Possible Cause Reduced or no air flow in heating High Pressure LP/LOC Fault Code 3 Low Pressure / Loss of Charge LT1 Fault Code 4 Water coil low temperature limit X X X X Compressor pump down at start-up X Reduced or no water flow in heating X X Inadequate antifreeze level Improper temperature limit setting (30°F vs 10°F [-1°C vs -2°C]) Water Temperature out of range Bad thermistor X Reduced or no air flow in cooling X X X X Air Temperature out of range Improper temperature limit setting (30°F vs 10°F [-1°C vs -12°C]) Bad thermistor Blocked drain Improper trap X Poor drainage X x X X X Moisture on sensor Plugged air filter Restricted Return Air Flow X X Under Voltage X X X X X Air coil low temperature limit X X X X Condensate Fault Code 6 (Auto resetting) Unit Performance Code 8 Swapped Thermistor Code 9 No Fault Code Shown Unit Short Cycles Only Fan Runs Only Compressor Runs Unit Doesn’t Operate in Cooling 38 Air temperature out of range in heating Overcharged with refrigerant Bad HP Switch Insufficient charge X LT2 Fault Code 5 Over/Under Voltage Code 7 X X X X X Over Voltage Heating mode LT2>125°F [52°C] Cooling Mode LT1>125°F [52°C] OR LT2< 40ºF [4ºC]) Solution Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor. Check for 24VAC between R and C on CXM/DXM2 Check primary/secondary voltage on transformer. Check pump operation or valve operation/setting. Check water flow adjust to proper flow rate. Bring water temp within design parameters. Check for dirty air filter and clean or replace. Check fan motor operation and airflow restrictions. Dirty Air Coil- construction dust etc. Too high of external static. Check static vs blower table. Bring return air temp within design parameters. Check superheat/subcooling vs typical operating condition table. Check switch continuity and operation. Replace. Check for refrigerant leaks Check charge and start-up water flow. Check pump operation or water valve operation/setting. Plugged strainer or filter. Clean or replace.. Check water flow adjust to proper flow rate. Check antifreeze density with hydrometer. Clip JW3 jumper for antifreeze (10°F [-12°C]) use. Bring water temp within design parameters. Check temp and impedance correlation per chart Check for dirty air filter and clean or replace. Check fan motor operation and airflow restrictions. Too high of external static. Check static vs blower table. Too much cold vent air? Bring entering air temp within design parameters. Normal airside applications will require 30°F [-1°C] only. Check temp and impedance correlation per chart. Check for blockage and clean drain. Check trap dimensions and location ahead of vent. Check for piping slope away from unit. Check slope of unit toward outlet. Poor venting. Check vent location. Check for moisture shorting to air coil. Replace air filter. Find and eliminate restriction. Increase return duct and/or grille size. Check power supply and 24VAC voltage before and during operation. Check power supply wire size. Check compressor starting. Need hard start kit? Check 24VAC and unit transformer tap for correct power supply voltage. Check power supply voltage and 24VAC before and during operation. Check 24VAC and unit transformer tap for correct power supply voltage. Check for poor air flow or overcharged unit. Check for poor water flow, or air flow. X X LT1 and LT2 swapped Reverse position of thermistors X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X No compressor operation Compressor overload Control board Dirty air filter Unit in "test mode" Unit selection Compressor overload Thermostat position Unit locked out Compressor Overload Thermostat wiring Thermostat wiring X X Thermostat wiring X Reversing valve X X Thermostat setup Thermostat wiring See "Only Fan Operates". Check and replace if necessary. Reset power and check operation. Check and clean air filter. Reset power or wait 20 minutes for auto exit. Unit may be oversized for space. Check sizing for actual load of space. Check and replace if necessary Ensure thermostat set for heating or cooling operation. Check for lockout codes. Reset power. Check compressor overload. Replace if necessary. Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode. Check G wiring at heat pump. Jumper G and R for fan operation Jumper G and R for fan operation. Check for Line voltage across BR contacts. Check fan power enable relay operation (if present). Check for line voltage at motor. Check capacitor. Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode Set for cooling demand and check 24VAC on RV coil and at CXM/DXM2 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’. X Thermostat wiring Fan motor relay Fan motor Put thermostat in cooling mode. Check 24 VAC on O (check between C and O); check for 24 VAC 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. Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Performance Troubleshooting Performance Troubleshooting Htg Clg Possible Cause X X Dirty filter Solution Replace or clean. Check for dirty air filter and clean or replace. X Reduced or no air flow 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. X Reduced or no air flow in cooling Check fan motor operation and airflow restrictions. Leaky duct work Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present. Too high of external static. Check static vs. blower table. Insufficient capacity/ Not cooling or heating X X X X Low refrigerant charge Check superheat and subcooling per chart. X X Restricted metering device Check superheat and subcooling per chart. Replace. X Defective reversing valve Perform RV touch test. X X Thermostat improperly located Check location and for air drafts behind stat. X X Unit undersized Recheck loads & sizing. Check sensible clg. load and heat pump capacity. X X Scaling in water heat exchanger Perform scaling check and clean if necessary. X X Inlet water too hot or too cold Check load, loop sizing, loop backfill, ground moisture. Check for dirty air filter and clean or replace. X Reduced or no air flow in heating Check fan motor operation and air flow restrictions. Too high of external static. Check static vs. blower table. High Head Pressure X Reduced or no water flow in cooling X Inlet water too hot Check load, loop sizing, loop backfill, ground moisture. Air temperature out of range in heating Bring return air temperature within design parameters. X X Check pump operation or valve operation/setting. Check water flow. Adjust to proper flow rate. X Scaling in water heat exchanger Perform scaling check and clean if necessary. X Unit overcharged Check superheat and subcooling. Re-weigh in charge. X X Non-condensables in system Vacuum system and re-weigh in charge. X X Restricted metering device. Check superheat and subcooling per chart. Replace. Check pump operation or water valve operation/setting. X Reduced water flow in heating. Plugged strainer or filter. Clean or replace. X Water temperature out of range. Bring water temperature within design parameters. Check water flow. Adjust to proper flow rate. Check for dirty air filter and clean or replace. Low Suction Pressure X Reduced air flow in cooling. Check fan motor operation and air flow restrictions. Too high of external static. Check static vs. blower table. X X Low Discharge Air Temperature in Heating High humidity X X X Air temperature out of range Too much cold vent air? Bring entering air temperature within design parameters. Insufficient charge Check for refrigerant leaks. Too high of air flow Check fan motor speed selection and air flow chart. Poor performance See ‘Insufficient Capacity’ X Too high of air flow Check fan motor speed selection and airflow chart. X Unit oversized Recheck loads & sizing. Check sensible clg load and heat pump capacity. Installation, Operation, Maintenance 39 Location: ________________________ Model Number: ________________________ WAT E R - S O U R C E H E AT P U M P S Serial Number: ________________________ Date: ________________________ Packaged Unit Refrigeration Schematic JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Customer: _____________________________________ Antifreeze: ________________________ Model#: ________________________ Troubleshooting Form Serial#: ________________ Loop type: _______________ Complaint: ________________________________________________________________________ HEATING CYCLE ANALYSIS - PSI SAT °F °F AIR COIL SUCTION °F COMPRESSOR EXPANSION FILTER DRIER* VALVE COAX DISCHARGE HWG °F °F °F FLASH GAS LINE FP2: HEATING LIQUID LINE °F FP1 SENSOR °F PSI WATER IN PSI °F PSI WATER OUT Look up pressure drop in I.O.M. or spec. catalog to determine flow rate. COOLING CYCLE ANALYSIS - PSI SAT °F Refrigerant Type: HFC-410A SAT °F AIR COIL SUCTION °F COMPRESSOR COAX EXPANSION FILTER DRIER* VALVE DISCHARGE Voltage: ________ HWG Comp Amps: _______ Total Amps: ________ °F °F °F FP2: FLASH OTHER SIDE OF FILTR DR GAS LINE °F FP1: CLG LIQ LINE °F PSI WATER IN PSI °F PSI WATER OUT SAT Look up pressure drop in I.O.M. or spec. catalog to determine flow rate. Heat of Extraction (Absorption) or Heat of Rejection = ________ flow rate (gpm) x ________ temp.diff. (deg. F) x ________ fluid factor Superheat = Suction temperature - suction saturation temp. = Subcooling = Discharge saturation temp. - liquid line temp. = Use 500 for water, 485 for antifreeze. = _____________ (Btu/hr) (deg F) (deg F) Rev. 12/08 Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water flow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort. 40 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Notes Installation, Operation, Maintenance 41 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Notes 42 Installation, Operation, Maintenance THE SMART SOLUTION FOR ENERGY EFFICIENCY JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Notes Installation, Operation, Maintenance 43 WAT E R - S O U R C E H E AT P U M P S JRC-Series R ev. : D e c e m b e r 8 , 2 0 2 1 Revision History Date: Item: Action: All Removed LON Controls, Updated Water Quality Standards 05/10/21 All Changed “Slave” to “Subordinate” 08/19/20 Created 12/08/21 14805-NOM1-1221 97B0035N10 Johnson Controls 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 Johnson Controls’ Customer Service Department at 1-877-329-7430 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 Johnson Controls’ opinion or commendation of its products. © 2020 Johnson Controls | 100 JCI Way, York, Pennsylvania USA 17406-8469 | www.johnsoncontrols.com Subject to change without notice. | Form 14805-NOM1-1221 | Supersedes: 14805-NOM1-0521 | All rights reserved. 44 Installation, Operation, Maintenance ">

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Key features
- Energy efficiency
- Various models
- Installation guide
- Operation instructions
- Maintenance procedures
- Troubleshooting guide
- Safety features
- Wiring diagrams
- Piping connections
- Water circuit options
Frequently asked questions
There are several water circuit options including copper, Cupro-nickel, and with or without extended range insulation.
The maximum working pressure for the base unit is 500 PSIG [3,445 kPa]. However, this can vary depending on the optional features installed, such as the internal secondary pump (ISP), motorized water valve (MWV), or auto flow valve.
CXM and DXM are different types of controls for the heat pumps. Details about each are found in the manual pages 25-28.
The manual provides sections on functional and performance troubleshooting, including tips for checking the compressor, blower, filter, and electrical connections.
The manual explains the different piping connections for various JRC model sizes, including right-hand and left-hand configurations and the use of hoses. It also details the importance of the condensate piping and its proper installation.