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Bryant
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Gt 024

Bryant Gt 024, GT 036, GT 048, GT 072, GT 060 Installation Instructions Manual

GT Series Geothermal Heat Pump Sizes 024, 036, 048, 060, 072
Installation Instructions
NOTE: Read the entire instruction manual before starting the installation.
TABLE OF CONTENTS
PAGE N O.
SAFETY CONSIDERATIONS 2......................................................................
Geothermal Systems 3..........................................................................
Well W a ter Systems 4...........................................................................
INSTALLATION RECOMMENDATIONS 6............................................................
CONDENSATE DRAIN 8.............................................................................
DUCT SYSTEM 8...................................................................................
PIPING 9..........................................................................................
ELECTRICAL 9....................................................................................
Safety Devices and UPM Controller 10..............................................................
ECM Interface Board 14.........................................................................
Constant Airflow Motor 17.......................................................................
Pump Relay 17................................................................................
Comfort Alert Diagnostics Module (CADM) 17.......................................................
Smart Start Assist 18............................................................................
Heat Recovery Package (HRP) 19..................................................................
SEQUENCE OF OPERATION 21.......................................................................
Cooling Mode 21...............................................................................
Heating Mode 21...............................................................................
ELECTRONIC THERMOSTAT INSTALLATION 21......................................................
SYSTEM CHECKOUT 22.............................................................................
UNIT START--UP 22..................................................................................
MAINTENANCE 22..................................................................................
TROUBLESHOOTING 23.............................................................................
OPERATING TEMPERATURES AND PRESSURES TABLES 27............................................
AIRFLOW TABLES 31...............................................................................
WATER SIDE PRESSURE DROP TABLE 33.............................................................
CONFIGURATIONS 34...............................................................................
Horizontal Configuration 34
Counter--Flow Configuration 40...................................................................
Vertical Configuration 40.........................................................................
......................................................................
Information in these installation instructions pertains only to GT series units.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and current editions of the National Electrical Code ( NEC ) NFPA 70. In Canada, refer to current editions of the Canadian electrical code CSA 22.1.
Recognize safety information. This is the safety--alert symbol When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
!
WARNING
EXPLOSION HAZARD
Failure to follow this warning could result in death, serious personal injury, and/or property damage.
Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.
1
!
!
2
3
!
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 and gloves when handling parts.
!
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury or equipment damage.
PuronR refrigerant systems operate at higher pressures than standard R --22 systems. Do not use R-- 22 service equipment or components on PuronR refrigerant equipment.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label.
WARNING
Fig. 1 -- Standard Package
A14032
1. GT Series Water-- To Air Heat Pump
2. Installation and Owner’s Manual
3. Hanging Bracket Kit (HZ unit only)
2
APPLICATION CONSIDERATIONS
Geothermal Systems
Closed loop and pond applications require specialized design knowledge. No attempt at these installations should be made unless the dealer has received specialized training. Anti-- freeze solutions
are utilized when low evaporating conditions are expected to occur. Refer to the Flow Center installation manuals for more specific instructions. (See Fig. 2)
(1) Line Voltage Disconnect (unit) (8) Ground Loop Connection Kit
(2) Flex Duct Connection (9) Ground Loop Pumping Package
(3) Low Voltage Control Connection (10) Polyethylene with Insulation
(4) Line Voltage Connection (11) Line Voltage Disconnect (electric heater)
(5) P/T Ports
(6) Vibration Pad
(7) Condensate Drain Connection
Fig. 2 -- Example Geothermal System Setup
Diagram shows typical installation and is for
illustration purposes only. Ensure access to Heat Pump is not restricted.
A14132
3
Well Water Systems
IMPORTANT: Table 1 must be consulted for water quality
requirements when using open loop systems. A water sample must be obtained and tested, with the results compared to the table. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH is <7.5 and the calcium hardness is l<100 ppm, the potential for scaling is low. For numbers out of the range listed, a monitoring plan must be implemented due to probable scaling. Other potential issues such as iron fouling, corrosion, erosion and clogging must be considered. Careful attention to water conditions must be exercised when considering a well water application. Failure to perform water testing and/or applying a geothermal heat pump to a water supply that does not fall within the accepted quality parameters will be considered a mis--application of the unit and resulting heat exchanger failures will not be covered under warranty. Where a geothermal system will be used with adverse water conditions, a suitable plate--frame heat exchanger MUST be used to isolate the well water from the geothermal unit.
Proper testing is required 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 cupronickel heat exchanger is recommended. Copper is adequate for ground water that is not high in mineral content.
In well water applications, water pressure must always be maintained in the heat exchanger. This can be accomplished with either a control valve or a bladder type expansion tank.
When using a single water well to supply both domestic water and the heat pump, care must be taken to insure that the well can provide sufficient flow for both.
In well water applications, a slow closing solenoid valve must be used to prevent water hammer (hammering or stuttering sound in the pipeline). Solenoid valves should be connected across Y1 and C1 on the thermostat interface board for all. Make sure that the VA draw of the valve does not exceed the contact rating of the thermostat. (See Fig. 3)
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment damage or improper operation.
Discharge air configuration change is not possible on Heat Pumps equipped with Electric Heat Option.
CAUTION
1
13
12
2
11
6
5
9
7
4
(1) Flex Duct Connection (8) Hose Kits (optional)
(2) Low Voltage Control Connection (9) Pressure Tank (optional)
(3) Vibration Pad (10) P/T Ports (optional)
(4) Ball Valves (11) Line Voltage Connection
(5) Solenoid Valve Slow Closing (12) Electric Heater Line Voltage Disconnect
(6) Condensate Drain Connection (13) Unit Line Voltage Disconnect
(7) Drain Valves
Fig. 3 -- Example Well Water System Setup
10
3
Typical Installation shown for
8
illustration purposes only.
A14130
4
Table 1 – Water Quality Requirements for Open--Loop Geothermal Heat Pump System
Water Quality Parameter HX Material Closed Recirculating Open Loop and Recirculating Well
Scaling Potential - Primary Measurement
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below:
pH/Calcium Hardness Method
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)
Scaling indexes should be calculated at 150°F for direct use and HWG applications, and at 90°F for indirect HX use. A monitoring plan should be implemented.
Ryznar Stability Index All --
Langelier Saturation Index All --
Iron Fouling
Iron Fe² (Ferrous) (Bacterial Iron Potential)
Iron Fouling All --
Corrosion Prevention
pH All
Hydrogen Sulfide (H2S) All --
Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds
Maximum Chloride Levels
Erosion and Clogging
Particulate Size and Erosion
NOTES:
S Closed recirculating system is identified by a closed pressurized piping system.
S Recirculating open wells should observe the open recirculating design considerations.
S NR - application not recommended
S "—" No design Maximum
All -- pH <7.5 and Ca Hardness <100ppm
6.0 - 7.5
If > 7.5 minimize steel pipe use
-0.5 to +0.5
If <-0.5 minimize steel pipe use.
Based upon 150°F HWG and Direct well,
84°F Indirect Well HX
<0.2 ppm (Ferrous)
All --
If Fe²* (ferrous) >0.2 ppm with pH 6-8, O2<5 ppm check
for iron bacteria
<0.5 ppm of Oxygen
Above this level deposition will occur
6-8.5
Monitor/treat as needed
Minimize steel pipe below 7 and no open tanks with pH <8
6-8.5
At H S>0.2 ppm, avoid use of copper and copper nickel
piping or HXs. Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK
to <0.5 ppm
All -- <0.5 ppm
Maximum Allowable at Maximum Water Temperature
50°F 75°F 100°F
Copper -- <20 ppm NR NR
cupronickel -- <150 ppm NR NR
304 SS -- <400 ppm <250 ppm <150 ppm
316 SS -- <1000 ppm <550 ppm <375 ppm
Titanium -- >1000 ppm >550 ppm >375 ppm
All
<10 ppm of particles and a maximum velocity of 1.8 m/s. Filtered for maximum 841 mi­cron [0.84 mm 20 mesh] size
<10 ppm (<1 ppm "sandfree" for reinjection) of particles and a maximum velocity of 1.8 m/s. Filtered for maximum 841 micron [0.84 mm. 20 mesh] size. Any particulate that
is not removed can potentially clog components
5
INSTALLATION RECOMMENDATIONS
The Water--to-- Air Heat Pumps are designed to operate with entering fluid temperature between 20_Fto90_F in the heating mode and between 30_F to 120_F in the cooling mode.
NOTE:50_ minimum Entering Water Temperature (EWT) is recommended for well water applications with sufficient water flow to prevent freezing. Antifreeze solution is required for all closed loop applications or EWT less than 45_. Cooling Tower/Boiler and Geothermal applications should have sufficient antifreeze solution to protect against extreme conditions and equipment failure. Frozen water coils are not covered under warranty. Other equivalent methods of temperature control are acceptable.
Check Equipment and Job Site
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.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage.
If unit stacking is required for storage, stack units as follows:
Do not stack units larger than 6 tons!
Vertical units: less than 6 tons, no more than two high. Horizontals units: less than 6 tons, no more than three high.
Inspect Equipment
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 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.
Location / Clearance
Locate the unit in an indoor area that allows easy removal of the filter and access panels, and has enough room for 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 face of unit’s air coil. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment damage or improper operation.
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.
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in equipment damage and/or improper equipment operation.
It is extremely important to take the proper precautions to insure that the heat pump unit is installed in the proper location and that measures have been taken to prevent rupturing the water coil due to freezing conditions.
Frozen water coils are not covered under the limited product warranty.
CAUTION
CAUTION
6
CONTROL
J15
GY
RD
TO ECM MOTOR
CFM ADJUST
WHBL ORBR YL
NO
HGRH
TEST
YES
NORM
(+)
(-)
A
BCD
THERMOSTAT
CFM
R C G O Y1 Y2 W1 W2 H C
J14
J17
GN/
GY
PU
BK
YL
WH
BL
ORGN/
BR
BK
J1 J2 J13
P1
GN/
YL
OR
BR
BK
GY
GYPU
RD
L1
P2
BL
WH
P13
GY
GY
RD
PU
L2
BK
WH
BK WH
GN/
LOW VOLT HIGH VOLT
YL
Fig. 4 -- Constant Airflow Motor
J19 P19
A150437
7
MOUNTING VERTICAL UNITS
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 Fig. 5.
NOTE: On VT and CF units, the condensate drain pan is internally sloped. There is no internal P--Trap.
CONDENSATE DRAIN
VIBRATION PAD FULL SIZE
A14117
Fig. 5 -- Vibration Absorbing Pad
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 manufacturer recommends these be attached to the unit corners by hanger bracket kits. The rods must be securely anchored to the ceiling. Refer to the hanging bracket assembly and installation instructions for details.
IMPORTANT: 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 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.
NOTE: HZ unit condensate drain pan is NOT internally sloped.
IMPORTANT: Horizontal (HZ) units must be installed pitched toward the Condensate Drain Connection 1/8” per foot.
Fig. 6 -- Condensate Drain
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.
IMPORTANT: This connection must be in conformance with local plumbing codes. A trap must be installed in the condensate line to insure free condensate flow.
NOTE: HZ heat pump drain pan is not internally sloped.
A vertical air vent is sometimes required to avoid air pockets. 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.
A14118
DUCT SYSTEM
A supply air outlet collar and return air duct flange are provided on all units to facilitate duct connections.
NOTE: Supply air duct and return air duct flanges are shipped unfolded with unit.
Fold the duct flange outwards along the perforated line. Refer to unit Dimensional Drawings for physical dimensions of the collar and flange.
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 one inch duct insulation to avoid heat loss or gain and prevent condensate from 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.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper equipment operation.
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 duct work, 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 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.
8
CAUTION
There should be no direct straight air path through 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.
PIPING
Supply and return piping must be as large as the unit connections on the heat pump (larger on long runs).
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper equipment operation.
Never use flexible hoses of a smaller inside diameter than that of the fluid connections on the unit.
GT units are supplied with either a copper or optional cupronickel condenser. Copper is adequate for ground water that is not high in mineral content.
NOTE: Proper testing is recommended to assure the well water quality is suitable for use with water source equipment. When in doubt, use cupronickel. See Application Considerations notes on page 4.
In conditions anticipating moderate scale formation or in brackish water, a cupronickel 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.
!
EQUIPMENT DAMAGE AND/OR UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment damage and/or improper operation.
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 Unit Dimensional Drawings.
NOTE: Teflon tape sealer should be used when connecting water piping connections to the units to insure against leaks and possible heat exchanger fouling.
NOTE: The unit is shipped with water connection O--rings. A 10 pack of O--rings (part #4026) can be ordered through Replacement Components Division (RCD).
IMPORTANT: Do not over-- tighten 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 (on open--loop systems).
CAUTION
CAUTION
ELECTRICAL
Refer to electrical component box layout. See Fig. 7.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment damage and/or improper operation.
S Field wiring must comply w ith local and national
electrical codes.
S Power to the unit must be within the operating voltage
range indicated on the unit nameplate or on the performance data sheet.
S 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 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 line side of compressor contactor as indicated on the wiring diagrams.
IMPORTANT: Units supplied with internal electric heat require two (2) separate power supplies:
1) Unit compressor
2) Electric Heat, blower motor and control circuit. Refer to the ELECTRIC HEATER PACKAGE OPTION section. See data plate for minimum circuit ampacities and maximum fuse/breaker sizing.
3
2
1
(1) Compressor Contactor (5) Auxiliary Pump Relay (Option)
(2) Comfort Alert Module (6) Transformer
(3) Second Stage Relay (7) Capacitor
(4) Unit Protection Module (UPM) (8) ECM Module
Fig. 7 -- Electrical Component Box Layout
CAUTION
4
8
5
6
7
A14119
-- mounts on E-- box cover
9
Safety Devices and UPM Controller
1
2
3
4
5
S Water side freeze protection sensor, mounted close to condensing
water coil, monitors refrigerant temperature between condensing
11
1213
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 26_F, however this can be changed to 15_F by cutting the R30 or Freeze1 resistor located on top of DIP switch SW1 (Refer to Fig. 8, item (3) for resistor location), RefertoFig.9forsensorlocation.
17
6
(1) Board Power Indicator (10) Compressor Contact Output
(2) UPM Status LED Indicator (11) High Pressure Switch Connection
(3) Water Coil Freeze Protection
Temperature Selection [R30]
(4) Air Coil Freeze Protection
Temperature Selection
(5) UPM Board Settings (14) 24VAC Power Common
(6) Water Coil Freeze Connection (15) Condensate Overflow Sensor
(7) Air Coil Freeze Connection (16) Dry Contact
(8) LCD Unit Display Connection (17) UPM Ground Standoff
(9) 24VAC Power Input
15
7
8
14
(12) Call for Compressor Y1
(13) Low Pressure Switch Connection
16
9
10
A14120
Fig. 8 -- Safety Device and UPM Controller
NOTES:
1. If the unit is being connected to a thermostat with a mal­function light, this connection is made at the unit malfunc­tion output or relay. Refer to Fig. 8.
2. 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.
3. 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:
S High pressure switch located in the refrigerant discharge line and
wired across the HPC terminals on the UPM.
S Low pressure switch located in the unit refrigerant suction line
and wired across terminals LPC1 and LPC2 on the UPM.
NOTE: UPM Board Dry Contacts are normally open (NO)
Fig. 9 -- Freeze Protection Sensor Location
A14121
!
CAUTION
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage and/or improper equipment operation.
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.
S 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. See Fig. 10.
Fig. 10 -- Evaporator Freeze Protection Sensor Location
A14122
10
S The condensate overflow protection sensor is located in the drain
pan of the unit and connected to the ”COND” terminal on the UPM board. See Fig. 11.
A14123
Fig. 11 -- Condensate Overflow Protection Sensor Location
UPM Board Factory Default Settings
S 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 ”CONT”, a continuous 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”.
NOTE: If 24 VAC output is needed, R must be wired to ALR--COM terminal; 24 VAC will be available on the ALR--OUT terminal when the unit is in the alarm condition.
S 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.
S UPM TEST MODE: UPM test mode will allow all time--delay
settings to be reduced to 10 seconds for troubleshooting and verification of unit operation. Reset unit to TEST mode: NO when test is completed. During UPM test mode, the UPM LED will flash a FREEZE SENSOR 6 flash code. Test mode will automatically defeat after approximately 5 minutes with no LED flash and normal delays.
TEMP
LOCKOUT
RESET
ALARM
TEST
UPM DIP SWITCH DEFAULT POSITION
lockout 4
reset
alarm
test
The UPM Board includes the following features:
S ANTI-- S HORT CYCLE TIMER: 5 minute delay on break
timer to prevent compressor short cycling.
S 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.
S LOW PRESSURE BYPASS TIMER:Ifthecompressoris
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 lockoutpower to the unit would need to bereset.
S BROWNOUT / SURGE / POWER INTERRUPTION
PROTECTION: The brownout 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.
30°F
2
Y
PULSE
NO
2
RY
Cont
yes
pulse
no
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage and/or improper equipment 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.
S FREEZE SENSOR: The default setting for the freeze limit trip is
26_F (sensor number 1); however this can be changed to 15_Fby cutting the R30 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 the code associated with this alarm condition three (3) times. 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 Fig. 10. 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 cont act will be activ e. T he LE D will flash the cod e associated with this alarm condition six (6) times. 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.
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage and/or improper equipment operation.
Freeze sensor will not guard against the loss of water. A flow switch is recommended to prevent the unit from running if water flow is lost or reduced.
CAUTION
CAUTION
11
Table 2 – 10K Temperature Sensor Resistance Table
°C °F OHM °C °F OHM °C °F OHM °C °F OHM
--- 55 --- 67 963,800 --- 9 16 52,410 37 99 6,015 83 181 1,141
--- 54 --- 65 895,300 --- 8 18 49,660 38 100 5,774 84 183 1,105
--- 53 --- 63 832,100 --- 7 19 47,070 39 102 5,545 85 185 1,071
--- 52 --- 62 776,800 --- 6 21 44,630 40 104 5,326 86 187 1,038
--- 51 --- 60 719,900 --- 5 23 42,330 41 106 5,116 87 189 1,006
--- 50 --- 58 670,200 --- 4 25 40,160 42 108 4,916 88 190 975
--- 49 --- 56 624,200 --- 3 27 38,120 43 109 4,725 89 192 945
--- 48 --- 54 581,600 --- 2 28 36,190 44 111 4,542 90 194 916
--- 47 --- 53 542,200 --- 1 30 34,370 45 113 4,368 91 196 889
--- 46 --- 51 505,800 0 32 32,650 46 115 4,201 92 198 862
--- 45 --- 49 472,000 1 34 31,030 47 117 4,041 93 199 836
--- 44 --- 47 440,700 2 36 29,500 48 118 3,888 94 201 811
--- 43 --- 45 411,600 3 37 28,050 49 120 3,742 95 203 787
--- 42 --- 44 384,700 4 39 26,690 50 122 3,602 96 205 764
--- 41 --- 42 359,700 5 41 24,400 51 124 3,468 97 207 741
--- 40 --- 40 336,500 6 43 24,170 52 126 3,339 98 208 720
--- 39 --- 38 314,900 7 45 23,020 53 127 3,216 99 210 699
--- 38 --- 36 294,900 8 46 21,920 54 129 3,099 100 212 679
--- 37 --- 35 276,200 9 48 20,890 55 131 2,986 101 214 659
--- 36 --- 33 258,800 10 50 19,900 56 133 2,878 102 216 640
--- 35 --- 31 242,700 11 52 18,970 57 135 2,774 103 217 622
--- 34 --- 29 227,600 12 54 18,090 58 136 2,674 104 219 604
--- 33 --- 27 213,600 13 55 17,260 59 138 2,579 105 221 587
--- 32 --- 26 200,500 14 57 16,470 60 140 2,488 106 223 571
--- 31 --- 24 188,300 15 59 15,710 61 142 2,400 107 225 555
--- 30 --- 22 177,000 16 61 15,000 62 144 2,316 108 226 539
--- 29 --- 20 166,400 17 63 14,330 63 145 2,235 109 228 525
--- 28 --- 18 156,400 18 64 13,380 64 147 2,157 110 230 510
--- 27 --- 17 147,200 19 66 13,070 65 149 2,083 111 232 496
--- 26 --- 15 138,500 20 68 12,490 66 151 2,011 112 234 483
--- 25 --- 13 130,400 21 70 11,940 67 153 1,942 113 235 470
--- 24 --- 11 122,800 22 72 11,420 68 154 1,876 114 237 457
--- 23 --- 9 115,800 23 73 10,920 69 156 1,813 115 239 445
--- 22 --- 8 109,100 24 75 10,450 70 158 1,752 116 241 433
--- 21 --- 6 102,900 25 77 10,000 71 160 1,693 117 243 422
--- 20 --- 4 97,080 26 79 9,573 72 162 1,637 118 244 411
--- 19 --- 2 91,620 27 81 9,166 73 163 1,583 119 246 400
--- 18 0 86,500 28 82 8,778 74 165 1,531 120 248 389
--- 17 1 81,700 29 84 8,409 75 167 1,480 121 250 379
--- 16 3 77,190 30 86 8,057 76 169 1,432 122 252 370
--- 15 5 72,960 31 88 7,722 77 171 1,386 123 253 360
--- 14 7 68,980 32 90 7,402 78 172 1,341 124 255 351
--- 13 9 65,250 33 91 7,098 79 174 1,298 125 257 342
--- 12 10 61,740 34 93 6,808 80 176 1,256 126 259 333
--- 11 12 58,440 35 95 6,531 81 178 1,216 127 261 325
--- 10 14 55,330 36 97 6,267 82 180 1,178 128 262 317
S HIGH PRESSURE SWITCH: The high pressure switch safety
is designed to shut down the compressor if it exceeds limits. Cut in 420 +/-- 15 psig and cut out 600 +/-- psig.
S LOW PRESSURE SWITCH: The low pressure switch safety is
designed to shut down thecompressor of loss of charge. Cut in 60 +/-- 15 psig and cut out 40 +/-- psig.
S 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 condensateoverflow fault will cause the unit to go into a hard lockout immediately,and willrequire a manual lockout reset.
S 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”.
NOTES: The blower motor will remain active during a lockout condition.
S ECM TEST MODE: ECM test mode is to override the motor to
constant torque mode for motor troubleshooting. If the motor runs in ECM test mode, the module and motor are good. To engagein ECM test mode, only one switch canbe selected. Select TEST ON and all others OFF. Reset the board to NORM ON and TEST OFF when test is complete. If the unit remains in test mode for normal operation, the system will not run different CFMs based on thermostat call such as Y1, Y2 or dehumidify. It may also experience problems with nuisance strip during electric heat operation. There is no way to check CFM based on number of blinks if the board is set to test mode.
12
START
Y1 = ON
NO
RESET ON
Y
NO
RESET ON R
YES
R = 24VAC
YES
POWER/ SWITCHES/SENSOR
STATUS CHECK
V > 18VAC
NO
YES
HPC =
CLOSED
NO
YES
LPC
=CLOSED
NO
YES
START TIMER
YES
CLEAR FAULTS
TIME > 120
NO
BLINK CODE ON STATUS LED
SOFT LOCKOUT
RECORD ALARM
START COUNTER (IF APPLICABLE)
LOCKOUT CAN BE SET
TO 4 VIA DIP SWITCH
BLINK CODE
ON STATUS LED
SEC
YES
NO
NO
NO
COUNTER NEEDED?
YES
COUNT = 2
OR
COUNT = 4
YES
HARD
LOCKOUT?
YES
NO
FRZ >TEMP
LIMIT
YES
CON > 0
YES
INITIAL
POWER UP
YES
NO
NO
NO
BLINK CODE ON STATUS LED
START TIMER
TIME > 30
SEC
YES
NO
START
ANTI SHORT CYCLE
START
RANDOM START UP
NO
T > ASC OR
RS SEC
YES
CC
Fig. 12 -- UPM Sequence of Operation (SOO) Flow Chart
DISPLAY OUTPUT = PULSE
ALR OUTPUT = ON/PULSE
CC OUTPUT = OFF
CC OUTPUT = ON
A14129
13
ECM INTERFACE BOARD
Refer to Fig. 7, item (12) for ECM interface board location. 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 provides thermostat signals to unit’s UPM board. The thermostat connections and their functions are as follows:
10
1
3
Dehumidification Mode
Position the HGRH DIP switch in the “NO” (OFF) position. When the switch is in this position, upon a dehumidification call, the unit will operate at a lower speed to increase dehumidification while cooling. See Fig. 14.
8
9
(1) Motor Harness Plug (7) Thermostat Input Status Indication (2) Blower CFM Adjustment (8) Reheat Digital Outputs (3) Motor Settings (9) Thermostat Outputs (4) Dehumidification Indication (10) 24 VAC (5) Thermostat Contact Inputs (11) Dehumidification Method Selector (6) CFM Count Indicator
27
5
11
46
A14124
Fig. 13 -- ECM Interface Board
NOTE: CFM LED indication is an approximation. Utilize
conventional Test and Balance equipment for accurate airflow measurement.
S CFM count indicator (see Fig. 13, item 6) blinks to indicate
approximate airflow in CFM and may flicker when the unit is off.
S 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.
Fig. 14 -- Dehumidification Method Selector
A14126
Thermostat Outputs
Dry Contact Left side terminal strip in the stat, D1, D2 YI First Stage Compressor Cool Y/Y2 Second Stage Compressor Cool W1 Auxiliary Electric Heat
(runs in conjunction with compressor) W2/E Emergency Heat (electric heat only) O Reversing Valve (energized in cooling) GFan R Transformer 24 VAC Hot C Transformer 24 VAC Common
NOTE: When unit is used with Carrier and Bryant thermostats with Relative Humidity Control (Carrier Edge TP--PRH or TP--NRH / Bryant Preferred T6-- PRH or T6--NRH), the unit’s dehumidification mode is in reverse logic and will not activate dehum unless a relay, as shown in Fig. 15, is used. A simplified explanation of the reverse logic follows.
RH ECM
Stat Logic: Board Logic: No Dehum Demand: Dh -- energized Dh--not energized Dehum Demand: Dh -- de--energized Dh -- energized
THERMOSTAT
24V OUTPUTS
DE-H UMID IFICATION CA LL
COOLING STAGE 1
COOLING STAGE 2
HEATING STAGE 1
HEATING STAGE 2
SWITCH OVER VALVE
BLOWER
24VAC (HOT)
24VAC (COMMON)
Fig. 15 -- Cool to Dehumidify Application for Thermostats with Dehumidification
Dry
Contact
Y1
Y2
W1
W2/E
O/B
G
R
C
RELAY
C
H
HUMIDISTAT
Y1
COOLING STAGE 1
Y2
COOLING STAGE 2
W1
HEATING STAGE 1
W2
HEATING STAGE 2
O
REVERSING VALVE
G
BLOWER
R
C
DHR – DEHUMIDIFICATION RELAY FIELD INST ALLE D
CAV42
(Not required for Cor / Housewise thermostats)
ECM CONTROLLER INTERFACE
24V INPUTS
YES N O
STLOV ENIL
EX: 230VAC
LOW VOLTAGE CLASS II WIRING – 18AWG
HGRH
A150487
14
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