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Console (CCE) Series Tranquility Console (TRC) Series Table of Contents Commercial Console Water-Source Heat Pumps 50Hz & 60Hz Installation, Operation & Maintenance Instructions 97B0035N01 Revision: 5 Nov., 2009B Model Nomenclature 3-4 General Information 5 Storage 6 Pre-Installation 6 Physical Data 7-9 Installation 10 Condensate Piping 11 Piping Connection 12-14 Piping Installation 15 Water-Loop Heat Pump Applications 16 Ground-Loop Heat Pump Applications 17 Ground-Water Heat Pump Applications 18 Water Quality Standards 20 Electrical Wiring - Line Voltage 21-23 Electrical Wiring - Low Voltage 24 Thermostat Wiring 25 Electrical Wiring Diagram Matrix 26 Electrical Wiring Schematics 27-31 CXM/DXM Controls 32-34 CXM/DXM Safety Control Reset 35-36 Unit Commissioning and Operating Conditions 37 Piping System Cleaning and Flushing 38 Unit and System Checkout Procedure 39 Unit Start-Up 40 Unit Operating Conditions 41 Preventive Maintenance 43 Functional & Performance Troubleshooting 44-45 Refrigerant Circuit Diagram 46 Warranties 47-48 Revision History 50 THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Model Nomenclature: Console (CCE) Series 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CCE 0 7 B G C A S S C S R S Model Type Standard CCE = Console S = Standard Piping Connections Unit Size R = Right Piping L = Left Piping 07 09 12 15 19 Water Circuit Options Revision Level C = Current Voltage A = 115/60/1 E = 265/60/1 G = 208-230/60/1 Controls A = MCO Unit Mounted Tstat w/CXM B = MCO Unit Mounted Tstat w/DXM C = ACO Unit Mounted Tstat w/CXM D = ACO Unit Mounted Tstat w/DXM R = Remote Mounted Tstat w/CXM S = Remote Mounted Tstat w/DXM L = Remote Mounted w/CXM & LON M = Remote Mounted w/DXM & LON N = Remote Mounted w/CXM & MPC P = Remote Mounted w/DXM & MPC Power Termination A = Field Connected (Hard Wire) B = 20Amp Plug & Cord D = Disconnect Switch & 15Amp Fuse F = Disconnect Switch (Non Fused) H = 20Amp Plug, Cord, Receptacle, Disconnect Switch & 15Amp Fuse K = 20Amp Plug, Cord, Receptacle & Disconnect Switch (Non Fused) Sweat FPT MPT 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 S A B C D E U F G H J K L V M N P Q R T W Heat Exchanger Options 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 S = 3” Subbase D = 3” Subbase w/Motorized Damper G = 5” Subbase H = 5” Subbase w/Motorized Damper N = None Cabinet Construction With UltraQuiet 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 Without UltraQuiet 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 Rev.: 8 Aug, 2008B c l i m a t e m a s t e r. c o m 3 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Model Nomenclature: Tranquility Console (TRC) Series (60Hz) 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 TRC 0 9 A G C A S S C S R S Model Type Standard TRC = Console S = Standard Piping Connections Unit Size R = Right Piping L = Left Piping V = Left Piping w/SS Drain Pan W = Right Piping w/SS Drain Pan 09, 12, 15, 18 Revision Level A = Current Revision B = Size 09 (115V) & Size 18 (265V) Water Circuit Options Sweat FPT MPT 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 Voltage G = 208-230/60/1 A = 115/60/1 E = 265/60/1 Controls A = MCO Unit Mounted Tstat w/CXM B = MCO Unit Mounted Tstat w/DXM C = ACO Unit Mounted Tstat w/CXM D = ACO Unit Mounted Tstat w/DXM R = Remote Mounted Tstat w/CXM S = Remote Mounted Tstat w/DXM L = Remote Mounted w/CXM & LON M = Remote Mounted w/DXM & LON N = Remote Mounted w/CXM & MPC P = Remote Mounted w/DXM & MPC S A B C D E U F G H J K L V M N P Q R T W Heat Exchanger Options 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 Power Termination Subbase A = Field Connected (Hard Wire) B = 20Amp Plug & Cord D = Disconnect Switch & 15Amp Fuse F = Disconnect Switch (Non Fused) H = 20Amp Plug, Cord, Receptacle, Disconnect Switch & 15Amp Fuse K = 20Amp Plug, Cord, Receptacle & Disconnect Switch (Non Fused) S = 5” Subbase H = 5” Subbase w/Motorized Damper N = None Cabinet Construction With UltraQuiet 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 Without UltraQuiet 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 Rev.: 29 July, 2009B Model Nomenclature: Tranquility Console (TRC) Series (50Hz) 1 2 3 4 5 6 8 TRC 12 B V E F S S E S R S 7 9 10 11 12 13 14 SERIES 15 S = STANDARD TRC = Tranquility Console PIPING CONNECTIONS UNIT SIZE R = Right Piping L = Left Piping 09 12 15 18 WATER CIRCUIT OPTIONS Sweat FPT MPT 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) REVISION LEVEL B = Current Revision VOLTAGE V = 220-240/50/1 CONTROLS E = MCO Unit Mounted Tstat w/CXM F = ACO Unit Mounted Tstat w/CXM J = MCO Unit Mounted Tstat w/DXM K = ACO Unit Mounted Tstat w/DXM Q = Remote Mounted Tstat w/CXM G = Remote Mounted Tstat w/DXM H = Remote Mounted LON w/CXM V = Remote Mounted LON w/DXM T = Remote Mounted MPC w/CXM U = Remote Mounted MPC w/DXM S A B C D E F G H J K L M N P Q R T HEAT EXCHANGER OPTIONS A = Copper Water Coil w/E-Coated Air Coil C = Copper Water Coil w/Non-Coated Air Coil J = Cupro-Nickel Water Coil w/E-Coated Air Coil N = Cupro-Nickel Water Coil w/Non-Coated Air Coil V = Copper Water Coil w/E-Coated Air Coil & Extended Range Insulation E = Copper Water Coil w/Non-Coated Air Coil & Extended Range Insulation M = Cupro-Nickel Water Coil w/E-Coated Air Coil & Extended Range Insulation F = Cupro-Nickel Water Coil w/Non-Coated Air Coil & Extended Range Insulation CE Mark SUBBASE POWER TERMINATION & OPTIONS OPTION A B D F H K FIELD CONNECTED (HARD WIRE) X - 20 Amp PLUG & CORD X X X DISCONNECT 15 Amp FUSE SWITCH X X X X X X - RECEPTACLE X X S = 5” Subbase (Black) H = 5” Subbase w/Motorized Damper N = None CABINET S = Bottom Return (Standard) L = Bottom Return w/Locking Control Door (Standard) F = Front Return (Standard) G = Front Return w/Locking Control Door (Standard) N = No Cabinet Chassis Only (Standard) Rev.: 21 Nov, 2007J 4 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage. NOTICE: Notification of installation, operation or maintenance information, which is important, but which is not hazardrelated. WARNING: Indicates a potentially hazardous situation, which if not avoided could result in death or serious injury. WARNING! 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. WARNING! Verify refrigerant type before proceeding. Units are shipped with R-22, R-407c and R-410A (EarthPure®) refrigerants. The unit label will indicate which refrigerant is provided. The EarthPure® Application and Service Manual should be read and understood before attempting to service refrigerant circuits with R-407c or R-410A. 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. CAUTION! CAUTION! To avoid equipment damage, DO NOT use these units as a source of heating or cooling during the construction process. The mechanical components and filters will quickly become clogged with construction dirt and debris, which may cause system damage. c l i m a t e m a s t e r. c o m 5 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B General Information Inspection Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment. If not 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. 3. Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components. 4. Inspect all electrical connections. Connections must be clean and tight at the terminals. 5. Remove any blower support packaging. 6. Loosen compressor bolts on units equipped with compressor spring vibration isolation until the compressor rides freely on the springs. Remove shipping restraints. 7. REMOVE COMPRESSOR SUPPORT PLATE 1/4” SHIPPING BOLTS (2 on each side) TO MAXIMIZE VIBRATION AND SOUND ATTENUATION. 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. CAUTION! DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. Always move and store units in an upright position. Tilting units on their sides may cause equipment damage. 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 cleanup. Examine all pipes, fittings, and valves before installing any of the system components. Remove any dirt or debris found in or on these components. CAUTION! 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. NOTICE! Failure to remove shipping brackets from springmounted compressors will cause excessive noise, and could cause component failure due to added vibration. 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. 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. 6 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Unit Physical Data Console (CCE) Series Model 07 09 12 Compressor (1 Each) Factory Charge R22 (oz) [kg] 15 19 Rotary 16 [0.454] 16 [0.454] 21 [0.595] 27 [0.765] 24 [0.680] 1/20 [27] 1/15 [50] 1/15 [50] 1/6 [124] 1/6 [124] 5-1/4 x 6-1/4 [133 x 159] 5-1/4 x 6-1/4 [133 x 159] 5-1/4 x 6-1/4 [133 x 159] 5-1/4 x 6-1/4 [133 x 159] 5-1/4 x 6-1/4 [133 x 159] 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] Optional IPT Fittings (in) 1/2 1/2 1/2 1/2 1/2 Optional EPT Fittings (in) 1/2 1/2 1/2 1/2 1/2 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] 5/8 [15.9] PSC Fan Motor & Blower (3 Speeds) Fan Motor (hp) [W] Blower Wheel Size (dia x w) (in) [mm] Water Connection Size O.D. Sweat (in) [mm] Condensate Connection Size I.D. Vinyl Hose (In) [mm] Air Coil Size Dimensions (h x w) - (in) [mm] 8 x 26 [20.3 x 66.0] 10 x 26 [25.4 x 66.0] Filter Size Bottom Return (in) [cm] 1 - 8 x 29-1/2 x 3/8 [20.3 x 74.9 x 0.95] Front Return (In) [cm] 1 - 7 x 29-1/2 x 1/8 [17.8 x 74.9 x 0.32] Cabinet Size Bottom Return (Std. 3" Base) (W x H x D) - (In) [cm] 48 x 24 x 12 [121.9 x 61.0 x 30.5] Bottom Return (Std. 5" Base) (W x H x D) - (In) [cm] 48 x 26 x 12 [121.9 x 66.0 x 30.5] Bottom Return (No Subbase) (W x H x D) - (In) [cm] 48 x 21 x 12 [121.9 x 53.3 x 30.5] Unit Weight Weight - Operating, (lbs) [kg] 173 [78.5] 177 [80.3] 187 [84.5] 193 [87.5] 198 [89.8] Weight - Packaged, (lbs) [kg] 181 [82.1] 185 [83.9] 195 [88.5] 201 [91.2] 206 [93.4] c l i m a t e m a s t e r. c o m 7 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Unit Physical Data Tranquility Console (TRC) Series (60Hz) Model 09 12 15 18 28 [0.794] 29 [0.822] 33 [0.907] 39 [1.105] 1/12 [62] 1/8 [93] 1/8 [93] Compressor (1 Each) Factory Charge R410A (oz) [kg] PSC Fan Motor & Blower (3 Speeds) Fan Motor (hp) [W] 1/20 [37] Blower Wheel Size (dia x w) (in) [mm] - Qty 2 5.25 x 6.25 [133 x 159] Water Connection Size O.D. Sweat (in) [mm] 1/2 [12.7] 3/4 [19.1] Optional IPT Fittings (in) 1/2 3/4 Optional EPT Fittings (in) 1/2 3/4 Condensate Connection Size I.D. Vinyl Hose (In) [mm] 5/8 [15.9] Air Coil Size Dimensions (h x w) - (in) [mm] 8 x 26 [203 x 660] 10 x 26 [254 x 660] 10 x 32 [254 x 812] Filter Size 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] Bottom Return (Std. 5" Base) (W x H x D) - (In) [mm] 48 x 26 x 12 [1219 x 660 x 305] 54 x 26 x 12 [1372 x 660 x 305] Front Return (No Subbase) (W x H x D) - (In) [mm] 48 x 21 x 12 [1219 x 533 x 305] 54 x 21 x 12 [1372 x 533 x 305] Bottom Return (in) [mm] Front Return (In) [mm] Cabinet Size Cabinet Size 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] * Data not available at time of publication. All units have rubber grommet compressor mountings and TXV expansion devices. 8 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Unit Physical Data Tranquility Console (TRC) Series (50Hz) Model 09 12 15 18 29 [0.822] 33 [0.936] 30 [0.850] 1/12 [62] 1/8 [93] 1/8 [93] Compressor (1 Each) Factory Charge R410A (oz) [kg] Rotary 26 [0.737] PSC Fan Motor & Blower (3 Speeds) Fan Motor (hp) [W] 1/20 [37] Blower Wheel Size (dia x w) (in) [mm] - Qty 2 5.25 x 6.25 [133 x 159] Water Connection Size O.D. Sweat (in) [mm] 1/2 [12.7] 3/4 [19.1] Optional IPT Fittings (in) 1/2 3/4 Optional EPT Fittings (in) 1/2 3/4 Condensate Connection Size I.D. Vinyl Hose (In) [mm] 5/8 [15.9] Air Coil Size Dimensions (h x w) - (in) [mm] 8 x 26 [203 x 660] 10 x 26 [254 x 660] 10 x 32 [254 x 813] Filter Size 1 - 10 x 30 x 1 [254 x 762 x 25] 1 - 10 x 36 x 1 [25.4 x 91.4 x 2.5] 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] Bottom Return (Std. 5" [127] Base) (W x H x D) - (In) [mm] 48 x 26 x 12 [1219 x 660 x 305] 54 x 26 x 12 [1372 x 660 x 305] Front Return (No Subbase) (W x H x D) - (In) [mm] 48 x 21 x 12 [1219 x 533 x 305] 54 x 21 x 12 [1372 x 533 x 305] Bottom Return (in) [mm] Front Return (In) [mm] Cabinet Size Cabinet Size 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. c l i m a t e m a s t e r. c o m 9 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. 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. 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. 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. Remove compressor isolation plate shipping screws (4) as shown in Figure 1a. (All CCE and TRC09-12) 4. Using a carpenter's square and a level, ensure the unit is level. Shim the unit if necessary to assure proper installation. CAUTION! Poor or inadequate installation may result in noisy unit operation or unattractive installation. Figure 1a: Compressor Shipping Screws (All CCE and TRC 09-12) 4 Shipping Screws 10 5. Select the proper fasteners to connect the backplate securely to the wall. 6. Fasten the backplate onto the wall through the screw holes located in the back flange. Secure the subbase in place. 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. 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: When necessary, use adapters to connect hoses. 10. Install any other system components as required following manufacturer's instructions. 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 are available for use with ClimateMaster Console Units. Use the following guidelines when installing supply and return hose assemblies. 1. Install supply and return hoses fitted with swivel-joint fittings at one end to prevent the hose from twisting. 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. C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Installation 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 [16mm] 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. 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. 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 [10mm per 46cm] 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. If the building drain connection is parallel with floor, the height can be up to 1-1/2 inches [38mm] above the subbase for proper pitch and correct drainage. Up to 5 inches [127mm] above the subbase is allowable, but drainage will be slower. When the drain connection is 2-1/2 to 5 inches [64 to 127mm] above, the hose inside the unit will act as a trap. Heights of more than 5 inches [127mm] 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. c l i m a t e m a s t e r. c o m 11 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Piping Connections - CCE Figure 1b: Water Connection Details 3.28 (83) 5.36 (136) 3.01 (76) Power Supply 1.84 (47) 30° Water Out Water In Control Box 0.87 (22) Optional Autoflow Valve *16.66 (423) Compressor Access Panel 7.5 (191) 4.46 (113) 0.75 (19) *1.94 (49) *7.06 (179) Condensate 3.56 (90) 3.88 (99) 5/8" (15.9 mm) ID Vinyl Hose Optional Motorized Water Valve 11.54 (293) 3.43 (87) Water Connections 5/8" (15.9 mm) OD Copper, 1/2" IPT or 1/2" EPT 0.99 (25) Right Hand Configuration 5.36 (136) 3.01 (76) Optional Autoflow Valve 3.50 (89) 1.93 (49) 0.87 (22) Optional Motorized Water Valve Water Connections 5/8" (15.9 mm) OD Copper, 1/2" IPT or 1/2" EPT Power Supply Water Out Water In 30° Optional Disconnect Box (mounted to cabinet not chassis) 3.42 (87) Blower Deck *16.66 (423) 7.5 (191) *1.94 (49) 3.56 (90) 3.22 (82) Optional Disconnect Box (mounted to cabinet not chassis) Blower Access Panel *7.06 (179) 11.54 (293) 3.88 (99) 4.49 (114) Condensate 0.75 (19) 5/8" (15.9 mm) ID Vinyl Hose Left Hand Configuration Notes: All Dimensions are in inches (mm) * For installed dimension, add to dimension shown 2.9" [74mm] with 3" subbase and 4.9" [124mm] for 5" subbase. Optional autoflow valve, motorized water valve and disconnect box are shown. Water connection in same location regardless of connection type. CAUTION! CAUTION! Corrosive system water requires corrosion resistant fittings and hoses, and may require water treatment. 12 CAUTION! CAUTION! Piping must comply with all applicable codes. C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Piping Connections TRC Size 06-15 1.62 (41) 2.00 (51) Control Box Optional Flow Regulator Optional Motorized Water Valve Out In Water Out Compressor Access Panel Water In Opti Auto Valv Water Connections 5/8” (15.9) OD Copper, 1/2” IPT, or 1/2” EPT 2.25 (57) Optio Motor Water *11.25 (286) 8.00 Min (203) 1.75 (44) Condensate 5/8" (15.9) ID Vinyl Hose 1.84 (77) Water C 5/8" (15 OD Cop 1/2" IPT 1/2" EP Right Hand Configuration Water Out Water In Out In Water Connections 5/8” (15.9) OD Copper, 1/2” IPT, or 1/2” EPT al ow ve onal ized alve 1.50 (38) 2.25 (57) 2.00 (51) onnections AA) er, or *11.25 (286) 2.25 (57) 8.00 Min (203) Condensate 5/8" (15.9) ID Vinyl Hose 2.72 (96) Left Hand Configuration Notes: * Dimension reduced by fitting if selected c l i m a t e m a s t e r. c o m Rev.: 10/06/08B 13 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Piping Connections TRC Size 18 1.62 (41) Optional Motorized Water Valve 2.00 (51) Control Box O R Out In Water Out Compressor Access Panel Water In Water Connections 5/8” (15.9) OD Copper, 1/2” IPT, or 1/2” EPT 2.25 (57) *11.25 (286) 8.00 Min (203) 1.75 (44) Condensate 1.84 (77) 5/8" (15.9) ID Vinyl Hose Right Hand Configuration Water Out Water In Out In Water Connections 5/8” (15.9) OD Copper, 1/2” IPT, or 1/2” EPT onal flow alve ptional orized Valve 1.50 (38) 2.25 (57) 2.00 (51) Connections 5.9AA) pper, T or T *11.25 (286) 2.25 (57) 8.00 Min (203) Condensate 5/8" (15.9) ID Vinyl Hose 2.72 (96) Left Hand Configuration * 14 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Piping Connections 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). 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. Note: When anti-freeze is used in the loop, insure that it is compatible with the Teflon tape or pipe joint compound that is applied. 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 ClimateMaster 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. 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] 1-1/4" [31.8mm] 6-3/4" [17.1cm] CAUTION! CAUTION! Do not bend or kink supply lines or hoses. 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. Figure 2: Supply/Return Hose Kit Rib Crimped Swivel Brass Fitting Brass Fitting Length (2 ft [0.6m] Length Standard) EPT CAUTION! CAUTION! Many units are installed with a factory or field supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any field provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The field installed high pressure switch shall have a cut-out pressure of 300 psig and a cut-in pressure of 250 psig. This pressure switch can be ordered from ClimateMaster with a 1/4” internal flare connection as part number 39B0005N02. 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. c l i m a t e m a s t e r. c o m 15 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B 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 ClimateMaster 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. ClimateMaster 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 or DXM Control When antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature (antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE: Low water temperature operation requires extended range Table 2: Antifreeze Percentages by Volume Table 3. Antifreeze Percentages by Volume Type 16 Minimum Temperature for Freeze Protection 10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C] Methanol 25% 21% 16% 10% 100% USP food grade Propylene Glycol 38% 30% 22% 15% C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. 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. Antifreeze In areas where minimum entering loop temperatures drop below 40°F [5°C] or where piping will be routed through areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F [9°C] below the lowest expected entering loop temperature. For example, if 30°F [-1°C] is the minimum expected entering loop temperature, the leaving loop temperature would be 25 to 22°F [-4 to -6°C] and freeze protection should be at 15°F [-10°C]. Calculation is as follows: 30°F - 15°F = 15°F [-1°C - 9°C = -10°C]. All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes. Calculate the total volume of 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 or DXM Control When antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature (antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE: Low water temperature operation requires extended range equipment. c l i m a t e m a s t e r. c o m 17 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended. 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. Water Quality Standards Table 3 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F [66°C] for direct use (well water/open loop) and DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3. 18 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.. 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. C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Ground-Loop Heat Pump Applications Water Coil Low Temperature Limit Setting For all open loop systems the 30°F [-1.1°C] FP1 setting (factory setting-water) should be used to avoid freeze damage to the unit. See “Low Water Temperature Cutout Selection” in this manual for details on the low limit setting. 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. CAUTION! CAUTION! Many units installed with a factory or field supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any field provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The field installed high pressure switch shall have a cut-out pressure of 235 psig and a cut-in pressure of 190 psig. This pressure switch can be ordered from ClimateMaster with a 1/4” internal flare connection as part number 39B0005N01. c l i m a t e m a s t e r. c o m 19 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Water Quality Standards Table 2: Water Quality Standards >H[LY8\HSP[` 7HYHTL[LY /? 4H[LYPHS *SVZLK 9LJPYJ\SH[PUN 6WLU3VVWHUK9LJPYJ\SH[PUN>LSS :JHSPUN7V[LU[PHS7YPTHY`4LHZ\YLTLU[ (IV]L[OLNP]LUSPTP[ZZJHSPUNPZSPRLS`[VVJJ\Y:JHSPUNPUKL_LZZOV\SKILJHSJ\SH[LK\ZPUN[OLSPTP[ZILSV^ W/*HSJP\T/HYKULZZ (SS 4L[OVK W/#HUK*H/HYKULZZ#WWT 0UKL_3PTP[ZMVY7YVIHISL:JHSPUN:P[\H[PVUZ6WLYH[PVUV\[ZPKL[OLZLSPTP[ZPZUV[YLJVTTLUKLK :JHSPUNPUKL_LZZOV\SKILJHSJ\SH[LKH[-B*DMVYKPYLJ[\ZLHUK/>.HWWSPJH[PVUZHUKH[ -B*DMVYPUKPYLJ[/?\ZL (TVUP[VYPUNWSHUZOV\SKILPTWSLTLU[LK 9`aUHY (SS :[HIPSP[`0UKL_ 0M%TPUPTPaLZ[LLSWPWL\ZL [V 3HUNLSPLY (SS 0M#TPUPTPaLZ[LLSWPWL\ZL)HZLK\WVU-B*D/>.HUK :H[\YH[PVU0UKL_ +PYLJ[^LSS-B *D0UKPYLJ[>LSS/? 0YVU-V\SPUN 0YVU-L -LYYV\Z )HJ[LYPHS0YVUWV[LU[PHS (SS 0YVU-V\SPUN (SS #WWT-LYYV\Z 0M-L MLYYV\Z%WWT^P[OW/6#WWTJOLJRMVYPYVUIHJ[LYPH #WWTVM6_`NLU (IV]L[OPZSL]LSKLWVZP[PVU^PSSVJJ\Y *VYYVZPVU7YL]LU[PVU W/ (SS /`KYVNLU:\SMPKL/: (SS (TTVUPHPVUHZO`KYV_PKLJOSVYPKL UP[YH[LHUKZ\SMH[LJVTWV\UKZ (SS 4VUP[VY[YLH[HZ ULLKLK 4PUPTPaLZ[LLSWPWLILSV^HUKUVVWLU[HURZ^P[OW/# #WWT ([/:%WWTH]VPK\ZLVMJVWWLYHUKJVWWLYUPJRLSWPWPUNVY/?Z 9V[[LULNNZTLSSHWWLHYZH[WWTSL]LS *VWWLYHSSV`IYVUaLVYIYHZZJHZ[JVTWVULU[ZHYL62[V#WWT #WWT 4H_PT\T(SSV^HISLH[TH_PT\T^H[LY[LTWLYH[\YL 4H_PT\T *OSVYPKL3L]LSZ *VWWLY *\WYV5PJRLS :: :: ;P[HUP\T (SS #WWTVMWHY[PJSLZ HUKHTH_PT\T ]LSVJP[`VMMWZBTZD -PS[LYLKMVYTH_PT\T TPJYVUBTT TLZODZPaL -* #WWT #WWT #WWT #WWT %WWT -* 59 59 #WWT #WWT %WWT 100¯F (38¯C) NR NR <150 ppm < 375 ppm >375 ppm ,YVZPVUHUK*SVNNPUN 7HY[PJ\SH[L:PaLHUK ,YVZPVU #WWT#WWTZHUKMYLLMVYYLPUQLJ[PVUVMWHY[PJSLZHUKHTH_PT\T ]LSVJP[`VMMWZBTZD-PS[LYLKMVYTH_PT\TTPJYVUBTT TLZODZPaL(U`WHY[PJ\SH[L[OH[PZUV[YLTV]LKJHUWV[LU[PHSS` JSVNJVTWVULU[Z Notes: s#LOSED2ECIRCULATINGSYSTEMISIDENTIFIEDBYACLOSEDPRESSURIZEDPIPINGSYSTEM s2ECIRCULATINGOPENWELLSSHOULDOBSERVETHEOPENRECIRCULATINGDESIGNCONSIDERATIONS s.2Application not recommended. s.ODESIGN-AXIMUM 20 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s Rev.: 01/21/09B THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Electrical - Line Voltage 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. 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. CAUTION! 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! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors. 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. Transformer All commercial dual voltage units are factory wired for 208/60/1 or 240/50/1. If supply voltage is 230/60/1 or 220/50/1, installer must rewire transformer. See wire diagram for connections. Table 4: CCE Electrical Data QTY RLA LRA Fan Motor FLA 104-126 1 7.1 46.5 0.50 7.6 9.3 15 208-230/60/1 197-254 1 3.7 19.0 0.33 4.0 5.0 15 E 265/60/1 239-292 1 2.8 16.0 0.35 3.1 3.8 15 CCE09 A 115/60/1 104-126 1 9.0 46.5 1.30 10.3 12.5 20 CCE09 G 208-230/60/1 197-254 1 4.7 23.0 0.50 5.2 6.3 15 CCE09 E 265/60/1 239-292 1 3.8 16.0 0.50 4.3 5.3 15 CCE12 A 115/60/1 104-126 1 10.6 63.0 1.30 11.9 14.6 25 CCE12 G 208-230/60/1 197-254 1 6.1 29.0 0.50 6.6 8.1 15 CCE12 E 265/60/1 239-292 1 4.8 21.6 0.50 5.3 6.5 15 CCE15 G 208-230/60/1 197-254 1 7.0 33.2 1.10 8.1 9.8 15 CCE15 E 265/60/1 239-292 1 5.4 29.0 1.00 6.4 7.8 15 CCE19 G 208-230/60/1 197-254 1 7.7 38.0 1.10 8.8 10.7 15 CCE19 E 265/60/1 239-292 1 5.8 29.0 1.00 6.8 8.2 15 Model Voltage Code Voltage Min/Max Voltage CCE07 A 115/60/1 CCE07 G CCE07 Compressor c l i m a t e m a s t e r. c o m Total Unit FLA Min Circuit Amps Max Fuse/ HACR 21 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Electrical - Line Voltage Table 5a: TRC Electrical Data (60Hz) Model TRC09 TRC12 TRC15 TRC18 Voltage Code Voltage Min/Max Voltage Fan Motor FLA Compressor QTY RLA LRA Total Unit FLA Min Circuit Amps A 115/60/1 104-126 1 8.1 46.5 0.6 8.6 10.7 15 G 208-230/60/1 197-254 1 4.5 23.0 0.4 4.9 6.0 15 E 265/60/1 239-292 1 3.1 24.0 0.4 3.5 4.3 15 A 115/60/1 104-126 1 10.6 55.8 1.0 11.6 14.3 20 G 208-230/60/1 197-254 1 5.2 24.0 0.6 5.8 7.1 15 15 E 265/60/1 239-292 1 4.2 25.0 0.4 4.6 5.7 G 208-230/60/1 197-254 1 6.1 30.0 0.8 6.9 8.4 15 E 265/60/1 239-292 1 4.7 28.5 0.6 5.3 6.5 15 G 208-230/60/1 197-254 1 6.8 38.0 0.7 7.5 9.2 15 E 265/60/1 239-292 1 6.2 29.0 0.6 6.8 8.4 15 Table 5b: TRC Electrical Data (50Hz) 22 Max Fuse/ HACR Compressor LRA Fan Motor FLA Total Unit FLA Min Circ Amp Max Fuse/ HACR 3.2 17 0.4 3.6 4.4 15.0 1 4.0 19 0.4 4.4 5.4 15.0 198-264 1 4.7 23 0.6 5.3 6.5 15.0 198-264 1 5.6 25 0.6 6.2 7.6 15.0 Model Voltage code Voltage Min/Max Voltage QTY RLA TRC09 V 220-240/50/1 198-264 1 TRC12 V 220-240/50/1 198-264 TRC15 V 220-240/50/1 TRC18 V 220-240/50/1 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Electrical - Line Voltage 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. 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. CAUTION! CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors. Figure 4: FP1 Limit Setting Low Water Temperature Cutout Setting CXM or DXM Control When antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature (antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE: Low water temperature operation requires extended range equipment. CXM PCB c l i m a t e m a s t e r. c o m JW3-FP1 jumper should be clipped for low temperature operation 23 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Electrical - Low Voltage Unit-Mounted Controls, TRC & CCE Units, Rev. B CCE Revision B models and TRC models include digital display unit-mounted controls (see picture, below). Either manual changeover (MCO) or auto changeover (ACO) controls are available, as indicated by the model number. The room temperature will appear after the set point has been displayed for 3 seconds. To read “set point” press “SET”. To change heating or cooling setpoints, slide switch to desired mode (i.e. heating or cooling), and press the arrow up or arrow down key to change the set point. The differential between heating and cooling set points is factory set at 3°F (1.5°C). Figure 5: Example MCO Thermostat Unit-mounted controls are shipped from the factory for display in degrees Farhenheit. To change display to Celcius, follow the instructions below. 1. Turn power OFF. 2. Remove the thermostat cover (NOTE: Make sure to depress the tab at the top of the thermostat to avoid damaging the cover) F/C jumper is located at top left of display case (see Fig 6). 3. Remove the Jumper for °C selection; position jumper on both pins for °F selection. 4. Turn power ON. 5. Press RESET if desired measurement scale has not been changed (See Fig 6). Figure 6: °F/°C Changeover °F 24 °C C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Electrical - Low Voltage Optional Wall-Mounted Thermostat CCE & TRC WSHP units are built with standard internal thermostats in either manual changeover (MCO) or automatic changeover (ACO) configuration. No external, field-installed low-voltage wiring is required. When desired, the unit can be furnished with a 24-volt control circuit which is field-wired to a ClimateMastersupplied accessory remote 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. Figure 7: Typical Thermostat Wiring Connection to CXM Control Thermostat CXM Compressor Y Y Reversing Valve Fan 24Vac Hot 24Vac Common O O G G R R C C Fault LED L AL1 Low-voltage wiring between the unit and the wall thermostat must comply with all applicable electrical codes (i.e., NEC and local codes), and be completed before the unit is installed. Table 6: Recommended Thermostat Wire Sizes WIRE SIZE MAX. WIRE LENGTH* 18-Gauge 16-Gauge 14-Gauge 75 feet [22m] 125 feet [38m] 200 feet [60m] *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 ClimateMaster units, provided it has the correct number of heating and cooling stages. c l i m a t e m a s t e r. c o m 25 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B TRC/CCE Series Wiring Diagram Matrix DIAGRAMS CAN BE LOCATED ONLINE AT CLIMATEMASTER.COM USING THE PART NUMBERS PRESENTED BELOW. Model Refrigerant Wiring Diagram Part Number R410A 96B0099N50 R410A 96B0099N03 R410A 96B0099N04 R410A 96B0099N05 R410A 96B0100N50 Electrical 96B0100N03 R410A 96B0100N04 R410A TRC06 TRC18 ETL REM ETL CXM LON ETL MPC ETL ACO/MCO ETL REM ETL 265/60/1 115/60/1, 208-230/60/1, Agency ACO/MCO 115/60/1, 208-230/60/1, R410A Control DXM LON ETL 96B0100N05 MPC ETL 265/60/1 R410A 96B0099N60 ACO/MCO CE R410A 96B0099N61 REM CE R410A 96B0099N62 LON CE R410A 96B0099N63 R410A 96B0100N60 CXM MPC CE MCO/ACO CE 220 - 240/50/1 R410A 96B0100N61 REM CE R410A 96B0100N62 LON CE R410A 96B0100N63 MPC CE DXM DIAGRAMS CAN BE LOCATED ONLINE AT CLIMATEMASTER.COM USING THE PART NUMBERS PRESENTED BELOW. Model Refrigerant Wiring Diagram Part Number R22 96B0099N50 R22 96B0099N03 R22 96B0099N04 R22 96B0099N05 R407C 96B0099N60 R407C 96B0099N60 Electrical Control 115/60/1, Agency MCO/ACO ETL REM ETL LON ETL MPC ETL 208-230/60/1, CCE07 CCE19 265/60/1 CXM 220-240/50/1 MCO CE ACO CE REM CE LON CE R407C 96B0099N61 R407C 96B0099N62 R407C 96B0099N63 MPC CE R22 96B0100N50 MCO/ACO ETL R22 96B0100N03 REM ETL 115/60/1, 208-230/60/1, 26 R22 96B0100N04 R22 96B0100N05 R407C 96B0100N60 265/60/1 DXM LON ETL MPC ETL MCO CE R407C 96B0100N60 R407C 96B0100N61 R407C 96B0100N62 LON CE R407C 96B0100N63 MPC CE 220-240/50/1 ACO CE REM CE C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Typical Wiring Diagram - Unit Mounted Manual & Auto Change Over CCE Units (Rev. B) & TRC Units with CXM Controller (2 Speed) c l i m a t e m a s t e r. c o m 27 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Typical Wiring Diagram - Remote Mounted Thermosat CCE & TRC Units with CXM Controller (1) Speed with Selector Switch 28 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Typical Wiring Diagram - Unit Mounted Manual & Auto Change Over CCE Units (Rev. B) & TRC Units with DXM Controller (2) Speed c l i m a t e m a s t e r. c o m 29 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Typical Wiring Diagram - Unit Mounted Manual & Auto Change Over TRC Units 50Hz with CXM Controller (2) Speed 30 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Typical Wiring Diagram - Remote Mounted Thermostat TRC Units 50Hz with DXM Controller (1) Speed with Selector Switch c l i m a t e m a s t e r. c o m 31 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B CXM Controls CXM Control For detailed control information, see CXM or DXM Application, Operation and Maintenance (AOM) manual (part # 97B0003N12 or part #97B0003N13). Field Selectable Inputs Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. 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 (JW3FP1 Low Temp) provides field selection of temperature limit setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Air coil low temperature limit setting: Jumper 2 (JW2-FP2 Low Temp) provides field selection of temperature limit setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory. Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides 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 1: Unit Performance Sentinel Disable provides field selection to disable the UPS feature. 32 On = Enabled. Off = Disabled. DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will NOT cycle during test mode. On = Stage 1. Off = Stage 2 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: CXM/DXM LED And Alarm Relay Operations Description of Operation LED Alarm Relay Normal Mode Normal Mode with UPS Warning CXM is non-functional Fault Retry Lockout Over/Under Voltage Shutdown On On Off Slow Flash Fast Flash Slow Flash Open Cycle (closed 5 sec., Open 25 sec.) Open Open Closed Open (Closed after 15 minutes) Test Mode - No fault in memory Flashing Code 1 Cycling Code 1 Test Mode - HP Fault in memory Flashing Code 2 Cycling Code 2 Test Mode - LP Fault in memory Flashing Code 3 Cycling Code 3 Test Mode - FP1 Fault in memory Flashing Code 4 Cycling Code 4 Test Mode - FP2 Fault in memory Flashing Code 5 Cycling Code 5 Test Mode - CO Fault in memory Flashing Code 6 Cycling Code 6 Test Mode - Over/Under shutdown in memory Flashing Code 7 Cycling Code 7 Test Mode - UPS in memory Flashing Code 8 Cycling Code 8 Test Mode - Swapped Thermistor Flashing Code 9 Cycling Code 9 -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 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B DXM Controls DXM Control For detailed control information, see CXM AOM (part # 97B0003N12), DXM AOM (part #97B0003N13), Lon controller AOM (part #97B0013N01) or MPC AOM (part # 97B0031N01). Table 7b: DXM Description of Operation Normal mode Normal mode with UPS DXM is non-functional Fault Retry Lockout Test Mode Night Setback ESD Invalid T-stat Inputs HP Fault LP Fault FP1 Fault FP2 Fault CO Fault Over/Under Voltage limit setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Air coil low temperature limit setting: Jumper 2 (JW2-FP2 Low Temp) provides field selection of temperature limit LED And Alarm Relay Operations setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, Status LED Test LED Fault LED (red) Alarm Relay (green) (yellow) as recommended by ClimateMaster technical On Off Open services. On - Flashing Code 8 Cycle (closed 5 sec, open 25 sec) Off Slow Flash Fast Flash Flashing Code 2 Flashing Code 3 Flashing Code 4 Off On - Off Flashing fault code Flashing fault code - Open Open Closed - 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 Open Open Open Open Open Flashing Code 7 Open (closed after 15 minutes) Slow Flash - -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 Field Selectable Inputs Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the DXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. 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 DXM control. Water coil low temperature limit setting: Jumper 3 (JW3FP1 Low Temp) provides field selection of temperature Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. 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). Low pressure normally open: Jumper 1 (JW1LP norm open) provides field selection for low pressure input to be normally closed or normally open. Not Clipped = LP normally closed. Clipped = LP normally open. DIP Switches Note: In the following field configuration options, DIP switches should only be changed when power is removed from the DXM control. DIP Package #1 (S1) DIP Package #1 has 8 switches and provides the following setup selections: 1.1 - Unit Performance Sentinel (UPS) disable: DIP Switch 1.1 provides field selection to disable the UPS feature. On = Enabled. Off = Disabled. 1.2 - Compressor relay staging operation: DIP 1.2 provides selection of compressor relay staging operation. The compressor relay can be selected to turn on with a stage 1 or stage 2 call from the thermostat. This is used with dual stage units (2 compressors where 2 DXM controls are being used) or with master/slave applications. In master/slave applications, each compressor and fan will stage according to its appropriate DIP 1.2 setting. If set to stage 2, the compressor will have a 3 second on-delay before energizing during a Stage 2 demand. Also, if set for stage 2, the alarm relay will NOT cycle during test mode. On = Stage 1. Off = Stage 2. 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/ c l i m a t e m a s t e r. c o m 33 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B DXM Controls 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 FP1 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 set point. Note that the FP1 thermistor is sensing refrigerant temperature between the coaxial heat exchanger and the expansion device (TXV or cap tube). Therefore, the 50°F [10°C] setting is not 50°F [10°C] water, but approximately 60°F [16°C] EWT. selection of ACC 1 relay personality (relay operation/ characteristics). See table 6c for description of functionality. 2.3 - Accessory1 relay personality: DIP 2.3 provides selection of ACC 1 relay options. See table 6c for description of functionality. 2.4 - Accessory2 relay personality: DIP 2.4 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table 6c for description of functionality. 2.5 - Accessory2 relay personality: DIP 2.5 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table 6c for description of functionality. 2.6 - Accessory2 relay personality: DIP 2.6 provides selection of ACC 2 relay options. See table 6c 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 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 6c for description of functionality. 2.2 - Accessory1 relay personality: DIP 2.2 provides 34 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. Random start: The control features a random start upon power up of 5-80 seconds. Fault Retry: In Fault Retry mode, the Status LED begins slowly 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: FP1/FP2 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 Example: 2 quick flashes, 10 sec pause, 2 quick flashes, 10 sec. pause, etc. Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 120 seconds of a compressor run cycle. Low pressure lockout code = 3 Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 120 seconds of a compressor run cycle. FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred. FP1 lockout code = 4 Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault. The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred. FP2 lockout code = 5 Condensate 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 Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating inefficiently. A UPS condition exists when: a) In heating mode with compressor energized, FP2 is greater than 125°F [52°C] for 30 continuous seconds, or: b) In cooling mode with compressor energized, FP1 is greater than 125°F [52°C] for 30 continuous seconds, or: c) In cooling mode with compressor energized, FP2 is less than 40°F [4.5°C] for 30 continuous seconds. c l i m a t e m a s t e r. c o m 35 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Safety Features - CXM/DXM Controls 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 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. Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout with code 9 after 30 seconds if: a) The compressor is on in the cooling mode and the FP1 sensor is colder than the FP2 sensor, or: b) The compressor is on in the heating mode and the FP2 sensor is colder than the FP1 sensor. Swapped FP1/FP2 thermistor code = 9. 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) 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. 36 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. For more specific unit performance reference the product catalog, the submittal data sheets or contact your supplier for assistance. Table 8: Building Commissioning BUILDING COMMISSIONING ALL CCE MODELS ALL TRC MODELS Cooling °F [°C] Heating °F [°C] Cooling °F [°C] Heating °F [°C] AMBIENT MIN - MAX DB 45-110 [7-43] 40-85 [4.5-29] 45-110 [7-43] 40-85 [4.5-29] RETURN AIR MIN DB/WB 60/45 [16/7] 40 [4.5] 60/45 [16/7] 40 [4.5] RETURN AIR MAX DB/WB 110/83 [43/28] 80 [27] 110/83 [43/28] 80 [27] STANDARD UNIT ENTERING WATER MIN* - MAX 40-110 [4.5-43] 60-90 [16-43] 40-120 [4.5-49] 60-90 [16-43] EXTENDED RANGE UNIT** ENTERING WATER MIN* - MAX 30-110 [-1-43] 20-90 [-6.7-32] 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 CCE Models All TRC Models Cooling °F [°C] Heating °F [°C] Cooling °F [°C] Heating °F [°C] AMBIENT MIN - MAX DB 50-100 [10-38] 50-85 [10-29] 50-100 [10-38] 50-85 [10-29] RETURN AIR MIN DB/WB 65/60 [18/15.5] 50 [10] 65/60 [18/15.5] 50 [10] RETURN AIR MAX DB/WB 95/75 [35/24] 80 [27] 95/75 [35/24] 80 [27] STANDARD UNIT ENTERING WATER MIN* - MAX 50-110 [10-43] 60-90 [16-43] 50-120 [10-49] 60-90 [16-43] EXTENDED RANGE UNIT** ENTERING WATER MIN* - MAX 30-110 [-1-43] 20-90 [-6.7-32] 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 9: Water Temperature Change Through Heat Exchanger c l i m a t e m a s t e r. c o m 37 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Piping System Cleaning and Flushing Piping System Cleaning and Flushing Cleaning and flushing the WLHP piping system is the single most important step to insure proper start-up and continued efficient operation of the system. Follow the instructions below to properly clean and flush the system: 1. Insure 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 (ClimateMaster 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 113°F [45°C]. NOTE: ClimateMaster 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. ClimateMaster 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. 38 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Unit and System Checkout Procedure Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT Balancing/shutoff valves: Insure that all isolation valves are open and water control valves are wired. Line voltage and wiring: Verify that voltage is within an acceptable range for the unit and wiring and fuses/breakers are properly sized. Verify that low voltage wiring is complete. Unit control transformer: Insure that transformer has the properly selected voltage tap. Commercial 208-230V 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 startup. Fan motors are pre-oiled 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. 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 springmounted compressors will cause excessive noise, and could cause component failure due to added vibration. 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. c l i m a t e m a s t e r. c o m 39 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B 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 ClimateMaster 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 40 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. 9. BE CERTAIN TO FILL OUT AND FORWARD ALL WARRANTY REGISTRATION PAPERS TO CLIMATEMASTER. Note: If performance during any mode appears abnormal, refer to the 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 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s Short test pins together to enter Test Mode and speed-up timing and delays for 20 minutes. THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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 TRC Series Typical Operating Pressures and Temperatures (60 Hz I.P. Units) TRC09 Full Load Cooling - without HWG Active Full Load Heating - without HWG Active Entering Water Temp °F Water Flow GPM/ Ton Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB 30 1.4 2 2.75 126-136 126-136 126-136 161-181 146-166 131-151 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 18-24 18-24 19-25 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 90 1.4 2 2.75 142-152 142-152 142-152 365-385 351-371 337-357 8-13 8-13 8-13 9-14 8-13 7-12 16-18 12-14 8-10 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 36-42 110 1.4 2 2.75 150-160 150-160 150-160 439-459 439-459 439-459 7-12 7-12 7-12 9-14 8-13 7-12 14.2-16.2 10.6-12.6 6.9-8.9 17-23 17-23 17-23 TRC12 Full Load Cooling - without HWG Active Full Load Heating - without HWG Active Entering Water Temp °F Water Flow GPM/ Ton Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB 30 1.75 2.6 3.5 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 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 21-27 21-27 22-28 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 90 1.75 2.6 3.5 138-148 138-148 138-148 366-386 353-373 340-360 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 18-24 122-132 123-133 124-134 376-396 378-398 380-400 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 32-38 110 1.75 2.6 3.5 145-155 145-155 145-155 453-473 442-462 431-451 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 c l i m a t e m a s t e r. c o m 41 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Unit Operating Conditions Table: 10 TRC Series Typical Operating Pressures and Temperatures (60 Hz I.P. Units) TRC15 Full Load Cooling - without HWG active Entering Water Temp °F Water Flow GPM/ton Suction Pressure PSIG Discharge Pressure PSIG Subcooling Water Temp Drop °F Superheat 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 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 70 2.1 3.15 4.2 132-142 132-142 132-142 300-320 263-282 245-265 90 2.1 3.15 4.2 138-148 138-148 138-148 110 2.1 3.15 4.2 145-155 145-155 145-155 TRC18 Full Load Heating - without HWG active Air Temp Rise °F DB Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB 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 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 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 30-36 366-386 353-373 340-360 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 36-42 453-473 442-462 431-451 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 Full Load Cooling - without HWG active Entering Water Temp °F Water Flow GPM/ton Suction Pressure PSIG Discharge Pressure PSIG Subcooling Water Temp Drop °F Superheat 30 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 50 2.5 3.75 5 118-128 118-128 118-128 215-235 200-220 185-205 22-27 22-27 22-27 70 2.5 3.75 5 132-142 132-142 132-142 300-320 263-282 245-265 90 2.5 3.75 5 138-148 138-148 138-148 110 2.5 3.75 5 145-155 145-155 145-155 Full Load Heating - without HWG active Air Temp Rise °F DB Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Air Temp Rise °F DB 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 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 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 30-36 366-386 353-373 340-360 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 36-42 453-473 442-462 431-451 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 42 Pressure Drop, PSI 30°F 50°F 70°F 90°F PD Added for Motorized Water Valve 1.1 1.6 2.3 1.6 2.6 4.5 1.2 2.2 3.8 1.0 2.0 3.5 0.9 1.9 3 0.3 0.6 1.2 TRC12 1.5 2.3 3 2.1 4.5 6.8 1.8 3.8 5.8 1.5 3.5 4.9 1.3 3 4.5 0.5 1.2 2.2 TRC15 1.9 2.8 3.7 1.5 3 4.7 1 2.3 3.9 0.9 2 3.3 0.8 1.7 2.9 0.7 1.7 3.3 TRC18 2.3 3.4 4.5 2.2 4.4 6.9 1.8 3.8 6 1.5 3.4 5.2 1.3 3 4.8 0.2 0.6 1.1 Model GPM TRC09 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B 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. 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. 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. c l i m a t e m a s t e r. c o m 43 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Functional Troubleshooting Fault Main power Problems Htg Clg Possible Cause X HP Fault-Code 2 High pressure Solution X Green Status LED Off Check Line Voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check for 24VAC between R and C on CXM/DXM Check primary/secondary voltage on transformer Check pump operation or valve operation/setting Check water flow adjust to proper flow rate X Reduced or no water flow in cooling X Water Temperature out of range in Bring water temp within design parameters cooling X Reduced or no Air flow in heating Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Dirty Air Coil- construction dust etc. X Air Temperature out of range in heating Bring return air temp within design parameters Overcharged with refrigerant Check superheat/subcooling vs typical operating condition table Bad HP Switch Insufficient charge Check switch continuity and operation. Replace Check for refrigerant leaks Compressor pump down at startup Check charge and start-up water flow Too high of external static. Check static vs blower table X X X X LP/LOC Fault-Code 3 X X Low Pressure/Loss of Charge X FP1 Fault - Code 4 X Reduced or no water flow Check pump operation or water valve operation/setting in heating Plugged strainer or filter. Clean or replace. X Inadequate anti-freeze level Check antifreeze density with hydrometer X Improper temperature limit setting (30°F vs 10°F [-1°C vs -12°C]) Clip JW3 jumper for antifreeze (10°F [-12°C]) use Water Coil low temperature limit Check water flow adjust to proper flow rate X Water Temperature out of range Bring water temp within design parameters X X Bad thermistor Reduced or no Air flow in cooling Check temp and impedance correlation per chart Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Too high of external static. Check static vs blower table X Air Temperature out of range Too much cold vent air? Bring entering air temp within design parameters X Improper temperature limit setting (30°F vs 10°F [-1°C vs -12°C]) Normal airside applications will require 30°F [-1°C] only X X Bad thermistor Check temp and impedance correlation per chart X X X X X Blocked Drain Improper trap Poor Drainage X Moisture on sensor 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 X X Plugged Air Filter Replace Air Filter X X Restricted Return Air Flow X X Under Voltage Find & 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? X FP2 fault - Code 5 Air Coil low temperature limit Condensate Fault-Code 6 Over/Under VoltageCode 7 (Auto resetting) Check 24VAC and unit transformer tap for correct power supply voltage X X Over Voltage Check power supply voltage and 24VAC before and during operation. Check 24VAC and unit transformer tap for correct power supply voltage Unit Performance Sentinel-Code 8 X 1R)DXOW&RGH6KRZQ 8QLW6KRUW&\FOHV 2QO\)DQ5XQV 44 Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit. ; Cooling Mode FP1>125°F [52°C] 25)3¯)>¯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l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Functional Troubleshooting Only Compressor Runs X X Thermostat wiring Check G wiring at heat pump. Jumper G and R for fan operation. X X Fan motor relay Jumper G and R for fan operation. Check for Line voltage across BR contacts. X X Fan motor Check fan power enable relay operation (if present) X Unit Doesn't Operate in Cooling X Thermostat wiring X Reversing Valve X Thermostat setup X Thermostat wiring X Thermostat wiring Check for line voltage at motor. Check capacitor Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode. Set for cooling demand and check 24VAC on RV coil and at CXM/DXM board. If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve. Check for 'O' RV setup not 'B' Check O wiring at heat pump. Jumper O and R for RV coil 'Click'. Put thermostat in cooling mode. Check for 24VAC on O (check between C and O); check for 24VAC on W (check between W and C). There should be voltage on O, but not on W. If voltage is present on W, thermostat may be bad or wired incorrectly. Performance Troubleshooting Performance Troubleshooting Insufficient capacity/ Not cooling or heating Htg Clg Possible Cause X X X properly High Head Pressure Solution Dirty Filter Replace or clean Reduced or no Air flow Check for dirty air filter and clean or replace in heating Check fan motor operation and airflow restrictions Too high of external static. Check static vs blower table Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Too high of external static. Check static vs blower table Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present Check superheat and subcooling per chart Check superheat and subcooling per chart. Replace. Perform RV touch test Check location and for air drafts behind stat Recheck loads & sizing check sensible clg load and heat pump capacity X Reduced or no Air flow in cooling X X Leaky duct work X X X X X X X Low refrigerant charge Restricted metering device Defective Reversing Valve Thermostat improperly located X X Unit undersized X X Scaling in water heat exchanger Perform Scaling check and clean if necessary X X Inlet Water too Hot or Cold Check load, loop sizing, loop backfill, ground moisture. Reduced or no Air flow in heating Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Reduced or no water flow in cooling Inlet Water too Hot Air Temperature out of range in heating Check pump operation or valve operation/setting Check water flow adjust to proper flow rate Check load, loop sizing, loop backfill, ground moisture. Scaling in water heat exchanger Unit Overcharged Non-condensables insystem Restricted metering device Reduced water flow in heating Perform Scaling check and clean if necessary Check superheat and subcooling. Reweigh in charge Vacuum system and reweigh in charge Check superheat and subcooling per chart. Replace. Check pump operation or water valve operation/setting Plugged strainer or filter. Clean or replace. Check water flow adjust to proper flow rate X Too high of external static. Check static vs blower table X X X Low Suction Pressure X X X X X X X X X Water Temperature out of range Bring water temp within design parameters X Reduced Air flow in cooling X Air Temperature out of range X Insufficient charge Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Too high of external static. Check static vs blower table Too much cold vent air? Bring entering air temp within design parameters Check for refrigerant leaks X Too high of air flow Check fan motor speed selection and airflow chart X X Poor Performance Too high of air flow X Unit oversized See 'Insufficient Capacity' Check fan motor speed selection and airflow chart Recheck loads & sizing check sensible clg load and heat pump capacity X Low discharge air temperature in heating High humidity Bring return air temp within design parameters c l i m a t e m a s t e r. c o m 45 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Troubleshooting Form Model Number: ________________________ Serial Number: ________________________ Date: ________________________ HEATING CYCLE ANALYSIS - PSI Refrigerant Type: SAT °F R410A °F AIR COIL SUCTION °F COMPRESSOR EXPANSION FILTER DRIER* VALVE Voltage: ________ COAX DISCHARGE HWG Comp Amps: _______ °F Total Amps: ________ °F °F FLASH GAS LINE FP2: HEATING LIQUID LINE °F FP1 SENSOR PSI °F PSI WATER IN SAT °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 °F AIR COIL SUCTION °F COMPRESSOR EXPANSION FILTER DRIER* VALVE COAX DISCHARGE HWG °F °F °F FP2: FLASH OTHER SIDE OF FILTR DR GAS LINE °F FP1: CLG LIQ LINE PSI °F PSI WATER IN SAT °F PSI WATER OUT 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. † = (Btu/hr) (deg F) (deg F) Use 500 for water, 485 for antifreeze. 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. 46 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s c l i m a t e m a s t e r. c o m Rev.: 11/09 Please refer to the CM Installation, Operation and Maintenance Manual for operating and maintenance instructions. LC083 *LC083* NOTE: Some states or Canadian provinces do not allow limitations on how long an implied warranty lasts, or the limitation or exclusions of consequential or incidental damages, so the foregoing exclusions and limitations may not apply to you. This warranty gives you speciÀc legal rights, and you may also have other rights which vary from state to state and from Canadian province to Canadian province. Climate Master, Inc. • Customer Service • 7300 S.W. 44th Street • Oklahoma City, Oklahoma 73179 (405) 745-6000 OBTAINING WARRANTY PERFORMANCE Normally, the contractor or service organization who installed the products will provide warranty performance for the owner. Should the installer be unavailable, contact any CM recognized dealer, contractor or service organization. If assistance is required in obtaining warranty performance, write or call: LIMITATION OF LIABILITY CM shall have no liability for any damages if CM’s performance is delayed for any reason or is prevented to any extent by any event such as, but not limited to: any war, civil unrest, government restrictions or restraints, strikes or work stoppages, Àre, Áood, accident, shortages of transportation, fuel, material, or labor, acts of God or any other reason beyond the sole control of CM. CM EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGE IN CONTRACT, FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, OR IN TORT, WHETHER FOR CM’s NEGLIGENCE OR AS STRICT LIABILITY. LIMITATION OF REMEDIES In the event of a breach of the Limited Express Warranty, CM will only be obligated at CM’s option to repair the failed part or unit or to furnish a new or rebuilt part or unit in exchange for the part or unit which has failed. If after written notice to CM’s factory in Oklahoma City, Oklahoma of each defect, malfunction or other failure and a reasonable number of attempts by CM to correct the defect, malfunction or other failure and the remedy fails of its essential purpose, CM shall refund the purchase price paid to CM in exchange for the return of the sold good(s). Said refund shall be the maximum liability of CM. THIS REMEDY IS THE SOLE AND EXCLUSIVE REMEDY OF THE BUYER OR THEIR PURCHASER AGAINST CM FOR BREACH OF CONTRACT, FOR THE BREACH OF ANY WARRANTY OR FOR CM’S NEGLIGENCE OR IN STRICT LIABILITY. Limitation: This Limited Express Warranty is given in lieu of all other warranties. If, notwithstanding the disclaimers contained herein, it is determined that other warranties exist, any such warranties, including without limitation any express warranties or any implied warranties of Àtness for particular purpose and merchantability, shall be limited to the duration of the Limited Express Warranty. CM is not responsible for: (1) The costs of any Áuids, refrigerant or other system components, or associated labor to repair or replace the same, which is incurred as a result of a defective part covered by CM’s Limited Express Warranty; (2) The costs of labor, refrigerant, materials or service incurred in removal of the defective part, or in obtaining and replacing the new or repaired part; or, (3) Transportation costs of the defective part from the installation site to CM or of the return of any part not covered by CM’s Limited Express Warranty. This warranty does not cover and does not apply to: (1) Air Àlters, fuses, refrigerant, Áuids, oil; (2) Products relocated after initial installation; (3) Any portion or component of any system that is not supplied by CM, regardless of the cause of the failure of such portion or component; (4) Products on which the unit identiÀcation tags or labels have been removed or defaced; (5) Products on which payment to CM is or has been in default; (6) Products which have defects or damage which result from improper installation, wiring, electrical imbalance characteristics or maintenance; or are caused by accident, misuse or abuse, Àre, Áood, alteration or misapplication of the product; (7) Products which have defects or damage which result from a contaminated or corrosive air or liquid supply, operation at abnormal temperatures, or unauthorized opening of refrigerant circuit; (8) Mold, fungus or bacteria damages; (9) Products subjected to corrosion or abrasion; (10) Products manufactured or supplied by others; (11) Products which have been subjected to misuse, negligence or accidents; (12) Products which have been operated in a manner contrary to CM’s printed instructions; or (13) Products which have defects, damage or insufÀcient performance as a result of insufÀcient or incorrect system design or the improper application of CM’s products. GRANT OF LIMITED EXPRESS WARRANTY CM warrants CM products purchased and retained in the United States of America and Canada to be free from defects in material and workmanship under normal use and maintenance as follows: (1) All complete air conditioning, heating and/or heat pump units built or sold by CM for twelve (12) months from date of unit start up or eighteen (18) months from date of shipment (from factory), whichever comes Àrst; (2) Repair and replacement parts, which are not supplied under warranty, for nintey (90) days from date of shipment (from factory). All parts must be returned to CM’s factory in Oklahoma City, Oklahoma, freight prepaid, no later than sixty (60) days after the date of the failure of the part; if CM determines the part to be defective and within CM’s Limited Express Warranty, CM shall, when such part has been either replaced or repaired, return such to a factory recognized dealer, contractor or service organization, F.O.B. CM’s factory, Oklahoma City, Oklahoma, freight prepaid. The warranty on any parts repaired or replaced under warranty expires at the end of the original warranty period. EXCEPT AS SPECIFICALLY SET FORTH HEREIN, THERE IS NO EXPRESS WARRANTY AS TO ANY OF CM’S PRODUCTS. CM MAKES NO WARRANTY AGAINST LATENT DEFECTS. CM MAKES NO WARRANTY OF MERCHANTABILITY OF THE GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PARTICULAR PURPOSE. It is expressly understood that unless a statement is speciÀcally identiÀed as a warranty, statements made by Climate Master, Inc., a Delaware corporation, (“CM”) or its representatives, relating to CM’s products, whether oral, written or contained in any sales literature, catalog or any other agreement, are not express warranties and do not form a part of the basis of the bargain, but are merely CM’s opinion or commendation of CM’s products. CLIMATE MASTER, INC. LIMITED EXPRESS WARRANTY/ LIMITATION OF REMEDIES AND LIABILITY THE SMART SOLUTION FOR ENERGY EFFICIENCY R e v. : 5 N o v. , 2 0 0 9 B Consoles Warranty (U.S. & Canada) 47 48 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s Rev.: 10/09 Please refer to the CM Installation, Operation and Maintenance Manual for operating and maintenance instructions. LC079 *LC079* NOTE: Some countries do not allow limitations on how long an implied warranty lasts, or the limitation or exclusions of consequential or incidental damages, so the foregoing exclusions and limitations may not apply to you. This warranty gives you speciÀc legal rights, and you may also have other rights which vary from state to state and country to country. Climate Master, Inc. • Customer Service • 7300 S.W. 44th Street • Oklahoma City, Oklahoma, U.S.A. 73179 • (405) 745-6000 • FAX (405) 745-6068 OBTAINING WARRANTY PERFORMANCE Normally, the contractor or service organization who installed the products will provide warranty performance for the owner. Should the installer be unavailable, contact any CM recognized Representative. If assistance is required in obtaining warranty performance, write or call: LIMITATION OF LIABILITY CM shall have no liability for any damages if CM’s performance is delayed for any reason or is prevented to any extent by any event such as, but not limited to: any war, civil unrest, government restrictions or restraints, strikes, or work stoppages, Àre, Áood, accident, allocation, shortages of transportation, fuel, materials, or labor, acts of God or any other reason beyond the sole control of CM. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW AND SUBJECT TO THE NEXT SENTENCE, CM EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR LOSS OF PROFITS, LOSS OF BUSINESS OR GOODWILL, CONSEQUENTIAL, INCIDENTAL, SPECIAL, LIQUIDATED, OR PUNITIVE DAMAGE IN CONTRACT, FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, OR IN TORT, WHETHER FOR CM’s NEGLIGENCE OR AS STRICT LIABILITY. Nothing in this Agreement is intended to exclude CM’s liability for death, personal injury or fraud. LIMITATION OF REMEDIES In the event of a breach of this Limited Express Warranty or any warranty that is mandatory under applicable imperative law, CM will only be obligated at CM’s option to either repair the failed part or unit or to furnish a new or rebuilt part or unit in exchange for the part or unit which has failed. If after written notice to CM’s factory in Oklahoma City, Oklahoma, U.S.A. of each defect, malfunction or other failure and a reasonable number of attempts by CM to correct the defect, malfunction or other failure and the remedy fails of its essential purpose, CM shall refund the purchase price paid to CM in exchange for the return of the sold good(s). Said refund shall be the maximum liability of CM. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, THIS REMEDY IS THE SOLE AND EXCLUSIVE REMEDY OF THE CUSTOMER AGAINST CM FOR BREACH OF CONTRACT, FOR THE BREACH OF ANY WARRANTY OR FOR CM’S NEGLIGENCE OR IN STRICT LIABILITY. Limitation: This Limited Express Warranty is given in lieu of all other warranties. If, notwithstanding the disclaimers contained herein, it is determined by a court or other qualiÀed judicial body that other warranties exist, any such warranty, including without limitation any express warranty or any implied warranty of Àtness for particular purpose and merchantability, shall be limited to the duration of the Limited Express Warranty. This Limited Express Warranty does not exclude any warranty that is mandatory and that may not be excluded under applicable imperative law. CM is not responsible for: (1) The cost of any Áuids, refrigerant or other system components, or the associated labor to repair or replace the same, which is incurred as a result of a defective part covered by CM’s Limited Express Warranty; (2) The cost of labor, refrigerant, materials or service incurred in diagnosis and removal of the defective part, or in obtaining and replacing the new or repaired part; (3) Transportation costs of the defective part from the installation site to CM or of the return of any part not covered by CM’s Limited Express Warranty; or (4) The costs of normal maintenance. This warranty does not cover and does not apply to: (1) Air Àlters, fuses, refrigerant, Áuids, oil; (2) Products relocated after initial installation; (3) Any portion or component of any system that is not supplied by CM, regardless of the cause of the failure of such portion or component; (4) Products on which the unit identiÀcation tags or labels have been removed or defaced; (5) Products on which payment by Customer to CM or its distributors or Representatives, or the Customer’s seller is in default; (6) Products which have defects or damage which result from improper installation, wiring, electrical imbalance characteristics or maintenance; or from parts or components manufactured by others; or are caused by accident, misuse, negligence, abuse, Àre, Áood, lightning, alteration or misapplication of the product; (7) Products which have defects or damage which result from a contaminated or corrosive air or liquid supply, operation at abnormal temperatures or Áow rates, or unauthorized opening of the refrigerant circuit; (8) Mold, fungus or bacteria damages; (9) Products subjected to corrosion or abrasion; (10) Products, parts or components manufactured or supplied by others; (11) Products which have been subjected to misuse, negligence or accidents; (12) Products which have been operated in a manner contrary to CM’s printed instructions; (13) Products which have defects, damage or insufÀcient performance as a result of insufÀcient or incorrect system design or the improper application, installation, or use of CM’s products; or (14) Electricity or fuel costs, or any increases or unrealized savings in same, for any reason. If requested by CM, all defective parts shall be returned to CM’s factory in Oklahoma City, Oklahoma, U.S.A, freight and duty prepaid, not later than sixty (60) days after the date of the request. If the defective part is not timely returned or if CM determines the part to not be defective or otherwise not to qualify under CM’s Limited Express Warranty, CM shall invoice Customer the costs for the parts furnished, including freight. The warranty on any part repaired or replaced under warranty expires at the end of the original warranty period. Warranty parts shall be furnished by CM if ordered through an authorized sales representative of CM (“Representative”) within sixty (60) days after the failure of the part. If CM determines that a parts order qualiÀes for replacement under CM’s warranty, such parts shall be shipped freight prepaid to the Representative or the ultimate user, as requested by Representative. All duties, taxes and other fees shall be paid by the ultimate user through the Representative. GRANT OF LIMITED EXPRESS WARRANTY CM warrants CM products purchased and installed outside the United States of America (“U.S.A.”) and Canada to be free from material defects in materials and workmanship under normal use and maintenance as follows: (1) All complete air conditioning, heating or heat pump units built or sold by CM for twelve (12) months from date of unit start-up or eighteen (18) months from date of shipment (from CM’s factory), whichever comes Àrst; and, (2) Repair and replacement parts, which are not supplied under warranty, for ninety (90) days from date of shipment (from factory). Disclaimer: It is expressly understood that unless a statement is speciÀcally identiÀed as a warranty, statements made by Climate Master, Inc., a Delaware corporation, U. S. A. (“CM”) or its representatives, relating to CM’s products, whether oral, written or contained in any sales literature, catalog, this or any other agreement or other materials, are not express warranties and do not form a part of the basis of the bargain, but are merely CM’s opinion or commendation of CM’s products. EXCEPT AS SPECIFICALLY SET FORTH HEREIN AND TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, CM MAKES NO WARRANTY AS TO ANY OF CM’S PRODUCTS, AND CM MAKES NO WARRANTY AGAINST LATENT DEFECTS OR ANY WARRANTY OF MERCHANTABILITY OF THE GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PARTICULAR PURPOSE. CLIMATE MASTER, INC. LIMITED EXPRESS WARRANTY /LIMITATION OF REMEDIES AND LIABILITY (FOR INTERNATIONAL CLASS PRODUCTS) C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Warranty (International) THE SMART SOLUTION FOR ENERGY EFFICIENCY Consoles R e v. : 5 N o v. , 2 0 0 9 B Notes: c l i m a t e m a s t e r. c o m 49 C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S Consoles R e v. : 5 N o v. , 2 0 0 9 B Revision History Date: Item: Action: 11/05/09 Warranty Updated 10/30/09 Functional Troubleshooting Table Updated 09/15/09 Safety Features - CXM/DXM Controls Updated 07/29/09 Unit Commissioning & Operating Conditions Data Tables Corrected 06/09/09 ‘Unit Starting & Operating Conditions’ Section & Table Edited and renamed ‘Unit Commissioning and Operating Conditions’ 12/02/08 TRC & CCE Wiring Diagrams Consolidated 12/02/08 TRC & Piping Connection Diagrams Added 09/09/08 Pressure Testing Note Updated 06/30/08 Shut-Off Valve Note Added to Piping Connections 05/21/08 Unit and System Checkout Added Pressure testing language 05/20/08 All Updated All Added TRC Controls Added CCE Rev B controls 01/01/07 Piping Added warnings on pressure switches when using water solenoid valves 01/01/07 Applications Added Notice on ground-water applications 01/01/06 First Published R AI BR I HE AT P U M P S A TO NE WATER TO IFIED TO ARI A RT S C CE NG WITH LYI MP O IR MANUFACT UR ER 01/01/07 01/01/07 IS ST AND 3 ARD 1 -1 R O 25 6 7300 S.W. 44th Street Oklahoma City, OK 73179 *97B0035N01* Phone: 405-745-6000 Fax: 405-745-6058 climatemaster.com 97B0035N01 ClimateMaster works continually to improve its products. As a result, the design and specifi cations of each product at the time for order may be changed without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products. © ClimateMaster, Inc. 2006 ClimateMaster Water-Source Heating and Cooling Systems 50 ">
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