Bosch LV007 Installation Manual

LV Series Heat Pump

LV007 Thru LV070

Installation and Maintenance Manual

8 733 905 683 (2014/11)

2 | LV Heat PumpSeries

CONTENTS

Model Nomenclature.......................................................... 3

General Description........................................................... 4

Moving and Storage ........................................................... 5

Initial Inspection ............................................................... 5

Location............................................................................ 5

Water Quality .................................................................... 6

Water Quality Table.......................................................7

Installation........................................................................ 7

Duct Flanges ............................................................... 7

Mounting Vertical Units................................................. 8

Mounting Horizontal Units ............................................. 8

Hanging Bracket Kit.......................................................9

Converting Horizontal Supply Air Configuration .............. 10

Condensate Connections ............................................ 10

Duct System ............................................................. 10

Piping ...................................................................... 11

Electrical - High Voltage .............................................. 11

Electrical - Low Voltage............................................... 12

Units Controls - UPM........................................................ 13

ECM Interface Board .................................................. 13

Sequence of Operation ............................................... 15

General .................................................................... 16

Cooling and Heating Modes ......................................... 16

UPM Safety Features .................................................. 16

Unit Check Out Sheet..................................................35

Customer Data...........................................................35

Unit Nameplate Data................................................... 35

Operating Conditions..................................................35

Auxiliary Heat ............................................................35

Troubleshooting ..............................................................36

Temperature/Pressure Table ............................................41

Waterside Pressure Drop Table.........................................47

Compressor Characteristics .............................................48

Corner Weights (HZ) ........................................................ 49

Water Coil Volume ........................................................... 49

Wiring Diagrams ..............................................................50

Dimensional Drawings......................................................57

Vertical..................................................................... 57

Horizontal.................................................................58

Notes .............................................................................. 59

Options........................................................................... 19

Extended Range Option .............................................. 19

Unit Mounted Non-Fused Disconnect Switch.................. 19

Hot Gas Reheat ......................................................... 20

Hot Gas Bypass ......................................................... 20

Internal 2-Way Water Valve ......................................... 20

Economizer .............................................................. 21

LED Annunciator........................................................ 21

Flow Proving Switch................................................... 21

DDC Controls ............................................................ 21

Application Considerations .............................................. 22

Boiler/Cooling Tower Systems ..................................... 22

Geothermal Closed Loop Systems ................................ 23

Open Well Water Systems ........................................... 24

Certified Performance Table ............................................ 25

Fan Motor Options ...........................................................26

Permanent Split Capacitor Motors (PSC) ...................... 26

Constant Torque Motors (ECM).................................... 27

Constant Airflow Motors (ECM).................................... 29

Standard Blower Motor.................................................... 31

Constant ECM Motor...................................................32

Constant CFM ECM Blower Motor................................. 33

Unit Start Up ................................................................... 33

Maintenance ................................................................... 34

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

MODEL NOMENCLATURE

LV 018 - 1

C- FL T PUA-XA SAMXXXX 5A X X

1XXXXSBA

LV AIR FILTRATION

1 - STANDARD THROWA WAY FILTER w/ 2-SIDED FILTER RACK 1"

Size 4 - MERV8 - 2" w/ 4-SIDED FILTER RACK

007 5 - MERV13 - 2" w/ 4-SIDED FILTER RACK

012 Refrigeration Circuit Options

X - None

C - Hot Gas Bypass with Hot Gas Reheat

036 S - Straight Cool

042 General Electrical Options (up to 5 available per unit)

A - EMS relay

060 B - Blower Monitor Relay

C - Compressor Monitor Relay

Voltage E - Pump/valve relay

0 115/60/1 F - Freeze Sensor Antifreeze Setting

1 208-230/60/1 G - Boilerless control

2 277/60/1

3 208-230/60/3 J - Disconnect Switch

4 460/60/3 K - Fire Alarm Relay/Dual Power

5 575/60/3 M - Wi re to 208 V

T - Fault LED

Cabinet Conguration X - As default for non used electrical codes

Z - EMS Relay + Pump/Valve Relay

VT - Vertical

CF - Downow (Counterow) Application

T - TXV Option

S - STANDARD RANGE (B oiler/Tower)

Coax Options Cabinet Construction

C - Copper A - G90 Steel / 1/2" Standard 1.5LB Dual Density Fiberglass

C - G90 Steel / 1/2" Closed Cell Foam

D - G90 Steel / 1/2" Standard 1.5LB Dual Density Fiberglass, Extra Quiet

F - G90 Steel / 1/2" Closed Cell Foam, Extra Quiet

Water Connections

F - Front Electric Heat

M - Marine

Revision Level

Return Air Conguration A - Current

R - Right Air Coil

D - DuoGuard

Discharge Air Conguration Fan/Motor Options

T - Top P - Standard PSC

S - Straight A - Constant Airow ECM

E - End T - Constant Torque ECM

Model Nomenclature | 3LV Heat Pump Series

ass

switch

rovin

D - Phase Monitor

H - Flow

G - EXTENDED RANGE W/ SCHRADER VALVE (Geothermal)

U - Uncoated

009

030

015

018 H - Hot Gas Reheat - On/O

024 B - Hot Gas B

041

048

HZ - Horizontal

ro-Nickel

N - Cu

B - Bottom X - None

L - Left

B - Bottom

Figure # 1

8 733 905 683 (2014/11)LV Heat Pump Series

4 | General Description LV Heat PumpSeries

SAFETY CONSIDERATIONS GENERAL DESCRIPTION

WARNING: 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.

DANGER: Before performing service or maintenance operations on the system, turn off main power to the unit. Electrical shock could cause personal injury or death.

WARNING: 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.

NOTE: 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.

NOTE: 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.

NOTE: To avoid equipment damage, DO NOT use these units as a source of heating or cooling during the construction process. Doing so may affect the unit’s warranty. The mechanical components and filters will quickly become clogged with construction dirt and debris, which may cause system damage.

The LV series water-to-air heat pump provides an unmatched combination of performance, features and flexibility for both high performance new construction applications and replacement of existing water-to-air heat pumps. All units are certified by the Air conditioning, Heating and Refrigeration Institute (AHRI) to AHRI/ANSI/ ASHRAE/ISO standard 13256-1 for water-to-air and brine-to-air heat pumps at both Water Loop Heat Pump and Ground Loop Heat Pump application points.

All Water-to-Air Heat Pumps conform to UL 1995 standard and are certified to CAN/CSA C22.2 No 236 by Intertek-ETL.

These units meet all current applicable requirements of ASHRAE 90.1.

LV series units are designed to operate with entering fluid temperatures between 50°F and 100°F in cooling and 50°F and 80°F in heating with the base configuration. With the extended range option, LV series models can operate with entering fluid temperatures between 50°F and 110°F in cooling and between 20°F and 80°F in heating. LV units can accommodate a wide range of air temperatures, however, standard LV models should not be used for 100% outside air without consulting the factory applications group. 100% outside air routinely requires higher levels of dehumidification than is available from equipment designed for return air applications.

LV series units are available in three basic configurations: vertical top supply air (VT), horizontal end supply air or straight through supply air (HZ) and counterflow down supply air (CF). Each of these configurations are available with either left or right hand return air. HZ models can have the supply air field converted from end discharge air to straight through with no extra parts required.

LV units are designed and rated for indoor installation only. LV units should not be installed in environments that fall below freezing or exceed 100°F ambient. LV cabinets are constructed of heavy gauge G-90 galvanized steel and will resist most common types of corrosion for the life of the equipment.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Moving and Storage | 5LV Heat Pump Series

LV series units are offered with a wide range of factory installed options including: PSC, constant torque ECM or constant air flow ECM fan motors; hot gas reheat; hot gas bypass; internal 2 way valves; tin plated air coils; 2“ 4-sided filter racks; MERV 13 filters (with constant airflow ECM motors); on board DDC controls; copper or cupro nickel water coils; water-side economizers and more.

Note that some options are offered in limited sizes and/or voltages.

On board safety features will protect the major unit components from damage under most foreseeable installation and operation problems.

MOVING AND STORAGE

If the equipment is not needed for immediate installation upon arrival at the job site, it should be left in its packaging and stored in a clean, dry area.

Units must be moved and stored in the normal upright position at all times.

Use caution to avoid damage to filter racks and duct flanges when storing or handling units.

NOTE: Never lift or move units by filter racks, external piping or attached options/ accessories.

INITIAL INSPECTION

Be certain to inspect all cartons or crates on each unit as received at the job site before signing the freight bill. Verify that all items have been received and that there is no visible damage. Note any damage or shortage on all copies of the freight bill. In the event of damage or a shortage it is the responsibility of the purchaser to file the necessary claims with the carrier. Concealed damage not discovered until after removing the units from packaging must be reported to the carrier within 24 hours of receipt.

LOCATION

Locate the unit in an indoor area that allows easy access to the filter, front access panel and blower access panel, and has enough room for service personnel to perform maintenance and repair work. Provide sufficient room to make fluid, electrical and ductwork connections.

Locate the unit in conditioned space and avoid installation in corrosive environments.

If the unit is installed in a confined space, such as a closet, provisions must be made for return air to freely enter the face of the unit’s air coil.

Unit condensate drains are not internally trapped. Allow room below the unit base for horizontal and

counterflow models for an adequate condensate trap.

NOTE: Never stack units when transporting them.

NOTE: When storing units: Do not stack units larger than 6 tons

capacity! Do not stack vertical or counterflow units

under 6 tons capacity more than 2 high Do not stack horizontal units 6 tons capacity

more than 3 high

NOTE: Do not locate the unit above supply piping. Do not locate the unit in areas subject to freezing or in areas subject to temperature or humidity extremes.

NOTE: LV series packaged units are not approved for outdoor installation. Units must be installed in conditioned space that is not subject to extremes of temperature or humidity to avoid cabinet sweating and/or equipment damage.

NOTE: Do not use LV series units for temporary heating, air conditioning or ventilation during construction, especially when plastering, sanding or painting. Care should be taken to avoid introduction of dust, paint or debris into the air coil.

8 733 905 683 (2014/11)LV Heat Pump Series

6 | Water Quality LV Heat PumpSeries

WATER QUALITY

NOTE: Failure to insure proper water quality

and flow rates can shorten the life of the heat pump and potentially void the unit warranty.

Maintaining proper water quality is important for insuring a long and trouble free service life for an LV series heat pump.

For closed loop and boiler/tower systems water chemistry can be checked and easily maintained to insure that corrosive elements, dissolved oxygen and pH levels are kept in check. It is important to insure that any additive, antifreeze or corrosion inhibitor that is added to the water loop is compliant with all applicable laws and regulations and is compatible with copper, brass and bronze alloys. Insure that all recommended safety precautions are followed when handling or adding chemicals to the water loop.

For open loop systems, water quality is very important. Refer to Quality Table on page# 6 shows acceptable ranges for a variety of water quality factors. The three main concerns in open loop installations are scaling, corrosion and fouling.

In installations with hard water, scaling due to a buildup of carbonates on the heat exchanger wall can gradually degrade the heat pump performance over time. Heat pumps that are affected by scaling may exhibit low suction pressures in heating and high head pressures in cooling with a gradual loss of capacity and efficiency. Scaled heat exchangers can be cleaned by a qualified technician but care should be taken to avoid scaling in the first place.

To limit scaling, water flow rates should be kept at 3 gallons/minute per nominal cooling ton (a 10°F temperature rise in cooling) and care should be taken to avoid air in the water lines from suction side leaks. Cupro-nickel coils are generally recommended.

In installations with high hydrogen sulfide, chlorine or ammonia, corrosion is a potential problem. In these installations a cupro-nickel heat exchanger is recommended along with maintaining proper flow and keeping air out of the system. If water quality is outside of the values in water quality table, then a closed loop is recommended.

Fouling due to iron bacteria can also pose problems in some open loop installations. Iron bacteria fouling can quickly degrade system performance and plug heat exchangers.

Air in the water system will greatly accellerate the fouling or corrosion process.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

WATER QUALITY TABLE

water quality table | 7LV Heat Pump Series

POTENTIAL PROBLEM

SCALING

Table 1: Water Quality

CORROSION

Water Characteristic Acceptable Value

Copper Cupro-Nickel

pH (Acidity/Alkalinity) 7-9 7-9 Hardness (CaCO3,

MgCO3) Ryznar Stability Index 6.0 - 7.5 6.0 - 7.5 Langelier Saturation Index -0.5 - +0.5 -0.5 - +0.5

Hydrogen Sulfide (H2S) < 0.5 ppm * 10-50 ppm Sulfates Chlorine Chlorides Carbon Dioxide Ammonia Ammonia Chloride Ammonia Nitrate

< 350 ppm < 350 ppm

< 125 ppm < 125 ppm < 0.5 ppm < 0.5 ppm < 20 ppm < 150 ppm < 50 ppm < 50 ppm < 2 ppm < 2 ppm < 0.5 ppm < 0.5 ppm

< 0.5 ppm < 0.5 ppm Ammonia Hydroxide Ammonia Sulfate Dissolved Solids Iron (Fe2+ Iron Bacteria

IRON FOULING

EROSION

* No "rotten egg" smell present at < 0.5 ppm H2S. ** Equivalent to 30 mesh strainer

Potential) Iron Oxide Suspended Solids < 10 ppm, < 600 μm size ** < 10 ppm, < 600 μm size ** Maximum Water Velocity

INSTALLATION

The following are instructions to follow for installation of all LV Series components.

Duct Flanges

LV heat pumps feature fold-out return and supply air duct flanges. These fold-out flanges allow the heat pumps to more easily fit through doorways and other tight spaces, and also prevent damage in shipping and handling.

< 0.5 ppm < 0.5 ppm

< 1,000 ppm < 1,500 ppm

< 0.2 ppm < 0.2 ppm

< 1 ppm < 1 ppm

6 ft/sec 6 ft/sec

It is recommended that all fold-out flanges be folded-out once the heat pump is installed to insure that return and supply air flow is not obstructed. These flanges can be easily folded using standard or duckbill pliers. Once folded out these flanges can be used to support light ductwork loads.

8 733 905 683 (2014/11)LV Heat Pump Series

8 | Installation LV Heat PumpSeries

Vibration Mounting Pad

Mounting Vertical Units

LV Series vertical and counter flow units should be mounted level on a vibration absorbing pad slightly larger than the unit base in order to minimize vibration transmission from the unit to the building structure. See Figure #2 It is generally not necessary to anchor the unit unless required by local code.

All major service access for the LV Series vertical and counterflow models is from the front side of the unit. When installing the unit in a confined space such as a closet, insure that the service panel screws are accessible, that the filter can be replaced without damage and that water and electrical connections are accessible. For models with a unit mounted disconnect switch, make sure the switch can be easily seen and operated.

To reduce sound transmission, units should be installed using flexible electrical conduit and hose kits. Care should be taken to insure that no part of the unit cabinet is touching part of the building structure. For ducted return applications, a flexible duct connection should be used. Refer to Figure’s #15, #16 and #17.

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 mesh.

The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a 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 eaves at a location that will be noticeable.

NOTE: Horizontal (HZ) units must be installed pitched toward the condensate drain connection 1/8” per foot.

Units larger than six tons include an integral angle iron frame with mounting holes present. (See unit horizontal detail drawing).

Figure # 2 Mounting Vertical Units

Mounting 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 930-008).

NOTE: 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.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

HANGING BRACKET KIT

Hanging Brackets Locations

Installation instructions

All horizontal units come with Hanging Bracket Kit to facilitate suspended unit mounting using

threaded rod. Hanging Brackets are to be installed as shown in Figure#3

Hanging Bracket Kit | 9LV Heat Pump Series

WARNING: Do not re-use screws removed

from the unit on step 1 to mount the hanging Brackets to the unit.

Figure # 5

Figure # 3

This kit includes the following: (5) Brackets. (5) Rubber Vibration Isolators (8) Screws # 10x1/2” (10) Bolts 1/4-28x1/2” hex Bolt (not used on this model) The following are needed and are to be field

provided: Threaded rod (3/8” max dia) Hex Nuts Washers (1-3/4” min O.D.)

1. Remove and discard factory provided screws from location where Hanging Brackets will be installed shown in Figure#4

WARNING: Follow all applicable codes requirements when hanging this unit.

Selecting threaded rod material, etc.

3. Install Rubber Grommet on the bracket as shown in Figure# 6.

4. Hang the unit and assemble the field provided Thread Rod, Nuts and Washers on to the Brackets as shown in Figure# 6.

DANGER: Rods must be securely anchored to the ceiling.

Figure # 4

2. Mount 4Brackets to unit corner post using the bolts provided in the kit as shown on Figure # 5

Figure # 6

CONVERTING HORIZONTAL SUPPLY AIR CONFIGURATION

The supply air location on LV Series Horizontal units can be quickly field converted from end blow to straight through or vice-versa. To convert the supply air direction, follow the steps below:

8 733 905 683 (2014/11)LV Heat Pump Series

10 | Converting Horizontal Supply Air Configuration LV Heat PumpSeries

1. If connected to power, shut off the unit and disconnect switch or circuit breaker.

2. Unscrew and remove the blower access panel.

3. Disconnect the wires from the unit electrical box to the blower motor. Note which speed taps are wired for units with PSC or constant torque motors.

4. Unscrew and carefully remove the blower panel with the blower and motor attached. Be careful not to damage the refrigerant coils or any other internal unit components.

5. Remove the blower support brackets from the bottom of the blower housing and relocate them to the top of the blower housing.

6. Turn the blower panel 180° so that the blower support brackets are now at the bottom of the blower.

7. Insert the blower panel with the blower and motor into the desired location. Be careful not to damage the refrigerant coils or any other internal unit components. Screw the panel into place.

8. Replace the wires between the blower motor and electrical box. Make sure to connect wires to the proper speed taps.

9. Replace the blower access panel.

10. Reconnect power to the unit.

Condensate Connections

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. 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 #7).

The depth 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 #8)

Figure # 8 Pitched Unit

Duct System

All LV Series models are provided with a return air duct flange and supply air duct connections.

Refer to unit Dimensional Drawings for physical dimensions of the collar and flange. (Pg#50)

A flexible connector is recommended for supply and return air duct connections on metal duct systems. All metal ducting should be insulated with a minimum of 1” (one inch) duct insulation to avoid heat loss or gain and prevent condensate from forming during the cooling operation. Application of the unit to no insulated 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 filter rack should be left in place on a free return system.

if the unit will be installed in a new installation with new duct work, the installation should be designed using current ASHRAE procedures for duct sizing. If the unit will be connected to an existing duct system, 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 duct work must be installed. Be certain to check for existing leaks and repair.

Figure # 7 Condensate Drain

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Piping | 11LV Heat Pump Series

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 through the air grill into the heat pump. The return air inlet to the heat pump must have at least one 90° turn away from the space return air grill. If air noise or excessive air flow are a problem, the blower speed can be changed to a lower speed to reduce air flow.

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 water connections on the unit. LV 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. Refer to Table #1.

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. (Refer to Table #1)

In conditions anticipating moderate scale formation or in brackish water a cupro-nickel heat exchanger is recommended. 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. 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 possible heat exchanger fouling. Do not overtighten the connections. Flexible hoses should be used between the 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.

Pressure/temperature ports are recommended in both the supply and return lines for system flow balancing. The water flow can be accurately set by measuring the water-to- refrigerant heat exchangers water side pressure drop. See the unit specification sheets for the water flow and pressure drop information.

NOTE: Water piping exposed to extreme, low ambient temperatures is subject to freezing

NOTE: Never exceed the recommended water flow rates. Serious damage or erosion of the water to refrigerant heat exchanger could occur.

Electrical - High Voltage

All field installed wiring must comply with the National Electric Code as well as all applicable local codes. Refer to the unit electrical data on the unit name plate for wire and branch circuit protection sizing. Supply power voltage and phasing should match the required voltage and phasing shown on the unit name plate. Operating the unit below the minimum voltage, above the maximum voltage or with incorrect phasing can result in poor system performance or damage to the heat pump. All field wiring should be installed by qualified and trained personnel. Refer to the unit wiring diagram for field connection requirements.

NOTE: All power connections must be properly torque to avoid the risk of overheating.

Power wiring to the heat pump should be enclosed in flexible conduit to minimize the transmission of vibration from the unit cabinet to the building.

For heat pumps with unit mounted disconnect switches, field power should be connected to the marked terminals on the disconnect switch. For heat pumps without unit mounted disconnect switches (except for 460 volt units noted below and units with dual power supply), power is connected to the line (L) side of the compressor contactor and the ground lug in the unit electrical box.

8 733 905 683 (2014/11)LV Heat Pump Series

12 | Electrical - Low Voltage LV Heat PumpSeries

Models with Dual Power Supplies

For models with dual power supplies, one power supply feeds the compressor and a second power supply feeds the unit fan motor and control circuit. The compressor power supply should be connected to the line (L) side of the compressor contactor. The fan motor and control circuit power supply should be connected to a provided terminal block. Care should be taken to insure that each power supply meets the voltage, amperage and phase requirements of its load. Refer to the unit nameplates for requirements.

460 V Models with Constant Air Flow Motors (LV015-LV070)

460 volt LV heat pumps with the constant airflow motor option require a properly sized neutral wire with the power supply wiring in addition to the three high voltage wires and the ground wire. These units employ a 265 V motor that requires power from one phase of the 460 V supply and the neutral wire.

WARNING: The power supply ground wire should never be used as a neutral wire.

ELECTRICAL - LOW VOLTAGE

For heat pumps with PSC or constant torque fan motors, all thermostat wiring is connected to a terminal block located in the unit electrical box. For heat pumps with a constant air flow fan motor, thermostat wiring is connected to a removable terminal strip located on the ECM motor control board located in the electrical box. Refer to the unit wiring diagram for connection details.

NOTE: Never route control wiring through the same conduit as power supply wiring.

Unless provided with DDC controls, the LV heat pump can be controlled by most commonly available single stage heat pump thermostats. Note that the reversing valve on the LV series is energized when the unit is in the cooling mode. Thermostats should be located on an interior wall away from supply ducts. Avoid locations subject to direct sunlight or drafts, or external walls. Thermostat wiring should be 18 AWG. Refer to the installation instructions for the thermostat for further details.

For 460 V models with constant air flow motors and a unit mounted disconnect switch, the power wires and neutral wire should be connected to the appropriate terminals on the disconnect switch and its enclosure. For units without a disconnect switch, power and neutral wires should be connected to a provided 4 pole terminal block in the unit electrical box

Transformer Settings for 208/230 V Units

As factory built, all 208/230 V units are wired for 230 V operation unless the wire for 208 V option is ordered. For jobsites with a 208 V power supply, the primary leads on the unit transformer will need to be changed from 240 V to 208 V. Refer to the unit wiring diagram for details.

Exceptionally long runs of thermostat wire should be avoided to prevent voltage drops in the control circuit.

LV heat pumps are supplied with a 50 VA control transformer as standard. Models with DDC, hot gas reheat or an economizer are supplied with a 75 VA transformer. 75 VA and 100 VA transformers are available as optional components for most models (size 018 and larger for 100 VA). The VA capacity of the transformer should be considered when connecting low voltage accessories to the heat pump such as thermostats or solenoid valves.

Table #2 shows the VA draw of factory mounted components in the LV heat pump. The total VA draw of the heat pump internal components plus any attached accessories must be lower than the VA capacity of the unit control transformer.

NOTE: Exceeding the transformer capacity can result in low control voltage, erratic unit operation or damage to the heat pump.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Table 2: Low Voltage VA Draw

Units Controls - UPM | 13LV Heat Pump Series

Standard Construction Hot Gas Reheat or

Economizer

Component Blower Relay (PSC

motors only) Reversing Valve

Solenoid

Compressor Contactor

UPM board

Total VA draw

6-7

8-9

6-8

22-26

Component

Total from ‘Standard’

Additional Control Relays

Hot Gas Reheat Solenoid

Total VA draw

UNITS CONTROLS - UPM ECM Interface Board

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 Electronic Commutated Motor (ECM) DC fan motor and displays an LED indication of operating status. The thermostat connections and their functions are as follows:

Optional Components

22-26

12-14

8-9

42-49

[9] Thermostat outputs [10] 24 VAC

Component Monitor Relay (VA draw

per relay) Internal 2 Way

Motorized Valve

LED Annunciator

6-7

Figure # 9

[1] Motor harness plug [2] Blower CFM adjustment

Figure # 10

[3] Motor settings [4] Dehumidification indication [5] Thermostat digital inputs [6] CFM count indicator [7] Thermostat input status indication [8] Reheat digital outputs

8 733 905 683 (2014/11)LV Heat Pump Series

14 | Units Controls - UPM LV Heat PumpSeries

THERMOSTAT OPTIONS Y1 First Stage Compressor Operation GFan O Reversing Valve (energized in cooling) W1 Auxiliary Electric Heat (runs in

conjunction with compressor)

NC Transformer 24 VAC Common (extra

connection)

C1 Transformer 24 VAC Common

(primary connection) R Transformer 24 VAC Hot H Dehumidification Mode

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 represent approximately 100 CFM of air delivery so if the LED blinks 12 times, pauses, blinks 12 times, etc. the blower is delivering approximately 1200 CFM.

CFM LED indication is an approximation. Utilize conventional Test and Balance equipment for accurate airflow measurement.

When the HGRH DIP switch (Figure# 10) is set to “YES” the heat pump is configured for hot gas reheat. With hot gas reheat, when there is a call for dehumidification (the “H” terminal on the thermostat is energized) the reheat digital outputs (Item 8 on Figure 6) will energize the hot gas reheat valve in the hot gas reheat circuit and the heat pump will start in dehumidification mode.

When the HGRH DIP switch is set to “NO” the heat pump is set for passive dehumidification. When “H” is energized and there is a call for cooling, the heat pump fan will operate at a lower speed to increase dehumidification while cooling. Note that in this mode, the heat pump will only dehumidify the space when it is running in cooling mode..

NOTE: Do not set the ADJ DIP switch 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 DIP switch bank is used to select the proper program in the ECM motor for the unit.

CAUTION: Always disconnect power before changing jumper positions on the interface board and reset the unit afterward.

To the right of the thermostat connection block is a green LED labeled dehumidify. Just above and to the right of the thermostat connection block are two banks of DIP switches labeled ADJ and CFM. The ADJ bank DIP switches are labeled NORM, (+), (-), Test and HGHR position from the factory, however, airflow can be increased (+) or decreased (-) by 15% from the pre-programmed setting by relocating the DIP switch in this section. The TEST position is used to verify proper motor operation. If a motor problem is suspected, move the ADJ DIP switch to the TEST position and 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 DIP switch to NORM, (+) or (-) after testing and reset the unit thermostat to restore normal operation.

HGRH switch is used to select operating mode between units equipped with:

1. Re-heat coils

2. Cool to dehumidify

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.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Sequence of Operation

LEGEND: HPC - HIGH PRESSURE CUTOUT LPC - LOW PRESSURE CUTOUT FRZ - FREEZE PROTECTION CONDITION CON - CONDENSATE OVERFLOW CONDITION CC - COMPRESSOR COIL ASC - ANTI SHORT CYCLE

LOCKOUT CAN BE SET

TO 4 VIA DIP SWITCH

BLINK CODE ON STATUS LED

SOFT LOCKOUT

RECORD ALARM

START COUNTER (IF APPLICABLE)

CC OUTPUT = ON

YES

LPC

=CLOSED

FRZ >TEMP

LIMIT

Y1 = ON

TIME > 30

SEC

CON > 0

POWER/ SWITCHES/SENSOR

STATUS CHECK

START TIMER

YES

T > ASC OR

RS SEC

YES

TIME > 120

SEC

START TIMER

YES

START

ANTI SHORT CYCLE

INITIAL

POWER UP

YES

START

RANDOM START UP

START

COUNTER NEEDED?

YES

COUNT = 2

COUNT = 4

BLINK CODE ON STATUS LED

DISPLAY OUTPUT = PULSE

ALR OUTPUT = ON/PULSE

YES

HARD

LOCKOUT?

CC OUTPUT = OFF

V > 18VAC

YES

BLINK CODE

ON STATUS LED

RESET ON

CLEAR FAULTS

R = 24VAC

YES

HPC =

CLOSED

RESET ON R

Units Controls - UPM | 15LV Heat Pump Series

8 733 905 683 (2014/11)LV Heat Pump Series

16 | Units Controls - UPM LV Heat PumpSeries

2 3 4

1213

General

LV series heat pumps are designed to be controlled by a standard 1 heat / 1 cool heat pump thermostat. The heat pump control circuit operates on 24 VAC control voltage regardless of the unit supply voltage. If direct digital control is required then the heat pump needs to be supplied with a DDC control option.

Fan operation is controlled by the “G” terminal on the heat pump thermostat terminal block. When “G” is energized the unit fan motor will start operating. For heat pumps with PSC motors, the fan will immediately ramp up to 100% air flow. For heat pumps with constant torque ECM motors, the fan will ramp up to 100% air flow over a 30 second period. For heat pumps with constant air flow ECM motors the fan will ramp up to 70% air flow over a 30 second period if there is no call for compressor operation (“Y”). If there is a call for compressor operation along with a call for fan operation, then the fan will ramp to 100% air flow.

Compressor operation is controlled by the “Y” terminal on the heat pump thermostat terminal block. When “Y” is energized, a signal to start the compressor is sent to the Unit Protection Module (UPM). The UPM checks a number of safety features before then starting the compressor. If any of the safety features connected to the UPM is in a fault condition, the UPM will not start the compressor and will flash a fault code on the red status LED indicating the nature of the fault.

Additionally the UPM will delay compressor operation randomly on initial start up (random start delay) and will prevent the compressor from restarting with less than 5 minutes of off time (anti short cycle delay). Once all faults are cleared and the time delays are satisfied, the UPM will energize the compressor. The compressor will operate as long as the thermostat calls for “Y” and there are no faults. Refer to the troubleshooting chart for fault diagnostics.

Cooling and Heating Modes

LV series heat pumps operate in cooling with the reversing valve energized. When the “O” terminal is energized, the heat pump will be in the cooling mode, however, will not be actively cooling until the “Y” and “G” terminals are also energized. If the “Y” and “G” terminals are energized without the “O” terminal, then the heat pump will operate in the heating mode.

UPM Safety Features

Figure # 11

[1] Board Power Indicator [2] UPM Status LED Indicator [3] Water Coil Freeze Protection Temperature

Selection [4] Air Coil Freeze Protection Temperature

Selection [5] UPM Board Settings [6] Water Coil Freeze Connection [7] Air Coil Freeze Connection [8] LED Unit Display Connection [9] 24VAC Power Input [10] Compressor Contact Output [11] High Pressure Switch Connection [12] Call for Compressor Y1 [13] Low Pressure Switch Connection [14] 24VAC Power Common [15] Condensate Overflow Sensor [16]Dry Contact [17]UPM Ground Standoff

If the unit is being connected to a thermostat with a malfunction light, this connection is made at the unit malfunction output or relay.

If the thermostat is provided with a malfunction light powered off of the common (C) side of the transformer, a jumper between “R” and “COM” terminal of “ALR” contacts must be made.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Units Controls - UPM | 17LV Heat Pump Series

If the thermostat is provided with a 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.

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.

UPM Board Dry Contacts are Normally Open (NO)

• Water side freeze protection sensor, mounted close to condensing water coil, monitors refrigerant temperature between condensing water coil and expansion valve or capillary tube. 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 26°F, however this can be changed to 15°F by cutting the R30 or Freeze1 resistor located on top of DIP switch SW1.

• Evaporator freeze protection sensor, mounted after the thermal expansion device and the evaporator, monitors refrigerant temperature between the evaporator 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 26°F (Figures #12 and #13)

Figure # 13

• The condensate overflow protection sensor is located in the drain pan of the unit and connected to the ‘COND’ terminal on the UPM board. (Figure #14)

NOTE: If unit is employing a fresh water system (no anti-freeze protection), it is extremely important to have the Freeze1 R30 resistor set to 26° F in order to shut down the unit at the appropriate leaving water temperature and protect your heat pump from freezing if a freeze sensor is included.

Figure # 12

Figure # 14

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18 | Units Controls - UPM LV Heat PumpSeries

UPM Board Factory Default Settings

TEMP LOCKOUT RESET ALARM TEST

26°F

PULSE

UPM DIP SWITCH DEFAULT POSITION

lockout 42

reset alarm

test

Table 3: UPM Fault Blink Codes

LED Blinks Fault Fault Criteria

None None

1High Pressure

2 Low Pressure

Water Coil

Freeze

6Brown Out

Condition

Condensate

Overflow

Air Coil Freeze

Condition

Cont pulse

yes no

All fault conditions

nominal

Refrigerant discharge

pressure has

exceeded 600 PSIG

Refrigerant suction pressure has fallen

below 40 PSIG

Refrigerant

temperature to the

water coil has fallen

below 26°F for 30

seconds

Condensate levels in

the unit drain pan are

too high

Refrigerant

temperature to the air

coil has fallen below 26°F for 30 seconds

Control voltage has

fallen below 18 VAC

• RANDOM START: Each controller has an unique

random start delay ranging from 270 to 300 seconds on initial power up to reduce the chance of multiple unit simultaneously starting at the same time after power up or after a power interruption, thus avoiding creating large electrical spike.

• LOW PRESSURE BYPASS TIMER: If the

compressor is running and the low pressure switch opens, the controller will keep the compressor ON for 120 seconds. After 2 minutes if the low pressure switch remains open, the controllers will shut down the compressor and enter a soft lockout. The compressor will not be energized until the low pressure switch closes and the anti-short cycle time delay expires. If the low pressure switch opens 2-4 times in 1 hour, the unit will enter a hard lockout. In order to exit hard lockout power to the unit would need to be reset.

• BROWNOUT/SURGE/POWER INTERRUPTION PROTECTION:

protection in the UPM board will shut does the compressor if the incoming power falls below 18 VAC. The compressor will remain OFF until the voltage is above 18 VAC and ANTI-SHORT CYCLE TIMER (300 seconds) times out. The unit will not go into a hard lockout.

The brownout

• MALFUNCTION OUTPUT: Alarm output is

Normally Open (NO) dry contact.

If pulse is selected the alarm output will be pulsed. The fault output will depend on the dip switch setting for "ALARM". If it is set to "CONST", a constant signal will be produced to indicate a fault has occurred and the unit requires inspection to determine the type of fault. If it is set to "PULSE", a pulse signal is produced and a fault code is detected by a remote device indicating the fault. See L.E.D Fault Indication below for blink code explanation. The remote device must have a malfunction detection capability when the UPM board is set to "PULSE".

If 24 VAC output is needed R must be wired to ALR-COM terminal; 24 VAC will be available o the ALR-OUT terminal when the unit is in the alarm condition.

The UPM Board includes the following features:

• ANTI-SHORT CYCLE TIMER:

break timer to prevent compressor short cycling.

5 minute delay on

• DISPLAY OUTPUT:

The Display output is a pulse output connected to the Unit Diagnostic Display (UDD) and it pulses 24VAC when the unit is in an lockout alarm condition.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

Options | 19LV Heat Pump Series

• TEST DIP SWITCH: A test dip switch is provided

to reduce all time delays settings to 10 seconds during troubleshooting or verification of unit operation.

Operation of unit in test mode can lead to accelerated wear and premature failure of components. The “TEST” switch must be set back to “NO” after troubleshooting/ servicing.

• FREEZE SENSOR: The default setting for the

freeze limit trip is 26°F (sensor number 1); however this can be changed to 15°F by cutting the R30 resistor located on top of the DIP switch SW1.

The

default setting for the freeze limit trip is 26°F(sensor number 1); however this can be changed to 15°F by cutting the R24 resistor located on top of the DIP switch SW1. Since freeze sensor 2 is dedicated to monitor the evaporator coil it is recommended to leave the factory default setting on the board. The UPM controller will constantly monitor the refrigerant temperature with the sensor mounted close to the condensing water coil between the thermal expansion valve and water coil. If temperature drops below or remains at the freeze limit trip for 30 seconds, the controller will shut the compressor down and enter into a soft lockout condition. Both the status LED and the Alarm contact will be active. The LED will flash (three (3) times) the code associated with this alarm condition. If this alarm occurs 2 times (or 4 if Dip switch is set to 4) within an hour the UPM controller will enter into a hard lockout condition. It will constantly monitor the refrigerant temperature with the sensor mounted close to the evaporator between the thermal expansion valve and evaporator coil as shown in Figure #13. If temperature drops below or remains at the freeze limit trip for 30 seconds, the controller will shut the compressor down and enter into a soft lockout condition. Both the status LED and the Alarm contact will be active. The LED will flash (three (6) times) the code associated with this alarm condition. If this alarm occurs 2 times (or 4 if Dip switch is set to 4) within an hour the controller will enter into a hard lockout condition.

It is recommended to have a flow switch to prevent the unit from running if water flow is lost.

• INTELLIGENT RESET: If a fault condition is

initiated, the 5 minute delay on break time period is 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 occurs 2 or 4 times (depending on 2 or 4 setting for Lockout dip switch) before 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. A single condensate overflow fault will cause the unit to go into a hard lockout immediately, and will require a manual lockout reset.

• LOCKOUT RESET: A hard lockout can be reset

by turning the unit thermostat off and then back on when the “RESET” dip switch is set to “Y” or by shutting off unit power at the circuit breaker when the “RESET” dip switch is set to “R”.

The blower motor will remain active during a lockout condition. ECM Interface Board Thermostat Connections

OPTIONS Extended Range Option

LV heat pumps are supplied standard with capillary style expansion device tuned to typical boiler/tower system operating conditions. For applications that will experience more extreme fluid flow rates or temperatures (heating fluid temperatures below 50°F and/or cooling fluid temperatures below 60°F or above 100°F), an extended range option is required.

The extended range option on the LV consists of a bi-flow, balanced port thermal expansion valve and an insulated water-to-refrigerant heat exchanger. With the extended range option installed LV units can provide heating with fluid temperatures as low as 20°F and as high as 80°F and cooling with fluid temperatures as low as 50°F and as high as 110°F.

Unit Mounted Non-Fused Disconnect Switch

LV heat pumps can be supplied with an optional unit mounted disconnect switch mounted to the electrical corner post of the unit.

Field electrical wiring is connected to the switch and the switch then routes power to the heat pump electrical box. When the switch is in the “OFF” position, the heat pump electrical box is completely de-energized.

8 733 905 683 (2014/11)LV Heat Pump Series

20 | Options LV Heat PumpSeries

Hot Gas Reheat

(Available on size 015 and larger) LV series heat pumps size 015 and larger can be

provided with hot gas reheat for active dehumidification. In operation hot gas reheat dehumidifies space by cooling the air and removing moisture and then reheating the air back to a neutral temperature using waste heat from the compressor. The net effect is to decrease the relative humidity of the space without changing the sensible temperature.

The major components of the hot gas reheat option are the hot gas reheat coil, the reheat solenoid valve and the control circuit. When the control circuit energizes the heat pump in reheat mode, the heat pump will operate in the cooling mode. The hot gas solenoid valve diverts the compressor discharge gas to the reheat coil which is mounted downstream of the unit evaporator.This hot gas re-heats the cooled air coming off of the evaporator.

To function, heat pumps with hot gas reheat must be controlled by both a thermostat and a humidistat (or a combination thermostat/ humidistat). The humidistat must provide a dry contact closure on a rise in humidity above set point.

Note that the ability of the reheat coil to reheat cooled air back to a neutral temperature is affected by the water temperature of the system.

At water temperatures of 85° F, the reheat coil can recover 95% to 100% of the sensible capacity of the evaporator. At water temperatures below 60°F, the reheat coil can only recover 5% to 25% of the sensible capacity of the evaporator.

Refer to the unit wiring diagram for control circuit details.

Hot Gas Bypass

(Available on size 024 and larger) The hot gas bypass option can be used to reduce

cooling capacity in low air temperature applications such as applications with a large percentage of outside air.

As the air temperature entering the unit drops, the suction pressure and evaporating temperature start to drop as well.

At an evaporating temperature of 40°F the hot gas bypass valve will start to divert a portion of the hot compressor discharge gas to the low temperature liquid entering the evaporator coil. This hot gas serves to warm the evaporator coil and reduces the cooling capacity of the heat pump.

Note that the hot gas bypass valve is inoperative in the heating mode.

Internal 2-Way Water Valve

In many applications, including variable pumping and well water installations, a motorized water valve is required on the heat pump water circuit. On the LV series this water valve can be factory mounted and wired internally to the unit.

The LV series internal water valve option features a 24VAC motorized water valve rated to 450 psig working pressure. This valve is wired to open on a thermostat call for compressor operation (heating or cooling) and will remain open as long as the thermostat calls. The valve can remain seated with up to 20 psi of back pressure on all sizes.

The valve consists of two main parts: the valve body and the actuator. The valve body is brazed into the leaving water line of the heat pump and is a permanent part of the unit. The valve actuator can be easily removed from the valve body for service.

Refer to the water side pressure drop table in the troubleshooting section of this manual to determine the appropriate pressure drop across the heat pump with and without the water valve option.

Note that the 2-Way Water Valve option will add additional pressure drop between the water in and water out connections of the heat pump.

Note that this water valve cannot be used as an isolation valve.

LV Heat Pump Series8 733 905 683 (2014/11) Subject to change without prior notice

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