Model Nomenclature ....................................................................................................................................1
General Description.......................................................................................................................................2
Moving and Storage......................................................................................................................................2
Duct System .....................................................................................................................................................3
Safety Devices & the UPM Controller......................................................................................................5
Sequence of Operation Single Stage Units ..........................................................................................8
Electric Heater Package Option ................................................................................................................8
Sequence of Operation Two-Stage Units..............................................................................................9
Well Water Systems .......................................................................................................................................9
Installation of Pressure Regulating Valves............................................................................................9
System Checkout .........................................................................................................................................10
Unit Start-Up..................................................................................................................................................10
Unit Check Out..............................................................................................................................................17
HEAT EXCHANGER MATERIAL:
C - COPPER
N - CUPRO-NICKEL
SUPPLY AIR LOCATION:
T - TOP (VT ONLY)
E - END BLOW (HZ ONLY)
B - BOTTOM (CF ONLY)
RETURN AIR LOCATION:
L - LEFT
R - RIGHT
B - BACK
F - FRONT
WATER CONNECTION
LOCATION
F - FRONT
2
ES SERIES
INITIAL INSPECTION:
Be certain to inspect all cartons or crates on each unit as
eceived at the job site before signing the freight bill. Verify
r
that all items have been received and that there are no
visible damages; note any shortages or damages on all
copies of the freight bill. In the event of damage or shortage,
remember that the purchaser is responsible for filing the
necessary claims with the carrier. Concealed damages not
discovered until after removing the units from the packaging
must be reported to the carrier within 24 hours of receipt.
GENERAL DESCRIPTION:
These Water-to-Air Heat Pumps provide the best combination
of performance and efficiency available. Safety devices are
built into each unit to provide the maximum system
protection possible when properly installed and maintained.
The ES Water-to-Air Heat Pumps are Underwriters
Laboratories (UL) and (cUL) listed for safety. The water-toAir Heat Pumps are designed to operate with entering fluid
temperature between 25°F to 75°F in the heating mode and
between 50°F to 110°F in the cooling mode.
NOTE: 50°F Min. EWT for well water applications with
sufficient water flow to prevent freezing. Antifreeze
solution is required for all closed loop applications. Cooling
Tower/Boiler and Earth Coupled (Geo Thermal) applications
should have sufficient antifreeze solution to protect against
extreme conditions and equipment failure. Frozen water
coils are not covered under warranty.
NOTE: This product should not be used for temporarily
heating/cooling during construction. Doing so may effect
the units warranty.
MOVING AND STORAGE:
If the equipment is not needed for immediate installation
upon its arrival at the job site, it should be left in its
shipping carton and stored in a clean, dry area. Units must
only be stored or moved in the normal upright position as
indicated by the "UP" arrows on each carton at all times. If
unit stacking is required, stack units as follows: Vertical
units less than 6 tons, no more than two high. Horizontal
units less than 6 tons, no more than three high. "Do not
stack units larger than 6 tons."
SAFETY CONSIDERATIONS:
Installation and servicing of this equipment can be
hazardous due to system pressure and electrical
components. Only trained and qualified personnel should
install, repair, or service the equipment. Untrained
personnel can perform basic functions of maintenance
such as cleaning coils and replacing filters.
WARNING: Before performing service or maintenance
operations on the system, turn off main power to the unit.
Electrical shock could cause personal injury or death.
When working on equipment, always observe precautions
described in the literature, tags, and labels attached to the
unit. Follow all safety codes. Wear safety glasses and work
gloves. Use a quenching cloth for brazing, and place a fire
extinguisher close to the work area.
6720220330 Revised 05-12
LOCATION:
Locate the unit in an indoor area that allows easy removal
f the filter and access panels, and has enough room for
o
service personnel to perform maintenance or repair.
Provide sufficient room to make fluid, electrical, and duct
connection(s). If the unit is located in a confined space such
as a closet, provisions must be made for return air to freely
enter the space. On horizontal units, allow adequate room
below the unit for a condensate drain trap and do not
locate the unit above supply piping. These units are not
approved for outdoor installation; therefore, they must be
installed inside the structure being conditioned. Do not
locate in areas that are subject to freezing.
INSTALLATION:
NOTE: Remove all shipping blocks under blower housing.
Loosen compressor mounting bolts.
MOUNTING VERTICAL UNITS:
Vertical units up to six tons are available in left, right, front,
or rear air return configurations. Vertical units should be
mounted level on a vibration absorbing pad slightly larger
than the base to minimize vibration transmission to the
building structure. It is not necessary to anchor the unit to
the floor. (See Figure #1). Vertical units larger than six tons
should be vibration isolated according to the design
engineers specifications.
MOUNTING
(Figure #1)
HORIZONTAL UNITS:
While horizontal units may
be installed on any level
surface strong enough to
hold their weight, they are
typically suspended above
a ceiling by threaded rods.
The rods are usually
attached to the unit
corners by hanger bracket
kits (P/N 930-004, 006).
(See Figure #2). The rods
must be securely
anchored to the ceiling.
Refer to the hanging bracket assembly and installation
instructions for details. Horizontal units installed above the
ceiling must conform to all local codes. An auxiliary drain pan
if required by code, should be at least four inches larger than
the bottom of the heat pump. Plumbing connected to the
heat pump must not come in direct contact with joists,
trusses, walls, etc.
Some applications
require an attic floor
installation of the
horizontal unit. In this
case the unit should be
set in a full size secondary
drain pan on top of a
vibration absorbing
(Figure #2)
mesh. The secondary
drain pan prevents
VIBRATION
PAD
FULL SIZE
ES SERIES
3
possible condensate overflow or water leakage damage to the
eiling. The secondary drain pan is usually placed on a
c
plywood base isolated from the ceiling joists by additional
layers of vibration absorbing mesh. In both cases, a 3/4" drain
connected to this secondary pan should be run to an eave at a
location that will be noticeable. If the unit is located in a crawl
space, the bottom of the unit must be at least 4" above grade
to prevent flooding of the electrical parts due to heavy rains.
CONDENSATE DRAIN:
NOTE: If equipped with float style condensate overflow
switch, final adjustment must be made in the field.
A drain line must be connected to the heat pump and
pitched away from the unit a minimum of 1/8" per foot to
allow the condensate to flow away from the unit.
(Figure #3)
This connection must be in conformance with local
plumbing codes. A trap must be installed in the condensate
line to insure free condensate flow. (Heat Pumps are not
internally trapped). A vertical air vent is sometimes required
to avoid air pockets. (See Figure #3). The length of the trap
depends on the amount of positive or negative pressure on
the drain pan. A second trap must not be included.
The horizontal unit should be pitched approximately 1/4"
towards the drain in both directions, to facilitate
condensate removal. (See Figure #4)
A flexible connector is recommended for supply and return
ir duct connections on metal duct systems. All metal
a
ducting should be insulated with a minimum of one inch
duct insulation to avoid heat loss or gain and prevent
condensate forming during the cooling operation.
Application of the unit to uninsulated duct work is not
recommended as the unit’s performance will be adversely
affected. Do not connect discharge ducts directly to the
blower outlet. The factory provided air filter must be
removed when using a filter back return air grill.The factory
filter should be left in place on a free return system.
If the unit will be installed in a new installation which
includes new duct work, the installation should be
designed using current ASHRAE procedures for duct sizing.
If the unit is to be connected to existing ductwork, a check
should be made to assure that the duct system has the
capacity to handle the air required for the unit application.
If the duct system is too small, larger ductwork should be
installed. Check for existing leaks and repair.
The duct system and all diffusers should be sized to handle
the designed air flow quietly. To maximize sound
attenuation of the unit blower, the supply and return air
plenums should be insulated. There should be no direct
straight air path thru the return air grille into the heat
pump. The return air inlet to the heat pump must have at
least one 90 degree turn away from the space return air
grille. If air noise or excessive air flow are a problem, the
blower speed can be changed to a lower speed to reduce
air flow. (Refer to ECM motor interface board section in this
manual and Figure #7)
PIPING:
Supply and return piping must be as large as the unit
connections on the heat pump (larger on long runs). Never
use flexible hoses of a smaller inside diameter than that of
the fluid connections on the unit. ES units are supplied with
either a copper or optional cupro-nickel condenser. Copper
is adequate for ground water that is not high in mineral
content. Should your well driller express concern regarding
the quality of the well water available or should any known
hazards exist in your area, we recommend proper testing to
assure the well water quality is suitable for use with water
source equipment. In conditions anticipating moderate
scale formation or in brackish water a cupro-nickel heat
exchanger is recommended.
(Figure #4)
DUCT SYSTEM:
A supply air outlet collar and return air duct flange are
provided on all units to facilitate duct connections. Refer to
the FHP individual data specification sheet for physical
dimensions of the collar and flange.
6720220330 Revised 05-12
Both the supply and discharge water lines will sweat if
subjected to low water temperature. These lines should be
insulated to prevent damage from condensation.
All manual flow valves used in the system must be ball
valves. Globe and gate valves must not be used due to high
pressure drop and poor throttling characteristics. Never
exceed the recommended water flow rates as serious
damage or erosion of the water to refrigerant heat
exchanger could occur.
Always check carefully for water leaks and repair
appropriately. Units are equipped with female pipe thread
fittings. Consult the specification sheets for sizes. Teflon
tape sealer should be used when connecting water piping
connections to the units to insure against leaks and
4
ES SERIES
possible heat exchanger fouling. Do not overtighten the
onnections. Flexible hoses should be used between the
c
unit and the rigid system to avoid possible vibration. Ball
valves should be installed in the supply and return lines for
unit isolation and unit water flow balancing.
ELECTRICAL:
(Refer to electrical component box layout, Figure #5)
Field wiring must comply with local and national electric
codes. Power to the unit must be within the operating
voltage range indicated on the unit nameplate or on the
performance data sheet. On three phase units (single stage
units only) phases must be balanced within 2%.
CAUTION: Operation of unit on improper line voltage or
with excessive phase imbalance will be hazardous to the
unit, constitutes abuse and may void the warranty.
Properly sized fuses or HACR circuit breakers must be
installed for branch circuit protection. See unit nameplate
for maximum fuse or breaker size.
The unit is provided with a concentric knock-out in the front
left corner post for attaching common trade sizes of conduit,
route power supply wiring through this opening. Always
connect the ground lead to the grounding lug provided in the
control box and power leads to the power supply terminal
block as indicated on the wiring diagram and Figure #5.
(Figure #5)
Electrical Box Component Layout
OTE:
N
(2) separate power supplies: one for the unit compressor
and one for the electric heater elements, blower motor and
control circuit. Refer to the ELECTRIC HEATER PACKAGE
OPTION section for wiring instructions, minimum circuit
ampacities and maximum fuse/breaker sizing.
Units supplied with internal electric heat require two
(Figure #6)
ECM INTERFACE BOARD:
THERMOSTAT CONNECTIONS:
Thermostat wiring is connected to the 10 pin screw type
terminal block on the lower center portion of the ECM
Interface Board. In addition to providing a connecting point
for thermostat wiring, the interface board also translates
thermostat inputs into control commands for the variable
speed programmable ECM DC fan motor and displays an
LED indication of operating status. The thermostat
connections and their functions are as follows:
6720220330 Revised 05-12
Single & Two Step
Y2Second Stage Compressor Operation
Y1First Stage Compressor Operation
GFan
OReversing Valve (energized in cooling)
W1Auxiliary Electric Heat
(runs in conjunction with compressor)
EM/W2Emergency Heat (electric heat only)
NCTransformer 24 VAC Common
(extra connection)
C1Transformer 24 VAC Common
(primary connection)
RTransformer 24 VAC Hot
HUMDehumidification Mode
If the unit is being connected to a thermostat with a
malfunction light, this connection is made at the unit
malfunction output or relay.
NOTE: If the thermostat is provided with a malfunction
light powered off of the common (C) side of the
transformer, the unit must be provided with a malfunction
relay (FHP option # 660-006) to properly energize the light.
The relay coil will be wired across the (ALR) and (C) contacts
on the unit’s UPM board and the relay’s normally open
contacts across (ALR) and the malfunction light connection
on the thermostat. If the thermostat is provided with a
ES SERIES
5
malfunction light powered off of the hot (R) side of the
transformer, then the thermostat malfunction light
connection should be connected directly to the (ALR)
contact on the unit’s UPM board.
To the left of the thermostat connection block are a row of
2 red and 4 green LED’s. These LED’s indicate the operating
status of the unit. They are labeled as follows:
EM (red)Emergency Heat On
W1 (red)Auxiliary Heat On
O(green)Reversing Valve Energized, unit is
in cooling mode
Y2(green)Second Stage Compressor On
Y1(green)First Stage Compressor On
G(green)Fan On
and TEST. ES units will all be set on the NORM position from
the factory, however, airflow can be increased (+) or
decreased (-) by 15% from the pre-programmed setting by
relocating the jumper in this section. The TEST position is
used to verify proper motor operation. If a motor problem
s suspected, move the ADJ jumper to the TEST position and
i
energize G on the thermostat connection block. If the
motor ramps up to 100% power, then the motor itself is
functioning normally. Always remember to replace the
jumper to NORM, (+) or (-) after testing and reset the unit
thermostat to restore normal operation.
NOTE: Do not set the ADJ jumper to the (-) setting when
electric heaters are installed. Doing so may cause the
heaters to cycle on their thermal overload switches,
potentially shortening the life of the switches.
The other three sets of jumper pins are used to select the
proper program in the ECM motor for the unit. Refer to
Figure #7 for the proper jumper placement.
NOTE: Always disconnect power before changing jumper
positions on the interface board and reset the unit
afterward.
To the left of the red and green status LED’s is a row of 1/4”
male quick connects. These are used to pass thermostat
inputs on to the rest of the control circuit. Remember to
always turn off unit power at the circuit breaker before
attaching or disconnecting any wiring from these
connections to avoid accidental short circuits that can
damage unit control components.
SAFETY DEVICES AND THE UPM CONTROLLER
Each unit is factory provided with a Unit Protection Module
(UPM) that controls the compressor operation and
monitors the safety controls that protect the unit.
Safety controls include the following:
•High pressure switch located in the refrigerant
discharge line and wired across the HPC terminals on
the UPM
•Low pressure switch located in the unit refrigerant
suction line and wired across terminals LPC1 and LPC2
on the UPM.
Just above the connector block is a single red LED labeled
CFM that will blink intermittently when the unit is running
and may flicker when the unit is off. This LED indicates the
air delivery of the blower at any given time. Each blink of
the LED represents approximately 100 CFM of air delivery
so if the LED blinks 12 times, pauses, blinks 12 times, etc.
the blower is delivering 1200 CFM. Refer to Figure #7 for
factory programmed air delivery settings for the ES Series.
To the right of the thermostat connection block is a green
LED labeled dehumidify. This feature is not utilized on the
ES Series.
Just above and to the right of the thermostat connection
block are four sets of jumper pins labeled ADJ, DELAY, HEAT
and COOL. The ADJ set of pins are labeled NORM, (+), (-)
6720220330 Revised 05-12
•Freeze Sensor—the freeze sensor input is active all the
time, if a freeze option is not selected the freeze
terminals will need a jumper. There are 2 configurable
freeze points, 30°F and 15°F. The unit will enter a soft
lock out until the temperature climbs above the set
point and the anti-short cycle time delay has expired.
The freeze sensor will shut the compressor output down
after 90 seconds of water flow loss and report a freeze
condition. It is recommended to have a flow switch to
prevent the unit from running if water flow is lost.
NOTE: If freeze protection sensor is not installed, a jumper
between freeze contacts must be installed on the UPM
board otherwise unit will not start.
6
ES SERIES
•Optional Condensate overflow protection sensor
located in the drain pan of the unit and connected to
the ‘cond’ terminal on the UPM board.
The UPM includes the following features:
ANTI-SHORT CYCLE TIMER – 5 minute delay on break
•
timer to prevent compressor short cycling.
•R ANDOM STAR T – Each controller has a unique
random start delay ranging from 270 to 300 seconds.
•LOW PR ESSURE BYPASS TIMER - The low pressure
switch is bypassed for 120 seconds after compressor
start-up to prevent nuisance low pressure lockouts
during cold start-up in the heating mode.
•
BROWNOUT/SURGE/POWER INTERRUPTION PROTECTION
– a 20 millisecond window is monitored for the above
condition. Should any of these conditions be detected,
the 5-minute delay on break timer and the random
start timer delay are initiated.
•MALFUNCTION OUTPUT – The controller has a set of
wet contacts for remote fault indication.
•TEST SERVIC E PIN – A jumper pin is provided to reduce
all time delay settings to 5 seconds during
troubleshooting or verification of unit operation. Note
that operation of the unit in test mode can lead to
accelerated wear and premature failure of the unit.
•L.E.D. FAULT INDICATION – Two L.E.D. indicators are
provided:
The fault pulse code may be sent to the ALR fault terminal
by placing the Alarm Output pin in the pulse position. The
pulse signal may be sent to a thermostat with a fault
indication LED (24v) and will display the fault code on the
thermostat.
mounted close to condensing water coil, monitors
refrigerant temperature between condensing water coil
and thermal expansion valve. If temperature drops
below or remains at freeze limit trip for 30 seconds, the
controller will shut down the compressor and enter into
a soft lockout condition. The default freeze limit trip is
30°F, however this can be changed to 15°F by cutting
the R42 resistor located on top of DIP switch SW1.
•
INTELLIGE NT RESET - If a fault condition is initiated
the 5 minute delay on break time period and the
random start timer are initiated and the unit will restart
after these delays expire. During this period the fault
LED will indicate the cause of the fault. If the fault
condition still exists or reoccurs before 60 minutes, the
unit will go into a hard lockout and requires a manual
lockout reset. A condensate overflow fault will cause
the unit to go into a hard lockout immediately.
•
LOCKOUT RESET - A hard lockout can be reset by
turning the unit thermostat off and then back on or by
shutting off unit power at the circuit breaker.
NOTE: The blower motor will remain active during a
lockout condition.
•GREEN: Power L.E.D. indicates 18 – 30 VAC present at
the board.
•RED: Fault indicator with blink codes as follows:
•
ONE BLINKHigh pressure lockout
•
TWO BLINKSLow pressure lockout
•
THREE BLINKSFreeze sensor lockout
•
FOUR BLINKSCondensate overflow
•
FIVE BLINKSBrownout Conditions
6720220330 Revised 05-12
UPM Sequence of Operation (SOO) Flow Chart
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
Y1=1
V > 1 8 V AC
HPC = 1
LPC = 1
FRZ
>
TEMP
LIM
CON
>
0
INITIAL
POWER UP
T
>
ASC OR
RS SEC
TIME
>
30
SEC
TIME
>
120
SEC
COUN T = 2
Start Timer
Start Timer
CC Output = On
CC Output = Off
Blink Code On Status LED
Report Alarm Fault
Hard Lockout
ALR Output = On/Pulse
Blink Code On Status LED
Soft Lockout
Record Alarm
Start Counter (If Applicable)
Start
Anti Short Cycle
Start
Random Start Up
Lockout Can Be Set To
4 Via Dip Switch
Power/Switchs/Sensor
Status Check
7
6720220330 Revised 05-12
8
ELECTRIC HEATER PACKAGE OPTION:
CAUTION: The HP series heater package requires its own
electrical service separate from the heat pump’s power
supply. DO NOT attempt to wire the package into the
same circuit as the heat pump.
Factory or field installed internal electric ES heater
packages are available for all series units. Two power
supplies are required when heater packages are utilized.
The power supply for the heater package (located in the
electric heater package control box) provides power for
the heater elements, the blower motor and the control
circuit for the unit. The power supply for the unit provides
power for the compressor. This allows the electric heaters
to continue to operate along with the blower motor in the
case of unit compressor and/or compressor power supply
failure. See HP Series Heater Kit Instructions for field
installations.
Each ES Series model has a number of heater sizes
available. Refer to Figure #9 for heater package
compatibility with specific ES Series units, models
nomenclature and electrical data.
SEQUENCE OF OPERATION-SINGLE STAGE UNITS:
(Figure #13 Wire Schematic)
COOLING MODE:
Energizing the “O” terminal energizes the unit reversing
valve in the cooling mode. The fan motor starts when the
“G” terminal is energized. Note that the fan motor will take
30 seconds to ramp up to operating speed and will run at
fan only air flow as long as there is no call for compressor
or heater operation.
hen “Y1” in the unit (“Y” on the thermostat) is energized
W
the compressor starts and the unit is now cooling.
Solenoid valves or loop pumps are brought on in
conjunction with the compressor.
When the thermostat is satisfied, the compressor shuts
own and the fan ramps down. If the “G” terminal is still
d
energized (fan operation is on “continuous” at the
thermostat) the fan will ramp down to fan only air flow in
30 seconds. If the “G” terminal is de-energized with “Y1”
then the fan ramps down to off in 30 seconds.
HEATING MODE:
Heating operation follows the same sequence as cooling
only without the “O” terminal. During heating operation if
the thermostat calls for auxiliary heat (“W1”), the fan
ramps up to auxiliary heat air flow immediately and the
electric heaters are energized (if installed) along with the
compressor. Note that if the unit compressor locks out for
any reason at this time, the electric heaters will continue
to function normally.
Emergency heat (W2/EM) energizes the emergency heat
relay in the heater control box, bringing on all of the
heating elements at once. The fan immediately ramps up
to full electric heat air flow.
As in cooling, once the thermostat is satisfied, the fan
will ramp back down over a period of 30 seconds.
All heaters rated single phase 60 Hz, an d include unit fan load. All fuses type “D” time delay or HACR type breaker or HRC FORM 1
Wire size based on 60 deg. C copper conductors.
6720220330 Revised 05-12
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