G Series Geothermal Indoor Split Heat Pump R-410A Refrigerant 2-6 Tons Single Speed 2-6 Tons Dual Capacity

Transcription

1 Series eothermal Indoor Split Heat Pump -40A efrigerant - 6 Tons Single Speed - 6 Tons Dual apacity Installation Information Water Piping onnections Hot Water enerator onnections Electrical Startup Procedures Series Indoor Split Installation Manual Troubleshooting Preventive Maintenance IM003S 03/

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3 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Table of ontents Model Nomenclature... 4 Physical Data... 4 Dimensional Data... 5 eneral Installation Information Physical Data - Air Handler... 0 Line Set Sizes... 0 Open Loop Well Water Systems losed Loop round Source Systems Hot Water enerator onnections Electrical Data Thermostat Wiring... 6 Wiring Schematics Microprocessor ontrol Operation Logic Data... DIP Switch Settings... 3 efrigeration Operating Parameters Pressure Drop Unit Startup and Troubleshooting Preventive Maintenance eplacement Procedures

4 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Model Nomenclature - S 3 Z S A B 3-4 SS 5 A Model Type S = Single Speed T = Two Stage abinet onfiguration Z = Split Unit apacity MBTUH ontrol Option S = Standard ontrols Voltage = 08-30/60/ Vintage A = urrent Non-standard Options SS = Standard Sound Kit B = Blanket oax Options = opper N = upronickel abinet Option A = White Hot Water Options 0 = No Hot Water eneration, No eostart = Hot Water eneration with factory installed pump, No eostart 3 = No Hot Water eneration, eostart 4 = Hot Water eneration with factory installed pump, eostart Physical Data Model ompressor ( each) Single Speed Scroll Dual apacity Scroll Factory harge 40a, oz [kg] 56 [.59] 56 [.59] 56 [.59] oax and Water Piping Water onnections Size - Swivel- in [mm] [5.4] [5.4] HW onnection Size - Sweat (I.D.) - in [mm] / [.7] / [.7] Brass Service Valve - Liquid Line - in [mm] Brass Service Valve - Suction Line - in [mm] oax & Piping Water Volume - gal [l] Weight - Operating, lb [kg] Weight - Packaged, lb [kg] 0.7 [.6] 64 [74] 84 [83] 3/8 [9.55] 5/8 [5.875].0 [3.8] 74 [79] 94 [88].3 [4.9] [96] 3 [05] 74 [.].3 [4.9] 3 [97] 33 [06] 3/4 [9.05] 90 [.55].6 [6.] 46 [] 66 [] 9 [.6] 08 [3.06] / [.7] 7/8 [.5].6 [6.] 5 [4] 7 [3] NOTES: All units have TXV expansion devices, and / in. [. mm] and 3/4 in. [9. mm] electrical knockouts. Brass service valves are sweat type valves..3 [8.7] 9 [3] 3 [4] 5 [.47] 5/8 [5.875] 0.7 [.6] 89 [86] 09 [95] 56 [.59] 3/8 [9.55] 3/4 [9.05].3 [4.9] 36 [07] 56 [6] 90 [.55].6 [6.] 50 [3] 70 [] 9 [.6] 04 [.95] / [.7] 7/8 [.5].6 [6.] 7 [3] 9 [3].3 [8.7] 90 [3] 30 [4] /9/ 4

5 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Dimensional Data B A M L K E F H J Water Service Valve HW Low External Line Height Width Depth Water In HW In Models Out Liquid as Out Voltage Pump Voltage A B D E F H J K L M in cm in cm Dimensions are in inches. 7/7/0 efrigerant line connections extend in. [50.8 mm] beyond the front of the cabinet. Water lines extend. in. [30.5 mm] beyond the front of the cabinet. D 5

6 SZ/TZ INDOO SPLIT INSTALLATION MANUAL eneral Installation Information Safety onsiderations WANIN: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. 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 qualified service 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 filters. 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, such as the following safety measures: Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations. Have a fire extinguisher available for all brazing operations. Moving and Storage Move units in the normal up orientation. Units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging 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. Unit Location Locate the unit in an indoor area that allows for easy removal of the access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and refrigerant line connections. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. are should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components. Air oil Location efer to the air handler manufacturer s instructions for the blower coil unit for details on installing the air handling portion of the system. ondensate Drain Follow the blower coil manufacturer s instructions. Duct System All blower coil units/air coils must be installed as specified by the manufacturer s installation instructions; however, the following recommendations should be considered to minimize noise and service problems. An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grill be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil. In applications using galvanized metal ductwork, a flexible 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 -inch thick glass fiber 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 -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 replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repairs made accordingly. The duct systems and diffusers should be sized to handle the design airflow quietly. If air noise or excessive airflow is a problem, the blower speed can be changed to a lower speed to reduce airflow. This will reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil. Airflow must still meet minimum requirements. Equipment Selection The following guidelines should be used when mating a SZ/TZ Series Split to an air handler/coil. Select -40A components only. Match the air handler to the air handler coil data table. Indoor matching adjustable TXV should be used with any air handler/coil. Fixed orifice or cap tube systems should not be used. 6

7 SZ/TZ INDOO SPLIT INSTALLATION MANUAL eneral Installation Information cont. Utilizing Existing oil or Air Handler It is recommended that a new -40A air handler be installed with a SZ/TZ Series Split considering the long term benefits of reliability, warranty, etc. versus the short term installation cost savings. However, the existing air handler may be retained provided the following: oil currently is -40A rated oil uses a TXV. No capillary or fixed orifice systems should be used A life expectancy of more than 7 years remaining for the air handler and components Flush air coil and line set When utilizing the existing air coil or line set, only flushing compounds that vaporize should be used; which means they are packaged in a pressurized disposable cylinder. It is preferable to use a flushing agent that removes oil, water, and acid, plus, is biodegradeable and non-toxic. The flushing agent should be safe to use with both HF and HF refrigerants. Once a flushing agent has been selected, follow the instructions provided with the product. The first step should be purging the lines or air coil with nitrogen. Purging with nitrogen first will remove some of the particulate and residual oil which will allow the flushing agent to work better. Never blow the flushing agent through a compressor, filter drier, or TXV as it will cause the components to fail. When flushing is complete and the final system is assembled, an acid check should be preformed on the system. Acid test kits are available from most HVA distributors. Air Handler Installation Air handlers used with dual capacity units must be capable of operating with a minimum of blower speeds. efer to the manufacturer s instructions for the blower coil unit for details on installing the air handling portion of the system. All blower coil units/air coils must be installed as specified by the manufacturer s installations instructions. However, the following recommendations should be considered to minimize noise and service problems. An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grille be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil. Ensure that the line set size is appropriate to the capacity of the unit (refer to Line Set Sizes table). Line sets should be routed as directly as possible, avoiding unnecessary bends or turns. All wall penetrations should be sealed properly. Line set should not come into direct contact with water pipes, floor joists, wall studs, duct work, floors, walls and brick. Line set should not be suspended from joists or studs with a rigid wire or strap which comes into direct contact with 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 refrigerant line. Notes: Improper installation of equipment may result in undesirable noise levels in the living areas. onnection to Air oil Figures and illustrate typical SZ/TZ Series Split installations. eference the Line Set Sizes table for typical line set diameters and maximum length. Line sets over 60 feet are not recommended. Longer line sets will significantly reduce capacity and efficiency of the system as well as adversely effect the system reliability due to poor oil return. If the line set is kinked or deformed and cannot be reformed, the bad section of pipe should be replaced. A restricted line set will affect unit performance. As in all -40A equipment, a reversible liquid line filter drier is required to ensure all moisture is removed from the system. This drier should be replaced whenever breaking into the system for service. All line sets should be insulated with a minimum of / closed cell insulation. All exterior insulation should be painted with UV resistant paint or covering to ensure long insulation life. 7

8 SZ/TZ INDOO SPLIT INSTALLATION MANUAL eneral Installation Information cont. Figure : Typical Split System Application with emote Blower oil Thermostat Wire From Air Handler Supply Duct Wire To Thermostat Disconnect eturn Duct Insulated Suction Line Lineset To Air Handler DHW Out DHW In emote Air Handler (Maximum ecommended Distance is 60' Between Units) To Drain ondensate Drain (must be trapped) P/T Plugs Water Out Water In Vibration Absorbing Pad or Air Pad Dual Fuel Systems SZ/TZ Series units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the SZ/TZ Series 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 SZ/TZ Series heat pump provides air conditioning through the furnace s refrigerant coils. efer to the furnace manufacturer s installation manual for the furnace installation, wiring and coil insertion. A dual fuel thermostat, a field-installed DPST relay or dual capacity auxiliary heat relay is required. See Figure for typical Dual Fuel application. In add-on SZ/TZ Series Split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the SZ/TZ Series Split will trip out on high pressure. A dual fuel thermostat can remove the Y and Y calls when a W call is energized to allow gas furnace backup on a SZ/TZ Series Split application. efer to thermostat wiring diagram for details. Figure : Typical Split System Heat Pump oil Add-On Fossil Fuel Furnace Maximum ecommended Distance is 60' Between Units "A" or Slab oil Supply Duct Air Temperature Limit Switch - prevents compressor operation when entering air is greater than 90 F. Disconnect Insulated Suction Line Lineset To Air Handler Thermostat Wire From Furnace Wire To Thermostat ondensate Drain (must be trapped) DHW Out DHW In Water Out Water In P/T Plugs Vibration Absorbing Pad or Air Pad eturn Duct 8 Up-Flow Fossil Fuel Furnace

9 SZ/TZ INDOO SPLIT INSTALLATION MANUAL eneral Installation Information cont. Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on residential units are swivel piping fittings (see Figure 3) that accept -inch male pipe threads (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any -inch threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. heck to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in K4L connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread the -inch MPT fitting (SH80 PV or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability. Never use flexible hoses smaller than -inch inside diameter on the unit. Limit hose length to 0 feet per connection. heck carefully for water leaks. Figure 3: Swivel onnections (esidential Units) Stainless Steel Snap ing asket Material Locking ing asket Support Sleeve 9

10 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Physical Data - Air Handler Air Handler Model Number (efrigerant) AH0 AH06 AH030 AH036 AH04 AH048 AH060 Air oil Total Face Area, ft [m] 5.83 [0.54] Tube outside diameter - in. [mm] 3/8 [9.5] Evaporator oil Number of rows 3 Fins per inch Suction line connection - in. [mm] sweat 5/8 [5.87] 7/8 [.] Liquid line connection - in. [mm] sweat 3/8 [9.5] efrigerant -40a Nominal cooling capacity - tons [kw].8 [6.44]. [7.59].5 [8.79] 3 [0.55] 3.5 [.30] 4 [4.06] 5 [7.58] ondensate drain connection - (FPT) in. [mm] 3/4 [9.05] Blower Wheel Size (Dia x W), in. [mm] x 0 [79 x 54] Blower motor type/speeds EM variable speed Blower motor output - hp [W] / [373] [746] Filter Standard - [5mm] MEV3 disposable, in. [mm] 0 x 4 [508 x 635] Electrical characteristics (60hz) 08/30 - ph Shipping weight - lbs. [kg] 05 0 Operating weight - lbs. [kg] 95 [88.45] 00 [90.7] Line Set Sizes Unit Size NOTES: Air Handler 0 feet 40 feet 60 feet Suction Liquid Suction Liquid Suction Liquid Factory harge (oz.) * The "harge Amount with AH Air Handler" column is based on the charge amount for a AH Air Handler+ompressor Section/Split. Additional charge will have to be added accordingly for line set length. After harge is added adjustments can be made to get appropriate subcooling and superheat. Additional charge for -40A is 0.50 oz. per ft. for 3/8 in. and.0 oz. per ft. for / in. tube. Longer line sets will reduce capacity and efficiency of the system as well as adversely effect system reliability due to poor oil return. *harge Amount with AH Air Handler (oz.) 0 AH0 5/8 OD 3/8 OD 5/8 OD 3/8 OD 3/4 OD 3/8 OD AH030 5/8 OD 3/8 OD 3/4 OD 3/8 OD 3/4 OD 3/8 OD AH036 5/8 OD 3/8 OD 3/4 OD 3/8 OD 3/4 OD / OD AH04 3/4 OD 3/8 OD 3/4 OD 3/8 OD 7/8 OD / OD AH048 3/4 OD 3/8 OD 7/8 OD 3/8 OD 7/8 OD / OD AH060 7/8 OD / OD 7/8 OD / OD -/8 OD / OD AH060 7/8 OD / OD 7/8 OD / OD -/8 OD / OD AH06 5/8 OD 3/8 OD 3/4 OD 3/8 OD 3/4 OD / OD AH036 3/4 OD 3/8 OD 3/4 OD 3/8 OD 3/4 OD / OD AH048 3/4 OD 3/8 OD 7/8 OD 3/8 OD 7/8 OD / OD AH060 7/8 OD / OD 7/8 OD / OD -/8 OD / OD 9 07 AH060 7/8 OD / OD 7/8 OD / OD -/8 OD / OD /6/0 0

11 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Open Loop Well Water Systems Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed bladder type expansion tank to minimize mineral formation due to air exposure. Ensure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in the unit capacity data tables in the specification catalog. Usually.5- PM of flow per ton of cooling capacity is recommended in open loop applications. In dual capacity units, stage is 70% of the total tonnage. Therefore, due to only minor differences in flow rate from low to high, only one solenoid valve should be used. The valve should be sized for full flow. 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 field, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal. onsult your local building and zoning departments to ensure compliance in your area. Notes: For open loop/groundwater systems or sytems that do not contain an antifreeze solution, set SW-Switch # to the WELL position (efer to the DIP Switch Settings table.) Slow opening/closing solenoid valves (type VM) are recommended to eliminate water hammer. Figure 4: Typical Split System Application Open Loop - Well Water Thermostat Wire From Air Handler Disconnect Vibration Absorbing Pad or Air Pad Lineset To Air Handler Boiler Drains for System Flushing P/T Plugs ubber Bladder Pressure Tank Water Solenoid ontrol Valve Flow egulator Shut-Off Valves Water Out Water In From W ell Figure 5: Open Loop Solenoid Valve onnection Option Typical quick operating external 4V water solenoid valve (type PPV00 or BPV00) wiring. Figure 9b: Open Loop Solenoid Valve onnection Option Typical slow operating external 4V water solenoid valve (type VM) wiring. P Violet() VM valve Acc om Blk() -ND SV Solenoid Valve Acc N Acc NO 3 P3 omfort Alert Y Y Violet(3) Wht(4) SV HI High Speed Logic Board

12 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Open Loop Well Water Systems cont. Solenoid Wiring Water control valves draw their power directly from a unit s 4V transformer and can overload and possibly burn out the transformer. heck total VA draw of the water valve and ensure that it is under 5 VA. Water Quality In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Failure to adhere to the guidelines in the water quality table could result in loss of warranty. Material opper 90/0 upro-nickel 36 Stainless Steel ph Acidity/Alkalinity Scaling alcium and Magnesium arbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm Hydrogen Sulfide Less than.5 ppm (rotten egg smell appears at 0.5 PPM) 0-50 ppm Less than ppm Sulfates Less than 5 ppm Less than 5 ppm Less than 00 ppm hlorine Less than.5 ppm Less than.5 ppm Less than.5 ppm hlorides Less than 0 ppm Less than5 ppm Less than 300 ppm arbon Dioxide Less than 50 ppm 0-50 ppm 0-50 ppm Ammonia Less than ppm Less than ppm Less than 0 ppm orrosion Ammonia hloride Less than.5 ppm Less than.5 ppm Less than.5 ppm Ammonia Nitrate Less than.5 ppm Less than.5 ppm Less than.5 ppm Ammonia Hydroxide Less than.5 ppm Less than.5 ppm Less than.5 ppm Ammonia Sulfate Less than.5 ppm Less than.5 ppm Less than.5 ppm Total Dissolved Solids (TDS) Less than 000 ppm ppm ppm LSI Index to to to -.05 Iron Fouling Note: rains = PPM divided by 7 mg/l is equivalent to PPM Bacterial Iron Potential (Biological rowth) Iron Oxide Erosion Suspended Solids Threshold Velocity (Fresh Water) <.ppm <. ppm <. ppm Less than ppm. Above this level deposition will occur. Less than ppm. Above this level deposition will occur. Less than ppm. Above this level deposition will occur. Less than 0 ppm and filtered for max of Less than 0 ppm and filtered for max of Less than 0 ppm and filtered for max of 600 micron size 600 micron size 600 micron size < 6 ft/sec < 6 ft/sec <6 ft/sec

13 SZ/TZ INDOO SPLIT INSTALLATION MANUAL losed Loop round Source Systems Note: For closed loop systems with antifreeze protection, set SW- to the loop position (see DIP Switch Settings table). Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a.5 HP pump minimum) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible then pressurize the loop to a static pressure of PSI (summer) or PSI (winter). This is normally adequate for good system operation. Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when initially charging the system. After pressurization, be sure to remove the plug in the end of the loop pump motor(s) (if applicable) to allow trapped air to be discharged and to ensure that the motor housing has been flooded. Ensure that the loop pumps provide adequate flow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in the specification catalog. Usually.5 to 3 PM of flow per ton of cooling capacity is recommended in earth loop applications. Figure 7: Typical Split System Application losed Loop - Earth oupled Thermostat Wire From Air Handler Disconnect Flow enter Electrical Supply Insulated Vibration Absorbing Pad or Air Pad Lineset To Air Handler DHW Out DHW In P/T Plugs To Loop eolink Flow enter ubber Hose onnector Kit K4L or K4S Multiple Units on One Flow enter When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the SL terminals on connector P in both units with -wire thermostat wire. These terminals are polarity dependant (see Figure 8). The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one flow center is generally limited to a total of 0 PM capacity. Figure 8: Primary/Secondary Hook-up -Series to -Series Microprocessor Units Dual apacity -Series Unit # Shut Down With pump wired to Unit With pump wired to Unit SL In SL Out -Series to -Series Microprocessor Units Single Speed -Series Unit # Shut Down SL In SL Out With pump wired to Unit With pump wired to Unit -Series to Electromechanical Units -Series Unit # Shut Down SL SL In Out Shut Down SL SL In Out -Series Unit # Dual apacity Shut Down SL SL In Out -Series Unit # Single Speed S To Electromechanical Unit 3

14 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Hot Water enerator onnections The heat reclaiming hot water generator coil is of vented double-wall copper construction and is suitable for potable water. To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended. For higher demand applications, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as shown below. A geo storage tank should not be used in this application unless it is plumbed in series with an electric water heater. The geo storage tank is equipped with a single 4500 Watt element and will not be able to provide adequate water heating if used as a standalone water heater. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are followed when installing a hot water generator. esidential units with hot water generators contain an internal circulator and fittings. A water softener is recommended for hard water applications (greater than 0 grains or70 ppm total hardness. Note: Under certain conditions, SZ/TZ Series dual capacity units operate with very low refrigerant discharge temperatures, producing little or no water heating capability. This scenario occurs when the unit is operating with cold entering source water (loop or well). Allowing the hot water generator pump to operate during these conditions actually removes heat from the DHW circulating through the unit. To overcome this, SZ/TZ Series unit microprocessors have been programmed to disengage the hot water generator pump during such conditions. (During low capacity cooling operation, the pump will operate only if the DHW temperature entering the unit is less than the liquid line temperature plus 35º F. During high capacity cooling operation, the pump will operate only if the DHW temperature is less than the liquid line temperature plus 60º F.) Using a preheat tank, as shown in Figure, will maximize hot water generator capabilities. Water Tank Preparation To install a unit with hot water generator, follow these installation guidelines.. Turn off the power to the water heater.. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or outdoors. 3. lose the cold water inlet valve to the water heater tank. 4. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water faucet. 5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. lose when draining water is clear. 6. Disconnect the garden hose and remove the drain valve from the water heater. 7. efer to Plumbing Installation and Hot Water enerator Startup. AUTION: Elements will burn out if energized dry. Figure 0: Typical Hot Water enerator Installation Figure : Hot Water enerator Installation in Preheat Tank Venting Waste Valve or Vent oupling 3/4 x 3/4 x / tee old Water In Hot Water Out Venting Waste Valve or Vent oupling 3/4 x 3/4 x / tee old Water In Hot Water Out DHW Water Out P/T elief Valve DHW Water Out P/T elief Valve P/T elief Valve In In DHW Water In Drain Valve DHW Water In Drain Valve Drain Valve 4

15 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Hot Water enerator onnections cont. Plumbing Installation. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur.. emove drain valve and fitting. 3. Thread the 3/4-inch NPT x 3-/-inch brass nipple into the water heater drain port. 4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple. 5. Attach the /-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit. 6. Install the drain valve on the tee opposite the adaptor. 7. un interconnecting tubing from the tee to DHW water out. 8. ut the cold water IN line going to the water heater. 9. Insert the reducing solder tee in line with cold water IN line as shown. 0. un interconnecting copper tubing between the unit DHW water IN and the tee (/-inch nominal). The recommended maximum distance is 50 feet.. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation. Note: All plumbing and piping connections must comply with local plumbing codes. Hot Water enerator Startup. lose the drain valve to the water heater.. Open the cold water supply to the tank. 3. Open a hot water faucet in the building to bleed air from the system. lose when full. 4. Open the pressure relief valve to bleed any remaining air from the tank, then close. 5. If so equipped, unscrew the indicator plug turn on the motor end of the pump until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines. 6. arefully inspect all plumbing for water leaks and correct as required. 7. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank. On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 00 F. The upper element should be adjusted to 0 F to 30 F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently. On tanks with a single element, lower the thermostat setting to 0 F. 8. After the thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater. 9. Make sure that any valves in the hot water generator water circulating circuit are open. 0. Turn on the unit to first stage heating.. The DHW pump should be running. When the pump is first started, open the inspection port turn (if equipped) until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly. Be sure the switch for the DHW pump (SW4) is ON. The DHW OFF LED on the unit should not be illuminated.. The temperature difference between the water entering and leaving the hot water generator should be 5 F to 5 F. The water flow should be approximately 0.4 PM per ton of nominal cooling. 3. Allow the unit to heat water for 5 to 0 minutes to be sure operation is normal. AUTION: Never operate the DHW circulating pump while dry. If the unit is placed in operation before the hot water generator piping is connected, be sure that the pump switch is set to the OFF position. 5

16 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Electrical Data eneral Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric ode, whichever is applicable. See unit electrical data for fuse or circuit breaker sizing information. Model ated Voltage Voltage Min/Max ompressor M LA LA LA* HWA Pump FLA Ext Loop FLA Total Unit FLA Min irc Amp Max Fuse/ HA /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ /60/ 97/ ated voltage of 08-30/60/ 5/6/09 HA circuit breaker in USA only Min/Max Voltage of 97/53 All fuses lass K-5 * With optional eostart Thermostat Wiring Figure a: Thermostat Wiring, Single and Dual apacity Units Figure b: Thermostat Wiring for Dual Fuel Applications Thermostat -Series Split Thermostat -Series Split Y st Stage ompressor Y Y st Stage ompressor Y Air Handler ommon 4 VA Y O L nd Stage ompressor eversing Valve Fault Signal ommon 4 VA Y O Lo P The fossil fuel furnace transformer supplies the 4 vac control voltage to the -Series Split and the fossil fuel furnace. Fossil Fuel Furnace W ommon 4 VA Y O L nd Stage ompressor eversing Valve Fault Signal ommon 4 VA Y O LO P W Fan W Auxiliary Heat elay Fan W Auxiliary Heat elay Shut Down P Air Handler transformer must be at least 75 VA. Auxiliary Heat elay Note: Field installed DPST dual fuel relay (equired for dual fuel installation) = chassis 6

17 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Wiring Schematics Single Speed Split Wiring Schematic /60/ S Notes: - 4 V Accessory relay (see SW - 3 for description of operation) - This Switch allows the unit to down stage with the t -stat when OFF and finish on second stage when ON. Ext Pump / hp Total 08-30/60/ Pump Pump PB Unit Power 08-30/60/ un apacitor Blue L ed omfort Alert Tan (6) L Black 3 - omfort Alert fault output to ontrol Board 4 - SW - 8 must be in the OFF position for pulsed L lockout signal and in the ON position for constant L lockout signal. 5 - DHW pump only in models with hot water generation option. 6 - onnection of remote unit that does not have a loop pump for slave operation. Duel Fuel Wiring Diagram Using Field Installed elay Thermostat Y st Stage ompressor - Series Split Y Blu Y nd Stage ompressor Y 3A Fuse Blu(7) DHW Pump Pink NOTE 5 Pink(3) Yel(8) ry(9) Org(4) Brn(5) Fossil Fuel Furnace o mmo n 4 VA O L eversing Valve Fault Signal ommon 4 VA O P L O NO Fused L NO Fused L NO 40V L N NO N 40V L F-0A 40V 40V L F-0A 40V W Auxiliary Heat elay F an Auxiliary Heat elay W Auxiliary Heat elay Sh u t Do wn P omfort Alert Status LED PB Blk( ) NOTE 6 SL In Violet(3) Violet() SL Out Optional emote Unit Without Loop Pump SW4 Y Y Yel(6) Blk(5) -ND P Y Y W O LO HI P Shut Down SL In SL Out Not Used NOTE P3 Acc om Acc N Acc NO 3 3 LED Drain Water Flow High Press Low Press / A Air Flow Status DHW Limit DHW off P4 OM *reen LED not flashing EM Air Flow Settings OM 3 OM 4 Microprocessor Logic ontrol (D Voltage) SW On SW On SW3 On Test / Norm Loop / Well 3 Fan / omp 4 Dehum / Norm 5 No Htg3 / Htg3 6 Inputs / Norm 7 Outputs / Norm 8 Pulse L / onstant L (NOTE 4) Speed / Speed Normal / Finish on nd (Note ) 3 No PM / PM 4 Electric Heat / Normal 5 -Series / E-Series or P-Series Normal Display Mode Field Selection Dips - # On, #6 On, #7 On Drain pan overflow Lockout FD thermistor (loop<5 F,well<30 F) Lockout High Pressure Low Pressure / omfort Alert EM PM < 00 rpm Lockout Microprocessor malfunction* HWL thermistor > 30 F DHW pump switch off urrent Fault Status # Off, #6 On, #7 On Drain pan overflow FD thermistor (loop <5 F, well<30 F) High Pressure Low Pressure / omfort Alert EM PM < 00 rpm Not Used HWL thermistor > 30 F DHW pump switch off Main Logic PB OM Diagnostic Modes Inputs #6 Off, #7 On Y Y O W SL SL -- Outputs #6 On, #7 Off ompressor Lo ompressor Hi V FAN DHW Pump Loop Pump Loop Pump -- Outputs #6 Off, #7 Off Blower Lo Blower Med Blower Hi Aux Heat # Aux Heat # AuxHeat #3 Aux Heat #4 -- P NOT USED Note : Field installed DPST dual fuel relay ( equired for dual fuel installation ) 3 6 P5 NOTE 3 Tan L omfort Alert 4 9 Orange V Orange 0 Not Used 3 Not Used 8 Pink Pink T HWL Yellow T FD 5 Yellow 3 Blue LP 6 Blue 7 Black HP 4 Black omfort Alert Status LED Flash ode Description Solid Module Has reen Power ed Solid Y Present But ompressor Not unning ode Long un Time ode System Pressure Trip ode 3 Short ycling ode 4 Locked otor Yellow ode 5 Open ircuit ode 6 Open Start ircuit ode 7 Open un ircuit ode 8 Welded ontactor ode 9 Low Voltage P T 3 L Legend = chassis Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block D Voltage PB traces Internal junction Quick connect terminal Wire nut Field wire lug round elay ontacts - N.O., N.. Fuse Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Switch -Hot Water On /Off Polarized connector A - omfort Alert - ompressor ontactor O - ondensate overflow sensor - DHW pump relay - Loop pump relay 3 - PS Fan Speed elay 4 - PS Fan Power elay S - ompressor Solenoid **D oil** F and F - Fuses HE - Heater element HP - High pressure switch E to E4 - Aux heat stage relays LP - Low pressure switch PB, PB - Power blocks PS - Power strip V - eversing Valve coil SW - DIP package position SW - DIP package 8 position SW3 - DIP package 5 position SW4 - Hot water pump enable switch TS - Thermal limit switch HWL - Hot water limit sensor S - Start ontactor S - Start elay FD - Freeze Detection 97P /8/08 7

18 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Wiring Schematics cont. Dual apacity Split Wiring Schematic /60/ Ext Pump / hp Total 08-30/60/ Pump Pump PB Unit Power 08-30/60/ un apacitor Blue L ed S omfort Alert Tan (6) L Black D SOL + - S Notes: - 4V Accessory relay (see SW - 3 for description of operation) - This Switch allows the unit to down stage with the t -stat when OFF and finish on second stage when ON. 3 - omfort Alert fault output to ontrol Board 4 - SW - 8 must be in the OFF position for pulsed L lockout signal and in the ON position for constant L lockout signal. 5 - DHW pump only in models with hot water generation option. 6 - onnection of remote unit that does not have a loop pump for slave operation. Duel Fuel Wiring Diagram Using Field Installed elay Thermostat Y st Stage ompressor - Series Split Y Blu Y nd Stage ompressor Y 3A Fuse Blu(7) DHW Pump Pink NOTE 5 Pink(3) Yel(8) ry(9) Org (4) Brn (5) Fossil Fuel Furnace o mmo n 4 VA O L eversing Valve Fault Signal ommon 4 VA O P L O NO Fused L NO Fused L NO 40V L N NO N 40V L F-0A 40V 40V L F-0A 40V W Auxiliary Heat elay Fan Auxiliary Heat elay W Auxiliary Heat elay Sh u t Do wn P omfort Alert Status LED PB Violet(3) Violet() Blk( ) NOTE 6 SL In SL Out Optional emote Unit Without Loop Pump SW4 Y Y Y Yel(6) Blk(5) Wht(4) HI -ND P Y Y W O LO P Shut Down SL In SL Out Not Used NOTE P3 Acc om Acc N Acc NO 3 3 P4 OM EM Air Flow Settings OM LED Normal Display Mode Field Selection Dips - # On, #6 On, #7 On Drain Drain pan overflow Lockout Water Flow FD thermistor (loop<5 F,well<30 F) Lockout High Press High Pressure Low Press / A Low Pressure / omfort Alert Air Flow EM PM < 00 rpm Lockout Status Microprocessor malfunction * DHW Limit HWL thermistor > 30 F DHW off DHW pump switch off *reen LED not flashing 3 OM 4 Microprocessor Logic ontrol (D Voltage) SW On SW On SW3 On Test / Norm Loop / Well 3 Fan / omp 4 Dehum / Norm 5 No Htg3 / Htg3 6 Inputs / Norm 7 Outputs / Norm 8 Pulse L / onstant L (NOTE 4) Speed / Speed Normal / Finish on nd (Note ) 3 No PM / PM 4 Electric Heat / Normal 5 -Series / E Series or Premier # Off, #6 On, #7 On Drain pan overflow FD thermistor (loop<5 F, well <30 F) High Pressure Low Pressure / omfort Alert EM PM < 00 rpm Not Used HWL thermistor > 30 F DHW pump switch off Main Logic PB OM Diagnostic Modes urrent Fault Status Inputs #6 Off, #7 On Y Y O W SL SL -- Outputs #6 On, #7 Off ompressor Lo ompressor Hi V FAN DHW Pump Loop Pump Loop Pump -- Outputs #6 Off, #7 Off Blower Lo Blower Med Blower Hi Aux Heat # Aux Heat # Aux Heat #3 Aux Heat #4 -- P NOT USED Note : Field installed DPST dual fuel relay ( equired for dual fuel installation ) 3 6 P5 NOTE 3 Tan L omfort Alert 4 9 Orange V Orange 0 Not Used 3 Not Used 8 Pink Pink T HWL Yellow T FD 5 Yellow 3 Blue LP 6 Blue 7 Black HP 4 Black omfort Alert Status LED Flash ode Description Solid Module Has reen Power ed Solid Y Present But ompressor Not unning ode Long un Time ode System Pressure Trip ode 3 Short ycling ode 4 Locked otor Yellow ode 5 Open ircuit ode 6 Open Start ircuit ode 7 Open un ircuit ode 8 Welded ontactor ode 9 Low Voltage P T 3 L A - - O S - F and F - HE - HP - E to E4 - LP - PB, PB - PS - V - SW - SW - SW3 - SW4 - TS - HWL - S - S - FD - Legend = chassis Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block D Voltage PB traces Internal junction Quick connect terminal Wire nut Field wire lug round elay ontacts - N.O., N.. Fuse Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Switch -Hot Water On/Off Polarized connector omfort Alert ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoid **D oil** Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch Power blocks Power strip eversing Valve coil DIP package position DIP package 8 position DIP package 5 position Hot water pump enable switch Thermal limit switch Hot water limit sensor Start ontactor Start elay Freeze Detection 97P /8/08 8

19 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Microprocessor ontrol Startup The unit will not operate until all the inputs and safety controls are checked for normal conditions. At first power-up, a four minute delay is employed before the compressor is energized. omponent Sequencing Delays omponents are sequenced and delayed for optimum space conditioning performance. Accessory elay An accessory relay on the control board allows for field connection of solenoid valves, electronic air cleaners, etc. The accessory relay has a normally open output and a normally closed output. Short ycle Protection The control employs a minimum "off" time of four minutes to provide for short cycle protection of the compressor. Shutdown Mode A 4VA common signal to the shutdown input on the control board puts the unit into shutdown mode. ompressor, hot water pump and fan operation are suspended. Safety ontrols The Series control receives separate signals for a high pressure switch for safety, a low pressure switch to prevent loss of charge damage, and a low suction temperature thermistor for low source water temperature sensing. Upon a continuous 30-second measurement of the fault (immediate for high pressure), compressor operation is suspended, the appropriate lockout LED begins flashing. (efer to the "Fault etry" section below.) Testing The Series control allows service personnel to shorten most timing delays for faster diagnostics. Fault etry All faults are retried twice before finally locking the unit out. An output signal is made available for a fault LED at the thermostat. The fault retry feature is designed to prevent nuisance service calls. Diagnostics The Series control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board diagnosis. Hot Water High Limit (Domestic Hot Water Option) This mode occurs when the hot water input temperature is at or above 30 F for 30 continuous seconds. The DHW limit status LED on the unit illuminates and the hot water pump de-energizes. Hot water pump operations resume on the next compressor cycle or after 5 minutes of continuous compressor operation during the current thermostat demand cycle. Hot Water Justification Since compressor hot gas temperature is dependant on loop temperature in cooling mode, loop temperatures may be too low to allow proper heating of water. The control will monitor water and refrigerant temperatures to determine if conditions are satisfactory for heating water. The DHW limit status LED on the unit illuminates when conditions are not favorable for heating water. Heating Operation Heat, st Stage (Y) The blower motor is started immediately, the loop pump is energized 5 seconds after the Y input is received, and the compressor is energized on low capacity 0 seconds after the Y input. The hot water pump is cycled 30 seconds after the Y input. Heat, nd Stage (Y,Y) Single-Speed Units The hot water pump is de-energized, which directs all heat to satisfying the thermostat, and the blower changes to high speed 5 seconds after the Y input (EM only). Heat, nd Stage (Y,Y) Dual apacity Units The second stage compressor will be activated 5 seconds after receiving a Y input as long as the minimum first stage compressor run time of minute has expired. The EM blower changes from medium to high speed 5 seconds after the Y input. The omfort Alert will delay the second stage compressor until 5 seconds after it receives a Y from the board. Heat, 3rd Stage (Y,Y,W) Single-Speed Units The first stage of resistance heat is energized 0 seconds after W input, and with continuous 3rd stage demand, the additional stages of resistance heat engage 90 seconds after the first stage. Heat, 3rd Stage (Y,Y,W) Dual apacity Units The hot water pump is de-energized which directs all heat to satisfy the thermostat. The st stage of resistance heat is energized 0 seconds after W input, and with continuous 3rd stage demand, the additional stages of resistance heat engage 90 seconds after the first stage. Emergency Heat (W only) The blower is started on high speed, and the first stage of resistance heat is energized 0 seconds after the "W" input. ontinuing demand will engage the additional stages of resistance heat 90 seconds after the first stage. ooling Operation In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized. ool, st Stage (Y,O) The blower motor and hot water pump are started immediately, the loop pump(s) is energized 5 seconds after 9

20 SZ/TZ INDOO SPLIT INSTALLATION MANUAL Microprocessor ontrol cont. the Y input is received. The compressor will be energized (on low capacity for Dual apacity units) 0 seconds after the Y input. The EM blower will operate at 85% of medium speed if in dehumidification mode. ool, nd Stage (Y, Y, O) Single Speed Units The blower changes to high speed (85% of high speed if in dehumidification mode) 5 seconds after the Y input (EM only). ool, nd Stage (Y, Y, O) Dual apacity Units The second stage compressor will be activated 5 seconds after receiving a Y input as long as the minimum first stage compressor run time of minute has expired. The EM blower changes to high speed 5 seconds after the Y input (85% of high speed if in dehumidification mode). The omfort Alert will delay the second stage compressor until 5 seconds after it receives a Y from the board. Blower ( only) The blower starts and operates on low speed. Lockout onditions During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The compressor, loop pump, hot water pump, and accessory outputs are de-energized. The blower will continue to run on low speed. If the thermostat calls for heating, emergency heat operation will occur. omfort Alert lockouts cannot be reset at the thermostat. All other lockout modes can be reset at the thermostat after turning the unit off, then on, which restores normal operation but keeps the unit lockout LED illuminated. Interruption of power to the unit will reset a lockout without a waiting period and clear all lockout LEDs. High Pressure This lockout mode occurs when the normally closed safety switch is opened momentarily (set at 600 PSI). Low Pressure This lockout mode occurs when the normally closed low pressure switch is opened for 30 continuous seconds (set at 40 PSI). A low pressure fault may also be indicated when a omfort Alert lockout has occurred. Freeze Detection (Water Flow) This lockout mode occurs when the freeze detection thermistor temperature is at or below the selected point (well 30 F or loop 5 F) for 30 continuous seconds. 0