WFI ES024, ES030, ES036, ES048, ES060 Installation Manual

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Page 1

Geothermal/Water Source Split Heat Pumps

• R-410A Refrigerant

• 2, 2.5 Ton Single Speed

• 3, 4, 5, 6 Ton Dual Capacity

Installation Information Water Piping Connections Desuperheater Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance

ES Split Installation Manual

IM1460 11/06

WFI

Page 2

ES SPLIT INSTALLATION MANUAL

Model Nomenclature

Family

ES=ESeriesSplit

Unit Capacity

024 MBTUH 048 MBTUH 030 MBTUH 060 MBTUH 036 MBTUH 072 MBTUH

Control Option

S = Standard Controls

Voltage

1 = 208-230/60/1

Loop Pump Options

A = Standard Loop Connections

ES 036 S 1 A N B SS A

Vintage

A = 024-030 B = 036-072

Non-Standard Option Details

S=Standard A-R, T-Z Non-standard Options

Sound Kit

A = None B = Blanket

Coax Options

N = Cupronickel

Page 3

ES SPLIT INSTALLATION MANUAL

T able of Contents

General Installation Information 4-5 Water Piping 6-8 Heat Recovery Unit 9 Electrical 10-11 Wiring Schematics 12-13 DIP Switch Settings 14 Refrigeration 15-16 Unit Startup 17 Modes of Operation 18-19 Checking Superheat and Subcooling 20-22 Pressure Drop and Recommended Flow Rates 23 Service 24-25 Pressure/Temperature Conversion Chart 26 Preventive Maintenance 27 Replacement Procedures 27

Page 4

ES SPLIT INSTALLATION MANUAL

General Installation Information

Safety Considerations

WARNING: Before performing service or maintenance operations on a system, turn off main power

switches to both units. Turn off accessory heater power switch if applicable. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualiﬁ ed ser- vice personnel should install, repair or service heating and air conditioning equipment.

Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing ﬁ lters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a ﬁ re extinguisher available.

Moving and Storage

Move units in the normal “up” orientation. Do not stack more than three units in total height. When the equipment is received, all items should be carefully checked against the bill of lading to be sure that all crates and cartons have been received. Examine units from the cartons if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage.

General Information

The ES split compressor section is designed for applications that are not feasible with packaged units. Common applications for the ES split are downﬂ ow, horizontal, attic or crawlspace installations (where there is a need to have water con- nections and duct work in different locations). Other applications that are easily adapted to the ES split are replacements of existing air-to-air heat pumps and fossil fuel furnace add-ons. It is required that the ﬁ nned air coil be installed on the supply side of the fossil fuel furnace to prevent condensation on the furnace heat exchanger during cooling mode. The installation of the ES split is similar to packaged units with the addition of refrigeration piping and charging. Refrigerant lines are to be limited to 50 feet in length. The ES split is manufactured with an extended range expansion valve for proper performance on earth coupled loop installations. ARI ratings are based upon a matched compressor section and blower coil section for each model number. Other manufacturers’ blower coils or mismatched sets may not produce similar/desired results. Using coils other than that speciﬁ ed in the ARI matched rating may alter unit performance.

Split Unit Location

Locate the split compressor section away from areas that may disturb the customer and in a way that allows easy re-

moval of the access panels and the top of the cabinet. Provide sufﬁ cient room to make water, electrical and refrigerant line connections and allow space for service personnel to perform maintenance. When installed indoors the unit should always be mounted on a vibration absorbing pad or mesh to reduce noise. The ES split is also approved for outdoor installation when properly installed.

Duct System

In applications using galvanized metal ductwork, a ﬂ exible duct connector is recommended on both the supply and return air plenums to minimize vibration from the blower. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of 1-inch thick glass ﬁ ber or be constructed of ductboard. Insulation is usually not installed in the supply branch ducts. Ducts in unconditioned areas should be wrapped with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected. If the air handler is connected to existing ductwork, a previous check should have been made to assure that the duct system has the capacity to handle the air required for the unit application. If ducting is too small, as in the replacement of heating only systems, larger ductwork should be installed, checked for leaks and repairs made accordingly. The duct system and diffusers should be sized to handle the design airﬂ ow quietly. If air noise or excessive airﬂ ow is a problem, the blower speed can be changed to a lower speed to reduce airﬂ ow. This will reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil. Airﬂ ow must still meet minimum requirements.

Page 5

ES SPLIT INSTALLATION MANUAL

General Installation Information (cont.)

Condensate Drain

Follow the blower coil manufacturer’s instructions.

Air Handler Installation

Air handlers used with Dual Capacity units must be capable of operating with a minimum of 2 blower speeds. For details on installing the air handling portion of the system, refer to the manufacturer’s instructions for the blower coil unit. All blower coil units/air coils must be installed as speciﬁ ed by the manufacturer’s instructions. However, the following recom- mendations should be considered to minimize noise and service problems: An air ﬁ lter must be installed upstream of the air coil on the return air side of the air handler or furnace. If there is lim- ited access to the ﬁ lter rack for normal maintenance, it is suggested that a return air ﬁ lter grille be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the ﬁ lter and plugging the air coil.

Notes: Improper installation of equipment may result in undesirable noise levels in the living areas.

Ensure that the line set size is appropriate to the capacity of the unit (refer to page 15). Line sets should be routed as directly as possible, avoiding unnecessary bends or turns. Seal all wall penetrations properly. Line sets should not directly contact water pipes, ﬂ oor joists, wall studs, duct work, ﬂ oors, walls and brick. Line sets should not be suspended from joists or studs with a rigid wire or strap which directly contacts the tubing. Wide hanger strips which conform to the shape of the tubing are recommended. Isolate hanger straps from line set insulation by using metal sleeves bent to conform to the shape of insulation. Line set insulation should be pliable, and should completely surround the vapor tube.

Compatible Air Handlers

ES MODEL

MATCHING VARIABLE SPEED

AIR HANDLER

ES024 FV4ANF003 (3 TON) ES030 FV4ANF003 (3 TON) ES036 FV4ANF003 (3 TON) ES036 FV4ANF005 (4 TON) ES048 FV4ANF005 (4 TON) ES048 FV4ANF006 (5 TON) ES060 FV4ANF005 (4 TON) ES060 FV4ANF006 (5 TON) ES072 FV4ANF006 (5 TON)

Notes: Matching equipment model numbers are

Carrier

Figure 1: Typical Split System Application - Remote Blower Coil with Electric Auxiliary Heat

Supply

Duct

Air

Handler

Return

Duct

Insulated

Suction Line

Lineset

To Air Handler

Condensate Drain (must be trapped)

Disconnect

Low

Voltage Wire

Remote Air Handler

(Maximum Recommended Distance is

50' Between Units)

Page 6

ES SPLIT INSTALLATION MANUAL

Water Piping

Residential ES split units are supplied standard with brass water connections which will connect to optional internal loop pump(s) or 3-way valves. The 3-way valves can be adapted to threaded, barb, or fusion ﬁ ttings. Flush and ﬁ ll adapters are available separately. ES units are supplied standard with pressure/temperature taps for checking pressure drop and ﬂ ow rates.

CAUTION: Never use ﬂ exible hoses smaller than 1-inch inside diameter on the unit and limit hose length to 10 feet per connection. Check carefully for water leaks.

CAUTION: Water piping exposed to outside temperatures may be subject to freezing.

Closed Loop - Earth Coupled Systems (Indoor Installations)

Once piping is completed between the unit, the ﬂ ow center and the earth loop, ﬁ nal purging and charging of the loop is

needed. A ﬂ ush cart (at least a 1.5 HP pump) is needed to achieve adequate ﬂ ow velocity in the loop to purge air and dirt particles from the loop itself. An antifreeze solution is used in most areas to prevent freezing. Maintain the pH in the 7.6 to

8.2 range for ﬁ nal charging. Flush the system adequately to remove as much air as possible. Pressurize the loop to a static pressure of 40 to 60 psi. This is normally adequate for good system operation. Ensure that the circulating system provides adequate ﬂ ow through the unit by checking pressure drop across the heat exchanger and comparing it to the ﬁ gures shown in the table on page 23.

Figure 2: Indoor Installation Using Closed Loop

Line set To Air Handler

Insulated

Thermostat Wire From Air Handler

Disconnect

To Loop

VibrationAbsorbing Pad or Air Pad with access hole for piping entry

Page 7

ES SPLIT INSTALLATION MANUAL

Water Piping (cont.)

Closed Loop - Earth coupled Systems (Outdoor Installations)

Locate unit on an air pad with access hole as shown below. When mounting on an existing concrete pad, holes must

be bored through to accommodate 1 1/4-inch P.E. pipe with 1/2-inch insulation.

Loop Circulator

The optional ﬁ eld installed, circulating pump(s) and 3-way valve assemblies should be used for outdoor installations. Wiring connections are supplied in the rear compartment of the unit.

Connecting To Earth Loop

The earth loop trench should be continued directly under the unit as shown in Figure 3. Make the connections to optional ﬁ ttings from the loop circulator pump(s) and insure proper backﬁ ll to support the loop pipe during trench settling. All 1 1/4-inch piping should be insulated with a minimum of 1/2-inch closed cell insulation from below the ground surface to the loop circulator.

IMPORTANT

circulator pump if loop temperature drops below 20°F. Loop freeze protection should also be maintained to the lowest temperature the insulated loop may encounter in the case of power failure.

- A freeze protection thermostat is installed in the unit to automatically start loop

Closed Loop Valve and Pump Kits

Two kits are available when installing pumps inside the unit. The ES-VPK1 contains one pump and ﬂ ush/ﬁ ll valves. The ES-VPK2 contains two pumps and ﬂ ush/ﬁ ll valves. To determine whether one or two pumps are required, do pressure drop calculation. Refer to installation instructions for valve/pump kits included in the kit.

Notes: Typically 3 GPM of ﬂ ow per ton of cooling capacity is recommended in earth loop applications.

Figure 3: Typical Split System Outdoor Installation Using Closed Loop

Loop Supply and Return Piping

Page 8

ES SPLIT INSTALLATION MANUAL

Water Piping (cont.)

Open Loop - Well Water Systems

CAUTION: Although the unit is approved for outdoor installations, the use of this product is prohibited in open loop applications unless installed indoors.

Open Loop Applications

To provide a copper sweat connection for water line piping, remove the brass connectors from the unit. This can be done with a tube cutter or torch. Be careful to keep debris and contamination out of the water lines. Clean the connections and pipe to the water source using standard plumbing practices. Reference well water piping kit instructions for the WWK2T, WWK3T as needed. Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing a water control valve at the outlet of the unit and use a closed bladder pressure tank to minimize mineral deposits. Ensure proper water ﬂ ow through the unit by checking pressure drop across the heat exchanger and comparing it to the ﬁ gures in the table on page 23.

Water control valves draw their power directly from a unit’s 24V transformer and can overload and possibly burn out the transformer. Check total VA draw of the water valve and ensure that it is under 15 VA.

Notes: Normally, about a 2 GPM ﬂ ow rate per ton (1.5 GPM/ton minimum for EWT > 50°F) of cooling capacity is needed in open loop systems.

Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways depending on local building codes (i.e. recharge well, storm sewer, drain ﬁ eld, adjacent stream or pond, etc.). Most local codes forbid use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

Water Quality

In applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit from the contaminated water. The following table outlines the water quality guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is recommended.

Figure 4: Typical Split System Indoor Installation Using Well Water

Line set ToAir Handler

Thermostat Wire From Air Handler

Disconnect

Water Solenoid

Control Valve

Regulator

Boiler Drains for

VibrationAbsorbing Pad or Air Pad with access hole for piping entry

System Flushing

Rubber Bladder Pressure Tank

Flow

Shut-Off Valves

Water In From Well

Water Quality Guidelines

Material Copper 90/10 Cupro-Nickel

pH Acidity/Alkalinity 7- 9 5 - 9

Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm

Corrosion

Iron Fouling

(Biological Growth)

Erosion

Note: Grains = PPM divided by 17 • mg/l is equivalent to PPM

Water

Out

Hydrogen Sulfide

Sulfates Less than 125 ppm Less than 125 ppm Chlorine Less than .5 ppm Less than .5 ppm

Chlorides Less than 20 ppm Less than125 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm

Ammonia Chloride Less than .5 ppm Less than .5 ppm

Ammonia Nitrate Less than .5 ppm Less than .5 ppm

Ammonia Hydroxide Less than .5 ppm Less than .5 ppm

Ammonia Sulfate Less than .5 ppm Less than .5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000-1500 ppm

Iron, Fe2+ (Ferrous)

Bacterial Iron Potential

Iron Oxide

Suspended Solids

Threshold Velocity (Fresh Water) 5-8 ft/sec 8-12 ft/sec

Less than .5 ppm

(rotten egg smell appears at 0.5 PPM)

None None

Less than 1 ppm. Above this level

deposition will occur.

Less than 10 ppm and filtered for max

of 600 micron size

10 - 50 ppm

Less than 1 ppm. Above this level

deposition will occur.

Less than 10 ppm and filtered for max

of 600 micron size

Page 9

ES SPLIT INSTALLATION MANUAL

Heat Recovery Unit for Domestic Hot Water

Service valves have been provided inside the unit for connecting the discharge gas line to a water heating heat recov-

ery unit (see ﬁ gure 5). To make the connections, close the service valves inside the unit by turning clockwise. Using a recovery canister connect to either of the schrader ports on the DSH service valves and recover the small amount of refrigerant trapped inside of the U-tube. Prior to brazing ensure that all refrigerant has been removed from U-tube. Once the refrigerant is removed, it is recommended that the tube be cut at the “U” to remove any excess oil that may be trapped. (This will also allow for easier removal of the tubing with a torch, since each section can be removed independently). Ser- vice valves must be protected to prevent overheating. Unbraze the 1/2-inch O.D. U-tube and run tubing from the left hand service valve to the inlet of the heat recovery unit and from the outlet of the heat recovery unit to the right hand of the service valve. Typically the one way discharge line length should be limited to 25-30 feet and line size must be increased depending on unit size and length of run. Follow the instructions supplied with the heat recovery unit for mounting location, water piping, and start up. A typical installation is shown below.

IMPORTANT - Reopen discharge line service valves before starting up unit, but only after leak checking, purging, and evacuating new discharge line.

Figure 5: Service Valves for Heat Recovery Unit Connections

Compressor

Heat Recovery

Unit “In”

Maximum One-Way Line Length

From

Heat Recovery

Unit “Out” to

Reversing

Valve

SIZE 1/2” OD 5/8” OD 3/4” OD

024 - 036 Up to 9 ft. Up to 25 ft. Up to 30 ft.

048 Up to 5 ft. Up to 13 ft. Up to 30 ft. 060 N/A Up to 9 ft. Up to 25 ft. 072 N/A Up to 6 ft. Up to 20 ft.

Figure 6: Typical Hot Water Piping Layout

Line set

To Hot Water

Generator

Venting

Waste Valve or

Vent Coupling

Cold

Hot

P/T Relief

Valve

Insulated Line set

With UV Paint To Air handler

Add-on

Hot Water

Generator with

Internal Pump

Drain Valve

Pipe Tee

Page 10

ES SPLIT INSTALLATION MANUAL

Electrical

General

Be sure that the available power is the same voltage and phase as shown on the unit serial plate. Line and low volt-

age wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. See tables below for fuse or circuit breaker sizing information. Refer to the wiring schematic inside the unit access panel for more information.

Accessory Pump Operation

Refer to the wiring diagram on the unit’s wiring schematic for instruction on wiring the pumps to the unit.

Electrical Data Without Loop Pump(s)

COMPRESSOR

MODEL

ES024 208-230/60/1 197/253 13.0 8.3 48.0 8.3 10.4 15 15 ES030 208-230/60/1 197/253 15.5 9.9 55.0 9.9 12.4 20 20 ES036 208-230/60/1 197/253 19.5 12.5 66.0 12.5 15.6 25 25 ES048 208-230/60/1 197/253 28.0 17.9 96.0 17.9 22.4 40 40 ES060 208-230/60/1 197/253 38.5 24.7 130.0 24.7 30.9 50 50 ES072 208-230/60/1 197/253 41.0 26.3 130.0 26.3 32.9 50 50

Notes: Always refer to unit nameplate data prior to installation. ACR circuit breaker in United States only. All

fuses are class RK-5.

RATED

VOLTAGE

MIN./MAX.

MCC RLA LRA

TOTAL

UNIT

FLA

MIN.

CIRCUIT

AMP.

RESIDENTIAL

MAX

FUSE

MAX. HACR

BRAKER

Electrical Data With Loop Pump(s)

COMPRESSOR

MODEL

ES024 208-230/60/1 197/253 13.0 8.3 48.0 1.8 10.1 12.2 20 20 ES030 208-230/60/1 197/253 15.5 9.9 55.0 1.8 11.7 14.2 20 20 ES036 208-230/60/1 197/253 19.5 12.5 66.0 1.8 14.3 17.4 25 25 ES048 208-230/60/1 197/253 28.0 17.9 96.0 1.8 19.7 24.1 40 40 ES060 208-230/60/1 197/253 38.5 24.7 130.0 3.5 28.2 34.1 50 50 ES072 208-230/60/1 197/253 41.0 26.3 130.0 3.5 29.8 36.4 60 60

Notes: Always refer to unit nameplate data prior to installation. HACR circuit breaker in United States only. All fuses are class

RK-5.

RATED

VOLTAGE

MIN./MAX.

MCC RLA LRA

INTERNAL

LOOP PUMP

FLA

TOTAL

UNIT

FLA

MIN.

CIRCUIT

AMP.

RESIDENTIAL

MAX

FUSE

MAX. HACR

BRAKER

Page 11

ES SPLIT INSTALLATION MANUAL

Electrical ( c on t.)

Dual Fuel Systems

ES units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the

ES heat pump for heating until the point that auxiliary heat is called for on the thermostat. At that point, the furnace will be enabled and the heat pump will be disabled. The ES heat pump provides air conditioning through the furnace’s refrigerant coils. Refer to the furnace manufacturer’s installation manual for the furnace installation, wiring and coil insertion. A ﬁ eld-in- stalled SPDT auxiliary heat relay is required. See Figure 7 for typical Dual Fuel application. Figure 8 shows the wiring for Single Speed ES units. Figure 9 shows wiring for Dual Capacity ES units.

Figure 7: Typical Split System Application - Heat Pump Coil Add-On Fossil Fuel Furnace

Supply

Duct

Disconnect

"A" or

Slab Coil

-Flow

Fossil Fuel

Insulated Suction

Line

Lineset

ToAir Handler

Wire To

Thermostat

Low

Voltage Wire

Remote Air Handler

(Maximum Recommended Distance is

50' Between Units)

Furnace

Condensate

Drain

(must be trapped)

Return

Duct

Figure 8: Single Speed Dual Fuel Wiring Figure 9: Dual Capacity Dual Fuel Wiring

Thermostat

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

Common

24 VA

Emergency Shutdown

Note: Field installed SPST dual fuel relay

(Required for dual fuel installation)

Fossil Fuel

Furnace

Commo n

24 VA C

Auxiliary Heat

Fa n

Auxiliary Heat Relay

Thermostat

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

Commo n

24 VA C

Split

Fossil Fuel

Furnace

Common

24 VAC

Auxiliary Heat

Fan

Auxiliary Heat Relay

ES Split

Page 12

ES SPLIT INSTALLATION MANUAL

Wiring Schematics

ES Series - Dual Capacity Split Wiring Schematic - 208-230/60/1

97P621-10 10/13/05

BRISTOL DUAL CAPACITY

CCH

Blk

CCL

NOTE 1

SL1 In SL1 Out

Optional

RemoteUnit

Without

Loop Pump

1/2 HP 208-230/60/1

White

Red

Black

LoopPump(s)

Heat

Recovery

Unit

FieldDiagnositcsLED Board

Pump

CR1

CCHI

CCLO

CC-GND

C Y1 Y2

P2 Shut DownC1

SL1 In

SL1 Out

Not Used

NOTE 2

Acc Com Acc NC Acc NO

123

StatusLED PCB

SW4

Current Switch

Black

Unit Power

Fused L2

NO NC

COM

CR3

Microprocessor

Test / Norm Loop / Well

2 3

Fan / Comp

Not Used

Inputs / Norm

Outputs / Norm

24 VAC / TA32E12

208-230/60/1

Blk/ Wht

NO NC

CR4

Black

Logic Control (DC Voltage)

Red

OnSW3OnSW2

Dual/Single Capacity

Must be OFF

2 3

No RPM / RPM

Not Used Must Be ON

#1 Off, #6 On, #7 On Not Used FP thermistor (loop<15°F, well<30°F) HighPressure > 600PSI Low Pressure < 40 PSI Not Used NotUsed Not Used Not Used

Red

White

Black

Fused L2

COM

CR2

1 2 3 4 5 6 7 8

1 2

2 3

3 4 5 6 7

1 2 3

R R R R R G

ECM2 AirFlow Settings

LED Normal Display Mode

Drain Water Flow High Press Low Press Air Flow Status DHW Limit DHW off

*GreenLED not flashing

Fused L2

COM

OnSW1

1 2 3 4 5 6 7 8 9

NOT USED

11 12

Field Selection Dips -#1 On, #6 On, #7 On Not Used FP thermistor (loop<15°F,well<30°F) Lockout High Pressure > 600PSI Lockout Low Pressure < 40 PSILockout Not Used Microprocessormalfunction* Not Used Not Used

Protector

Black

L2 L1

Blk/ Wht

Crankcase Heater

F1-10A 240V

COM

Fused L1

Current Fault Status

Main

Red

240V L2

Start

Red

CCH

Violet

RUN CAP

Pink

Black

240V L1

F1-10A 240V

7 4 5

6 15 10

11 16

1 12

7 14

Diagnostic Modes

Inputs

#6 Off, #7 On

Y1 Y2

Not Used Not Used

SL1 SL2

Tan

Orange

Pink

START

CAPACITOR

Dual Fuel Wiring Diagram

Fossil Fuel

Furnace

Note: Fieldinstalled DPST dual fuel relay

(Requiredfor dual fuel installation)

Notes

1 - Connectionof remote unit thatdoes not have

a loop pump forslave operation.

2 - 24VAccessory relay (see SW2 - 3 for

description of operation)

3 - Fieldinstalled DPST dual fuel relay.

(Requiredfor dual fuelinstallation)

NOT USED

Tan

Tan Orange Orange

Brown

Brown Not Used Not Used Yellow Yellow

Blue Blue Black Black

Outputs

#6 On, #7 Off Lo Capacity Compressor Hi Capacity Compressor

FAN

Not Used Loop Pump 1 Loop Pump 2

Tan

24 VAC

Auxiliary Heat R elay

Fan

Auxiliary Heat Relay

Outputs2

#6 Off, #7 Off

Not Used Not Used Not Used Not Used Not Used Not Used Not Used

Not UsedNot UsedNot Used

CCL

1st Stage Compressor

2nd Stage Compressor

Pink

Tan

Reversing Valve

Fault Signal

24 VAC

Auxiliary

Heat Relay

nommoCnommoC

=chassis

ES Split

Shut

Down

Pink

Thermostat

Legend

Factory Low voltagewiring Factory Line voltage wiring Fieldlow voltage wiring Fieldline voltage wiring Optionalblock DC Voltage PCB traces Internal junction Quick connect terminal

Wirenut Fieldwire lug

Ground RelayContacts-

N.O., N.C.

Fuse

132

CurrentSwitch Compressor Contactor Not Used Loop pump relay 1 Loop Pump relay 2 Not Used Fuses Freeze protection sensor High pressure switch

Low pressure switch Power strip Reversing Valve coil Not Used DIP package 8 position DIP package 5 position Not Used

Thermistor Light emitting diode -Green Relaycoil Capacitor w/ bleed resistor

Switch - High pressure

Switch - Low pressure

Polarized connector

CS CC CR1 CR2CR3 CR4 F1 and F2 FP -

HP LP PS -

RV SW1 SW2 SW3 SW4 -

Blue

Page 13

ES SPLIT INSTALLATION MANUAL

Wiring Schematics (cont.)

ES Single Capacity Series - Wiring Schematic - 208-230/60/1

97P621-11 06/22/04

Power Supply

208-230/60/1

PTCR

Unit

Compresso r

Blue

Cap

Violet

Red

T2 T1

Black

Blk

L1L2

Black

Current Switch

Orange

LoopPump

1/2 HP 208-230/60/1

Heat

Recovery

Unit

Fossil Fuel Furnace Connection

Thermostat

Fossil

Fuel

Furnace

Common

24 VAC

Auxillary Heat

Fan

Auxillary Heat Relay

Note 4: Field Installed SPST daul fuel relay.

Pump

Black

1st Stage Compressor

Reversing Valve

Fault Signal

Common

24 VAC

Blk/Wht

Violet

Premie

Split

Blk/Wht

Com

CCL

Note 5

Outdoor Air

Temperature

Violet

Air handler

24 VAC

Common

Black

White

Violet

CCG

SW1

Off

1 2 3 4 5

Test / Normal Loop / Well Commercial/ Normal Not Used/ E Split Not Used/ Single Cap Split

Violet

Note4

W/W1

Orange

CPu

Thermostat

24 VAC

Common

Crankcase

Heater

R R

C C

1 6 2 7 8 3 4 9 5

Note 6

G/Y2

OYCR

LSNSESLO

Loadshed Night Setback Emergency Shutdown

NOTE 2

NOTE 1

Black Black

Blue Blue

Orange Orange

Yellow Yellow

RV FP

Lockout

Emergency Heat

Factory low voltage wiring Factory line voltage wiring Field low voltage wiring Field line voltage wiring Optional block

DC voltage PCBtraces Internaljunction

Quick connect terminal Wire nut

Field wire lug Ground

Relay ContactsN.O., N.C.

Thermistor

Relay coil

Loop Freeze Protection Switch

Legend

Switch- High pressure

Switch- Low pressure

Polarized connector

CondensateOverflow

CC -

Compressorcontactor

CO -

Condensate overflow

FP -

Freeze protection sensor

HP -

High pressure switch

LP -

Low pressure switch

RB -

Blower power relay

RV -

Reversing Valve coil

SW1 -

DIP switch #1

LPR - Single capacity loop pump relay

PTCR -

Positive Temperature Coefficient Resistor

CS -

Current Switch

1 - Requires common connection or24 VAC for

activation.

2 - Night setback used only with TA32U02

thermostat.

3 - Switch transformer switchfor 208Voperation. 4 - Field installedDPDT auxiliaryheat relay.

(Required for dual fuel installation) 5 - Field installedoutdoor thermostat(optional). 6 - This terminalis notused in the split

application.

Notes:

Page 14

ES SPLIT INSTALLATION MANUAL

DIP Switch Settings

DIP SWITCH

NUMBER

Service / Test Mode. Allows control of “normal” or “test” Test Mode Normal Timing

operational modes. Test mode accelerates most timing Operation

1 functions 16 times to allow faster troubleshooting. Test

SW1- mode allows viewing the “current” status of the fault

(Single inputs on the LED.

speed Freeze Protection Setting. Allows selection of freeze Loop Water Well Water

units only*) 2 thermistor fault sensing temperatures for well water or Freeze Protection Freeze Protection

antifreeze- protected earth loops. 15º F 30º F

3 Application Selection. Commercial w/ Night Setback Commercial, Night Normal Residential

using TA32U02 thermostat or “Normal” Residential. Setback w/TA32U02 4Split Operation N/ASplit 5Not Used N/AN/A

Service / Test Mode. Allows control of “normal” or “test” Test Mode Normal Timing

operational modes. Test mode accelerates most timing Operation

1 functions 16 times to allow faster troubleshooting. Test

mode allows viewing the “current” status of the fault

Freeze Protection Setting. Allows selection of freeze Loop Water Well Water

2 thermistor fault sensing temperatures for well water or Freeze Protection Freeze Protection

SW2- antifreeze- protected earth loops. 15º F 30º F

(Dual 3 Accessory Relay. Allows selection of the accessory Accessory tracks Accessory tracks

capacity relay to operate with either the compressor or fan. Fan Compressor

units only) 4Not Used N/AN/A

5Not Used N/AN/A

Diagnostics-Inputs. Allows viewing the inputs from the Diagnostic Normal display

6 control board such as the compressor, reversing valve, Inputs viewed viewed at LED

blower, hot water pump, and loop pump on the LED. at LED

Diagnostics-Outputs. Allows viewing the outputs from the Diagnostic Normal display

7 control board such as the compressor, reversing valve, Outputs viewed viewed at LED

blower, hot water pump, and loop pump on the LED. at LED 8 Thermostat selection 24VAC Thermostat N/A

SW3- 1 Dual Capacity Operation Dual Capacity N/A (Dual 2Not Used N/AN/A

capacity 3 Split Operation Split N/A

units only) 4Not Used N/AN/A

5Not Used N/AN/A

DESCRIPTION

inputs on the LED.

OFF

POSITION

Notes: * Although Dual Capacity units have SW1 switches, they are not used.

Page 15

ES SPLIT INSTALLATION MANUAL

Refrigeration

The ES split compressor section contains an adequate charge amount for the compressor section and matching nomi-

nal size air handler. See table below for additional charge amount needed for line set and larger or smaller air handler. Refrigeration piping on the split consists of installing a brazed copper line set between the blower coil unit and the unit’s split compressor section. To select the proper tube diameters for the installation, refer to the table below. Line sets over 50 feet long are not recommended because of oil return and pressure drop problems. The suction line must always be insulated. Handle and route the line sets carefully to avoid kinking or bending the tubes. If the line set is kinked or distorted and it cannot be formed back into its original shape, the bad portion of the pipe should be replaced. A restricted line set will affect the performance of the system.

Line Set Size and Charge Amount

25’ 50’

SIZE AIR HANDLER

ES024 FV4ANF003 (3 TON) 5/8” OD 3/8” OD 5/8” OD 3/8” OD 84 oz. 84 oz. ES030 FV4ANF003 (3 TON) 5/8” OD 3/8” OD 5/8” OD 3/8” OD 86 oz. 86 oz. ES036 FV4ANF003 (3 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 90 oz. 90 oz. ES036 FV4ANF005 (4 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 90 oz. 104 oz. ES048 FV4ANF005 (4 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 116 oz. 116 oz. ES048 FV4ANF006 (5 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 116 oz. 116 oz. ES060 FV4ANF005 (4 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 148 oz. 150 oz. ES060 FV4ANF006 (5 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 148 oz. 148 oz. ES072 FV4ANF006 (5 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 140 oz. 140 oz.

SUCTION LIQUID SUCTION LIQUID

FACTORY

CHARGE

TOTAL CHARGE NEEDED

Notes: Line set installations longer than 50’ are not recommended.

* Total charge needed is for air handler and 25 feet of line set. Add 0.5 oz. for each additional foot of line set

Connecting Air Coil

Fasten the copper line set to the blower coil unit as instructed by the coil installation instructions. Install biﬂ ow ﬁ lter/drier

in liquid line between split unit and air handler. Nitrogen should be bled through the system at 2 to 3 psi to prevent oxidation inside the refrigerant tubing. Use a low silver phos-copper braze alloy on all brazed connections.

Notes: The air coil should be thoroughly washed with a ﬁ lming agent (automatic dishwashing detergent) to help condensate drainage. Apply a 20-to -1 solution of detergent and water and spray both sides of coil. Repeat and rinse thoroughly with water.

Connecting Split Unit

Braze line set to the service valve stubs on the front of the split cabinet. Nitrogen should be bled through the system

at 2 to 3 psi to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections. ES split units are shipped with a factory charge and service valves are not to be opened until the line set has been leak tested, purged and evacuated. Schrader cores should be removed before brazing. A heat sink should be used on the service valves to prevent damage caused by excessive heat.

Page 16

ES SPLIT INSTALLATION MANUAL

Refrigeration (cont.)

Leak Testing

The refrigeration line set must be pressurized and checked for leaks

before purging and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60 to 90 PSIG. Never use oxygen or acetylene to pressure test. Use an electronic leak detector or a good quality bubble solution to detect leaks on all connections made in the ﬁ eld. Check the service valve ports and stem for leaks and all connec- tions made in the ﬁ eld. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize the system above 150 psi. Purge pressure from line set. The system is now ready for evacuating and charging.

System Evacuation

Ensure that the line set and air coil are evacuated before opening ser-

vice valves to the split unit. The line set must be evacuated to at least 200 microns to remove moisture and air that may still be in the line set and coil. Evacuate the system through both service ports to prevent false readings on the gauge because of pressure drop through service ports.

Charging the System

Total Charging Method - See table on page 15 for the factory charge and total charge of the split units. For line sets, add the speciﬁ ed refriger- ant to the factory charge for every installed foot of liquid line over 25 feet. Example: Model ES048 with 29 feet of installed liquid line (3/8-inch O.D.). The factory charge of an ES048 is 116 oz. plus 4 feet of liquid line x

0.50 oz. per ft. = 2.0 oz. + 116 oz. = 118.0 oz. (Total Charge). The ES048 is shipped from the factory with 116 oz. of refrigerant; the amount to be added is 118.0 oz. - 116 oz. = 2.0 oz. Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system. Fully open the service valves by turning counterclockwise. Start the unit in heating mode and measure superheat and subcooling values after at least ﬁ ve minutes of run time. See page 20 for examples of measuring superheat and subcooling performance values. After values are measured, compare to tables on pages 21 and 22 and go to FINAL EVALUATION. Partial Charge Method - After purging and evacuating the line set, fully open the service valves counterclockwise. Add R-410A (liquid) into the liquid line service port until the pressure in the system reaches approximately 200 PSIG. Never add liquid refrigerant into the suction side of a compressor. Start the unit and measure superheat and subcooling. Keep adding refrigerant until the unit meets the superheat and subcooling values on pages 21 and 22.

Figure 10: Typical Split System Refrigerant Line Connections

Replace caps after

adjusting service valves

Service ports for attaching

refrigerant gauges

Braze

Connections

Suction Line Liquid Line

Final Evaluation

After the initial check of superheat/subcooling values in the heating mode, shut off the unit and allow it to sit 3 to 5 min-

utes until pressures equalize. Restart the unit in the cooling mode and check the values against those in tables on pages 21 and 22. If the unit performs satisfactorily, charging is complete. If the unit does not perform to speciﬁ cations, the charge may need to be readjusted until the values are close. Adding refrigerant will increase subcooling. Recovering some of the refrigerant will decrease subcooling and increase superheat. If the superheat/subcooling values are still not close to the speciﬁ cations in tables on pages 21 and 22, analyze refrigerant circuit operation.

Page 17

Unit Startup

Before Powering Unit, Check The Following:

High voltage is correct and matches nameplate.

• Fuses, breakers and wire size correct.

• Low voltage wiring complete.

• Piping completed and water system cleaned and ﬂ ushed.

• Air is purged from closed loop system.

• Isolation valves are open, water control valves or loop pumps wired.

• Condensate line is open, trapped, and correctly pitched (blower coil unit).

• Blower rotates freely (blower coil unit).

• Blower speed is correct (blower coil unit).

• Air ﬁ lter is clean and in position (blower coil unit).

• Service/access panels are in place.

• Thermostat is in the “off” position.

• Return air temperature is between 65°F and 80°F in heating and 70° to 95°F in cooling.

• Service valves are open.

•

Startup Steps

ES SPLIT INSTALLATION MANUAL

Notes: Starting the compressor without a minimum of 1-2 hours of crankcase heat prior to initial startup may result in compressor chattering and possible damage to the compressor.

The unit is equipped with a crankcase heater which operates when the compressor is OFF. Energize crankcase heater

1. 24 hours before starting unit. To energize heater only, set indoor thermostat to OFF position and close power disconnect to unit. Turn thermostat fan to the “ON” position. Blower should operate.

2. Balance airﬂ ow at registers and adjust fan speed if necessary.

3. Set thermostat to highest temperature.

4. Set thermostat operation switch to “COOL” position. Compressor should NOT come on.

5. Slowly reduce the thermostat setting until both the compressor and water control valve or loop pumps are activated.

6. Verify that the compressor is on and that the water ﬂ ow rate is correct by measuring pressure drop through the heat exchanger (using the P/T plugs and comparing to table on page 23). Check the temperature of both the supply and discharge water (see tables on pages 21 - 22).

7. If temperature rise is within range of tables on page 21-22 proceed to step 9. Otherwise check the cooling refrigerant

8. pressures and compare to tables on pages 21-22. Check for air temperature drop of 16°F to 25°F across the air coil.

9. Turn thermostat switch to “OFF” position. A hissing should indicate proper functioning of reversing valve.

10. Leave unit “OFF” for approximately ﬁ ve (5) minutes to allow pressure to equalize.

11. Turn thermostat to lowest setting.

12. Set thermostat switch to “Heat” position.

13. Turn thermostat operation to higher temperatures until both compressor and water control valve are activated.

14. If temperature drop through the coaxial heat exchanger is within range of the tables on pages 21-22, proceed to step

15.

16. Otherwise check the heating refrigerant pressures and compare to tables on pages 21-22. Check for air temperature rise of 20°F to 35°F across the air coil.

16. Turn the thermostat to a higher setting to make certain that the ﬁ rst stage of auxiliary heat is activated and (if installed

17. and mode switch set correctly) with the appropriate temperature rise across the heater. Conﬁ rm that all stages of the auxiliary heat come on when the thermostat is in “EMERGENCY HEAT” mode.

18. Check for vibrations, noise and water leaks.

19. Set system to maintain desired comfort level.

20. Instruct the owner/operator on correct thermostat and system operation.

21.

Page 18

ES SPLIT INSTALLATION MANUAL

Modes of Operation

Heating Operation

Notes: At ﬁ rst power up, a four-minute time delay is employed before the compressor is energized. Heat, 1st Stage (Y1)

The compressor and loop pumps are energized 10 seconds after the Y1 input.

Heat, 2nd Stage (Y1, W) Single-Speed Units

The auxiliary heat relay will disconnect the compressor, and the auxiliary heat will operate normally.

Heat, 2nd Stage (Y1, Y2) Dual Capacity Units

The 1st stage compressor and loop pumps are de-energized 10 seconds after the Y2 input. The 2nd stage compressor

and loop pumps are energized 1 minute after the 1st stage compressor is de-energized.

Heat, 3rd Stage (Y1, Y2, W) Dual Capacity Units

The auxiliary heat relay will disconnect the compressor, and the auxiliary heat will operate normally.

Cooling Operation

In all cooling operations, the reversing valve directly tracks the

reversing valve will be energized.

Cool, 1st Stage (Y1, O)

The compressor and loop pumps are energized 10 seconds after the Y1 input.

Cool, 2nd Stage (Y1, Y2, O) Dual Capacity Units

The 1st stage compressor and loop pumps are de-energized 10 seconds after the Y2 input. The 2nd stage compressor

and loop pumps are energized 1 minute after the 1st stage compressor is de-energized.

“O”

input. Thus, anytime the

“O”

input is present, the

Fan Only Operation

The Fan Only mode is controlled directly from the unit thermostat to the unit air handler. No input is given to the micro-

processor to operate the fan function.

Page 19

ES SPLIT INSTALLATION MANUAL

Modes of Operation (cont.)

Lockout Conditions

During lockout mode, the appropriate thermostat lockout LEDs (if available) will illuminate. The compressor and loop

pumps are de-energized and if the thermostat calls for third stage heating, emergency heat operation will occur.

Lockout modes of any kind can be reset at the thermostat after a 5-second waiting period, which restores normal

operation.

High Pressure

This lockout mode occurs immediately when the normally closed safety switch is momentarily opened.

Low Pressure

This lockout mode occurs when the normally closed switch is opened for 30 continuous seconds.

Freeze Protection (Water Flow)

This lockout mode occurs when the freeze protection thermistor temperature (located between the TXV and coax) is at

or below the selected freeze protection point (well 30°F or loop 15°F) for 30 continuous seconds.

The unit also contains a secondary freeze protection sensor located on the entering water line of the unit. If the loop reaches a temperature of 20°F the secondary freeze protection sensor will cycle the loop pumps "on" until the loop temperature rises to or above 25°F.

Single Speed Operation Logic

OPERATION

Compressor On Off On

Fan On On On

Loop Pump On Off On

Reversing Valve Off Off On

T-Stat Signal Y1 W Y1, O

HEATING COOLING

STG1 STG2 STG1

Dual Capacity Operation Logic

OPERATION

Compressor-Low On Off Off On Off

Compressor-Hi Off On Off Off On

Fan On On On On On

Loop Pump On On Off On On

Reversing Valve Off Off Off On On

T-Stat Signal Y1 Y1, Y2 W Y1, O Y1, Y2, O

STG1 STG2 STG3 STG1 STG2*

HEATING COOLING

Page 20

ES SPLIT INSTALLATION MANUAL

Checking Superheat and Subcooling

Determining Superheat

Measure the temperature of the suction line at the point where the expansion valve bulb is clamped.

1. Determine the suction pressure in the suction line by attac hing refrigeration gauges to the schrader connection on

2. the suction side of the compressor. Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature

3. Conversion Chart on page 26. Subtract the temperature obtained in Step 3 from Step 1. The difference is the amount of superheat for the unit. Refer

4. to tables on pages 21-22 for superheat ranges at speciﬁ c entering water conditions. The ﬁ gure below illustrates a typical example of how to measure superheat on the unit using R-410A. The temperature of the suction line at the sensing bulb is 50°F. The suction pressure at the compressor is 114 PSIG which is equivalent to 38°F saturation temperature (R-410A Pressure/Temeprature Conversion Chart, page 26).

50°F - 38°F = 12°F Superheat

Determining Subcooling

Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This

1. location will be adequate for measurement in both modes unless a signiﬁ cant temperature drop in the liquid line is anticipated. Measure the liquid line pressure by attaching refrigerant gauges to the schrader connection on the liquid line service

2. valve. Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature

3. Conversion Chart on page 26. Subtract the temperature in Step 1 from the temperature in Step 3. The difference will be the subcooling value for

4. that unit. Refer to tables on pages 21-22 for values at speciﬁ c entering water temperatures. The ﬁ gures below illustrate a typical example of measuring refrigeration subc o oling using R-410A. The temperature of the liquid line after leaving the condensing coil is 90°. The liquid line pressure at the service valve is 356 PSIG, which is equivalent to 108°F.

108°F - 90°F = 18°F Subcooling

Figure 11: Subcooling Check

Suction Line

356 psig (see chart) = 108oF Liquid Line = -90

Subcooling = 18oF

356 psig =108°F

Temperature of Liquid Line Outside the ES Cabinet. Use in Both Modes.

T emperatureof Liquid Line

= 90°F

Liquid Line

Figure 12: Superheat Check

114psig=38°F

Suction Line = 50oF 114psig (see chart) = -38

Superheating = 12

Temperature at Suction of Compressor

=50°F

Expansion ValveBulb

Page 21

ES SPLIT INSTALLATION MANUAL

Checking Superheat and Subcooling (cont.)

Superheat, Subcooling, Pressures and Water/Air Temperatures

First Stage Operation

ENTERING

WATER

TEMP °F

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

SUCTION

PRESSURE

PSIG

144-155

142-153

145-157 145-155

155-165 153-163

DISCHARGE

PRESSURE

PSIG

195-203 180-186

257-264 242-249

330-340

315-325

COOLING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

10-14 10-14

8-12 8-12

WATER

TEMP

RISE °F

21-25 10-15

20-24

9-13

18-22

8-12

AIR TEMP

DROP °F

18-22 18-22

17-21 17-21

16-20 16-20

ENTERING

WATER

TEMP °F

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

SUCTION

PRESSURE

76-84 80-88

112-120 116-124

141-151

145-155

Note: * Deduct 25# psig for ES036.

Second Stage Operation

ENTERING

WATER

TEMP °F

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

SUCTION

PRESSURE

126-132 124-130

132-139 131-137

139-145

137-143

PSIG

DISCHARGE*

PRESSURE

PSIG

250-265 255-270

290-310 295-315

300-325 305-330

DISCHARGE

PRESSURE

PSIG

223-237 198-212

285-295 255-275

365-385 335-355

HEATING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

6-10 6-10

8-12 8-12

10-14 10-14

COOLING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

12-16 12-16

10-14 10-14

9-13 9-13

2-8 2-8

2-10 2-10

4-12 4-12

10-16 10-16

WATER

TEMP

DROP °F

4-6 2-4

6-8 4-6

7-9 5-7

WATER

TEMP

RISE °F

20-24

10-14

19-23

9-13

18-22

8-12

AIR TEMP

RISE °F

12-16 14-18

18-22 20-24

26-30 28-32

Rev. 08/08/05

AIR TEMP

DROP °F

18-22 18-22

17-21 17-21

16-20 16-20

ENTERING

WATER

TEMP °F

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

SUCTION

PRESSURE

PSIG

66-74 70-78

96-106

100-110 126-141

130-145

Note: * Deduct 10# psig for ES036.

DISCHARGE*

PRESSURE

PSIG

280-310 285-315

309-335

314-339 335-375

340-380

HEATING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

6-10 6-10

10-14 10-14

12-16 12-16

10-16 10-16

14-18 14-18

18-24 18-24

WATER

TEMP

DROP °F

5-7 3-5

6-8 4-6

9-11

7-9

AIR TEMP

RISE °F

15-21 17-23

22-28 24-30

30-36 32-38

Rev. 08/08/05

Page 22

ES SPLIT INSTALLATION MANUAL

Checking Superheat and Subcooling (cont.)

Superheat, Subcooling, Pressures and Water/Air Temperatures (cont.)

Single Speed Units

ENTERING

WATER

TEMP °F

30 50 70 90

ENTERING

WATER

TEMP °F

30 50 70 90

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

1.5

3.0

WATER

FLOW

GPM/TON

1.5

3.0

1.5

3.0

1.5

3.0

1.5

3.0

SUCTION

PRESSURE

PSIG

127-133 125-130

136-144 134-142

141-149 139-147

SUCTION

PRESSURE

PSIG

74-77

78-84

95-114

109-118 136-146

140-150

DISCHARGE

PRESSURE

PSIG

220-235 190-210

280-300 250-270

360-380 330-350

DISCHARGE

PRESSURE

PSIG

285-310 290-315

315-345 320-350

355-395 360-390

COOLING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

13-19 13-19

11-15 11-15

10-14 10-14

HEATING - NO DESUPERHEATER

SUPERHEAT SUBCOOLING

8-12 8-12

9-13 9-13

10-14 10-14

10-16 10-16

8-14 8-14

3-9 3-9

5-11 5-11

6-12 6-12

WATER

TEMP

RISE °F

19-23

9-12

19-23

9-12

18-22

9-12

WATER

TEMP

DROP °F

5-7 3-5

7-9 5-7

9-11

7-9

AIR TEMP

DROP °F

18-22 18-22

17-21 17-21

16-20 16-20

AIR TEMP

RISE °F

12-18

14-20 18-24

20-26 24-30

26-32

Page 23

ES SPLIT INSTALLATION MANUAL

Pressure Drop & Recommended Flow Rates

UNIT

ES024

ES030

ES036

ES048

ES060

ES072

(PSI CHANGE THROUGH HEAT EXCHANGER AT EWT ºF)

30° 50° 70° 90° 110° GPM

1.0 1.0 0.8 0.8 0.7 3.0

1.9 1.8 1.6 1.5 1.3 4.5

2.9 2.7 2.6 2.5 2.4 6.0

1.7 1.6 1.5 1.4 1.3 4.0

2.9 2.7 2.6 2.5 2.4 6.0

4.7 4.4 4.2 4.0 3.8 8.0

0.8 0.7 0.7 0.7 0.6 3.0

1.2 1.2 1.1 1.0 1.0 4.0

1.8 1.7 1.5 1.5 1.4 5.0

3.1 2.9 2.8 2.7 2.5 7.0

5.0 4.7 4.5 4.3 4.1 9.0

1.4 1.3 1.2 1.2 1.1 3.0

2.1 2.0 2.0 1.9 1.8 6.0

3.7 3.5 3.3 3.3 3.0 9.0

5.9 5.6 5.4 5.2 4.8 12.0

1.1 1.0 0.9 0.9 0.9 5.0

2.1 2.0 2.0 1.9 1.8 8.0

3.1 2.9 2.8 2.7 2.6 11.0

4.8 4.6 4.4 4.2 3.9 14.0

1.5 1.4 1.3 1.2 1.1 7.0

2.7 2.6 2.4 2.3 2.2 10.0

4.3 4.1 3.8 3.6 3.4 13.0

6.1 5.8 5.4 5.1 4.8 16.0

FLOW RATE (GPM)

CLOSED LOOP WELL WATER

4.5 - 6 3 - 4

6 - 8 4 - 5

4 - 5 Lo cap 3 - 4 Lo cap

7 - 9 Hi cap 6 - 7 Hi cap

6 - 9 Lo cap 3 - 4 Lo cap

9 - 12 Hi cap 6 - 7 Hi cap

8 - 11 Lo cap 5 - 6 Lo cap

11 - 14 Hi cap 8 - 9 Hi cap

10 - 13 Lo cap 7 - 8 Lo cap

13 - 16 Hi cap 10 - 11 Hi cap

Page 24

ES SPLIT INSTALLATION MANUAL

Service

Should a problem develop, refer to the following information for possible causes and corrective steps:

If neither fan nor compressor run:

The fuse may be blown or the circuit breaker may be open. Check electrical circuits and motor windings for shorts or

1. grounds. Investigate for possible over loading. Replace fuse or reset circuit breakers after fault is corrected. Supply voltage may be too low. Check it with a VOM.

2. Control system may be faulty. Check thermostat for correct wiring and check 24-volt transformer.

3. Wires may be loose or broken. Replace or tighten.

If fan operates and the compressor doesn’t:

The low pressure switch may have tripped due to:

1. a. fouled or plugged coaxial heat exchanger (heating). b. lack of or no water ﬂ ow (heating). c. water too cold (heating). d. not enough air over the air coil due to dirty ﬁ lters (cooling). e. air coil or fan motor failure (cooling). f. lack of refrigernat (heating or cooling). The high pressure may have tripped due to:

2. a. fouled or plugged coaxial heat exchanger (cooling). b. lack of or no water ﬂ ow (cooling). c. water too warm (cooling). d. not enough airﬂ ow over the air coil due to dirty ﬁ lters (heating). e. air coil or fan motor failure (heating). Check capacitor.

3. Wires may be loose or broken. Replace or tighten.

4. The compressor overload protection may be open. If the compressor dome is extremely hot, the overload will not reset

5. until it has cooled down. If the overload does not reset when cool, it may be defective. Replace the compressor. The internal winding of the compressor motor may be grounded to the compressor shell. This should cause breaker to

6. trip when voltage is applied. If so, replace the compressor. The compressor winding may be open. Check continuity with ohmmeter. If the winding is open, replace the compres-

7. sor. Make sure compressor is cool before checking windings. Check thermostat setting, calibration and wiring.

If sufﬁ cient cooling or heating is not obtained:

Check thermostat for improper location. Make sure hole in wall behind thermostat is sealed properly.

1. Check and clean the ﬁ lter. Airﬂ ow may be insufﬁ cient.

2. Check for restriction in water ﬂ ow.

3. Check superheat and subcooling for possible refrigerant problem. Refer to pages 18-19 for proper numbers.

4. The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not cool, check the reversing

5. valve coil.

If the unit operation is noisy:

Check for fan wheel hitting the housing. Adjust for clearance.

1. Check for bent fan wheel. Replace if damaged.

2. Check for loose fan wheel on the shaft. Tighten it.

3. Check compressor mounting bolts. Make sure compressor is ﬂ oating free on its isolator mounts.

4. Check for tubing touching the compressor or other surfaces. Readjust it by bending slightly.

5. Check screws on all panels.

6. Check for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. Replace the

7. component. Check for proper installation of vibration absorbing material under the unit. Unit must be fully supported, not just on

8. corners. Check for abnormally high discharge pressures.

Page 25

Service ( con t.)

Refrigeration Schematic and Troubleshooting Form

Measure suction temperature

here at TXV bulb in heating modes. Measure suction temperature here at TXV bulb in cooling modes.

Line set length

ES SPLIT INSTALLATION MANUAL

Suct PSI____ Suct sat temp____ Suct temp____ Superheat____

Suctio

Air

Coi

Clg TXV

COOLING TXV -ACTIVE RIGHT TO LEFT

Bi-flow

filter/drier

Measure liquid line temperature and pressure here in both heating and cooling modes

Htg TXV

COAX

Desuperheater

Discharge PSI____ Disch. sat temp____ Liquid temp____ Subcooling____

HEATING TXV -ACTIVE LEFT TO RIGHT

Com

Discharge

Page 26

ES SPLIT INSTALLATION MANUAL

Pressure/Temperature Coversion Chart for R-410A

PRESSURE

(PSIG)

60 8.5 180 63.5 300 96.3 420 120.6 540 140.0 62 9.9 182 64.2 302 9 6. 8 422 120.9 542 140.3 64 11.2 184 64.8 304 97.2 424 121.3 544 140.6 66 12.5 186 65.5 306 97.7 426 121.6 546 140.9 68 13.8 188 66.1 308 98.1 428 122.0 548 141.2 70 15.1 190 66.8 310 98.6 430 122.3 550 141.4 72 16.3 192 67.4 312 99.0 432 122.7 552 141.7 74 17.5 194 68.0 314 99.5 434 123.0 554 142.0 76 18.7 196 68.7 316 99.9 436 123.4 556 142.3 78 19.8 198 69.3 318 100.4 438 123.7 558 142.6 80 21.0 200 69.9 320 100.8 440 124.1 5 6 0 142.9 82 22.1 202 70.5 322 101.2 442 124.4 562 143.2 84 23.2 204 71.1 324 101.7 444 124.8 564 143.5 86 24.3 206 71.7 326 102.1 446 125.1 566 143.7 88 25.4 208 72.3 328 102.5 448 125.4 568 144.0 90 26.5 210 72.9 330 103.0 450 125.8 570 144.3 92 27.5 212 73.5 332 103.4 452 126.1 572 144.6 94 28.6 214 74.1 334 103.8 454 126.5 574 144.9 96 29.6 216 74.7 336 104.2 456 126.8 576 145.1

98 30.6 218 75.3 338 104.7 458 127.1 578 145.4 100 31.6 220 75.8 340 105.1 460 127.5 580 145.7 102 32.6 222 76.4 342 105.5 462 127.8 582 146.0 104 33.5 224 77.0 344 105.9 464 128.1 584 146.2 106 34.5 226 77.5 3 46 106.3 466 128.5 586 146.5 108 35.4 228 78.1 348 106.7 468 128.8 588 146.8 110 36.4 230 78.7 350 107.2 470 129.1 590 147.1 112 37.3 232 79.2 352 107.6 472 129.4 592 147.3 114 38.2 234 79.8 354 108.0 474 129.8 594 147.6 116 39.1 23 6 80.3 356 108.4 476 130.1 596 147.9 118 40.0 238 80.9 358 108.8 478 130.4 598 148.2 120 40.9 240 81.4 360 109.2 480 130.7 600 148.4 122 41.7 242 81.9 362 109.6 482 131.1 602 148.7 124 42.6 244 82.5 3 64 110.0 484 131.4 604 149.0 126 43.4 246 83.0 366 110.4 486 131.7 606 149.2 128 44.3 248 83.5 368 110.8 488 132.0 130 45.1 250 84.1 370 111.2 490 132.3 132 45.9 252 84.6 372 111.6 492 132.7 134 46.7 254 85.1 374 112.0 494 133.0 136 47.5 256 85.6 376 112.3 496 133.3 138 48.3 258 86.1 378 112.7 498 133.6 140 49.1 260 86.6 380 113.1 500 133.9 142 49.9 262 87. 1 382 113.5 502 134.2 144 50.7 264 87.7 384 113.9 504 134.5 146 51.5 266 88.2 386 114.3 506 134.9 148 52.2 268 88.7 388 114.7 508 135.2 150 53.0 270 89.2 390 115.0 510 135.5 152 53.7 272 89.6 392 115.4 512 135.8 154 54.5 274 90.1 394 115.8 514 136.1 156 55.2 276 90.6 396 116.2 516 136.4 158 55.9 278 91.1 398 116.5 518 136.7 160 56.6 280 91.6 400 116.9 520 137.0 162 57.4 282 92.1 402 117.3 522 137.3 164 58.1 284 92.6 404 117.6 524 137.6 166 58.8 286 93.0 406 118.0 52 6 137.9 168 59.5 288 93.5 408 118.4 528 138.2 170 60.2 290 94.0 410 118.7 530 138.5 172 60.8 292 94.5 412 119.1 532 138.8 174 61.5 294 94.9 414 119.5 534 139.1 176 62.2 296 95.4 416 119.8 536 139.4 178 62.9 298 95.8 418 120.2 538 139.7

TEMP°FPRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

TEMP °FPRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

608 149.5

TEMP

°F

Page 27

ES SPLIT INSTALLATION MANUAL

Preventive Maintenance

Water Coil Maintenace

Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to

1. inﬁ ltrate the water line. Lines should always be airtight. Keep the system under pressure at all times. It is recommended in open loop systems that a water control valve be

2. placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure or airvents may draw air into the system. If the installation is performed in an area with a known high mineral content in the water, it is best to establish a periodic

3. maintenance schedule with the owner when the coil can be checked on a regular basis. (the manufacturer recommends cleaning once a year in poor water areas). Should coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water-to-refrigerant heat exchanger. Generally, the more water ﬂ owing through the unit, the less chance there is for scaling. Low water ﬂ ow rates produce higher tempera- tures through the coil and increase the possibility of scale buildup during cooling. To avoid excessive pressure drop and the possibility of copper erosion, do not exceed GPM ﬂ ow rate as shown on the speciﬁ cation sheets for each unit.

Filter/Coil Maintenance

Filters must be clean to obtain maximum performance. They should be inspected every two to three months under normal operating conditions and be replaced when necessary. Units should never be operated without a ﬁ lter. In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty ﬁ lters. Inspect twice a year to avoid the possibility of overﬂ ow. The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must be taken not to damage the aluminum ﬁ ns while cleaning.

Replacement Procedures

Obtaining Parts

When ordering replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

In-Warranty Material Return

Material may not be returned except by permission of authorized service personnel. Contact your local distributor for warranty return authorization and assistance.

Page 28

Manufactured by WFI 9000 Conservation Way Fort Wayne, IN 46809

Product: ES Split Type: Geothermal/Water Source Heat Pumps Size: 2 thru 6 Ton

Document Type: Installation Manual Part Number: IM1460 Release Date: 11/06 Supercedes: IM1460 (10/05)