Versatec Installation Manual

Transcription

1 Water Source/Geothermal Heat Pumps 7 thru 10 Ton Horizontal 7 thru 23 Ton Vertical Versatec Installation Manual Installation Information Water Piping Connections Electrical Connections Microprocessor Control Startup Procedures Preventive Maintenance IM /06 WFI

2 Model Nomenclature VL 240 T L C A 4 S S C Model Type VL = Versatec (Low Temp) VX = Versatec (Ext. Range) Unit Capacity 080 MBTUH 095 MBTUH 120 MBTUH 180 MBTUH 240 MBTUH 275 MBTUH Discharge Air Configuration T = Top Discharge Vertical E = End Discharge Horizontal S = Side Discharge Horizontal Return Air Configuration L = Left R= Right Voltage 3 = /60/3 4 = 460/60/3 5 = 575/60/3 Blower Options 0 = Standard Blower 1 = Oversized Blower Vintage C = All Non-Standard Options Details Non-Standard Options Control Options 4 = FX10 (standard - no communication) 5 = FX10 w/ Open N2 Com Card 6 = FX10 w/ Lonworks Com Card 7 = FX10 w/ BacNet Com Card 8 = FX10 std. no communication, w/user Interface 9 = FX10 w/open N2 Com Card, w/user Interface 0 = FX10 w/lonworks Com Card, w/user Interface 3 = FX10 w/bacnet Com Card, w/user Interface Sound Kit A = None B = Blanket Source Coax Options C = Copper N = Cupronickel Cabinet Options 0 = Painted 1 = Nonpainted 2

3 Table of Contents General Installation Information 4 Water Quality 5 General Piping 6 Installing Horizontal Units 7-8 Installing Vertical Units 9 Electrical Connections Wiring Schematic 12 FX10 Microprocessor Control & Operation Duct System 16 Blower Drive Sheaves 16 Blower Performance Data 17 System Cleaning and Flushing 18 Unit Startup 19 Unit Operating Parameters 20 Water Pressure Drop 21 Preventive Maintenance 22 Replacement Procedures 23 3

4 General Installation Information Safety Considerations Installing and servicing air conditioning and heating equipment can be hazardous due to system pressure and electrical components. Only trained and qualifi ed service personnel should install, repair or service these systems. Untrained personnel can perform the basic maintenance functions of cleaning coils and replacing air fi lters. Trained service personnel should perform all other operations. When working on air conditioning and heating 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 quenching cloth for brazing operations. Have a fi re extinguisher available for all brazing operations. Note: Before installing, check voltage of unit(s) to ensure proper voltage. WARNING: Before performing service or maintenance operations on the system, turn off main power switches to the unit. Turn off accessory heater power switch if applicable. Electrical shock could cause serious personal injury. Moving and Storage Move units in the normal Up orientation as indicated by the labels on the unit packaging. Units may be stacked a maximum of two high and should be unstacked before attempting to move units. When the equipment is received, all items should be carefully checked against the bill of lading to ensure that all crates and cartons have been received in good condition. Examine units for shipping damage, removing unit packaging if necessary to properly inspect unit. Units in question should also be internally inspected. If any damage is observed, the carrier should make the proper notation on delivery receipt acknowledging the damage. Water Source Temperatures Low temperature units (VL series) should not be installed in applications where entering water temperatures will be consistently below 50 F. Unit Location Locate the unit in an indoor area that allows for easy removal of the air fi lter, service access panels and has enough space for service personnel to perform maintenance or repair. Provide suffi cient room to make water, electrical and duct connections. If the unit is located in a confi ned space such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Care 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. CAUTION: Duct connections should be made with 1/2-inch sheet metal screws to prevent damage to piping and other internal components. If the unit is connected to existing ductwork, the capacity and condition of the duct should be inspected to ensure that the new system will be capable of delivering adequate airfl ow. If any defects or problems are identifi ed during the inspection, repairs should be made to the ductwork prior to the unit s installation. The duct system should be sized to handle the design airfl ow quietly. To maximize sound attenuation of the unit blower, the supply and return air plenums should be lined with an insulated duct liner or be constructed of ductboard for the fi rst few feet. If air noise or excessive airfl ow is a problem, the blower speed can be changed. See the Blower Performance Data table for further details and blower motor speed selections. CAUTION: Be sure to remove the shipping material from the blower throat before connecting ductwork. 4

5 Water Quality General 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 qualifi ed service mechanic, as special solutions and pumping equipment are required. Desuperheater 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 fl ushing. Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Material Copper 90/10 Cupro-Nickel ph Acidity/Alkalinity Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm Corrosion Iron Fouling (Biological Growth) Erosion Hydrogen Sulfide Less than.5 ppm (rotten egg smell appears at 0.5 PPM) ppm 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 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 ppm Iron, Fe 2 + (Ferrous) Bacterial Iron Potential None None Iron Oxide Suspended Solids Less than 1 ppm. Above this level deposition will occur. Less than 10 ppm and filtered for max of 600 micron size Less than 1 ppm. Above this level deposition will occur. Less than 10 ppm and filtered for max of 600 micron size Threshold Velocity (Fresh Water) 5-8 ft/sec 8-12 ft/sec Note: Grains = PPM divided by 17 mg/l is equivalent to PPM 5

6 General Piping Water Connections All supply and return water connections are female pipe thread of size specifi ed in physical dimensions. Never use fl exible hoses smaller than separate water connections on the unit and limit hose length to 10 ft. per connection. Check carefully for water leaks. Interior Piping All units are recommended to be connected to supply and return piping in a two-pipe reverse return confi guration. A reverse return system is inherently self-balancing and requires only trim balancing when multiple quantities of units with different fl ow and pressure drop characteristics are connected to the same loop. A direct return system may also be made to work acceptably, but proper water fl ow balance is more diffi cult to achieve and maintain. Supply and return runouts are usually connected to the unit by short lengths of high pressure fl exible hose which are sound attenuators for both unit operating noise and hydraulic pumping noise. One end of the hose should have a swivel fi tting to facilitate removal for service. Hard piping can also be connected directly to the unit although it is not recommended since no vibration or noise attenuation can be accomplished. The hard piping must have unions to facilitate unit removal (see fi gure 1 & 6) for typical application). Some fl exible hose threaded fi ttings are supplied with sealant compound. If not, apply Tefl on tape to assure a tight seal. Supply and return shutoff valves are required at each unit. The return shutoff valve can be used for balancing and should be adjusted for proper fl ow required, or a manual or automatic fl ow control device should be on the leaving water hose assembly. No unit should be connected to the supply and return piping until the water system has been cleaned and fl ushed completely. After the cleaning and fl ushing has taken place, the initial connection should have all valves wide open in preparation for water system fi lling. 6

7 Installing Horizontal Units Mounting Horizontal Units Units are available with side or end discharge in left-hand or right-hand return air confi gurations. Horizontal units are normally suspended from a ceiling by four 1/2-inch diameter threaded rods. The rods are usually attached to the unit corners by the bottom panel mounting channel and the mounting grommets furnished with each unit. CAUTION: Do not use rods smaller than 1/2-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling (the units are approximately 800 lbs.). Figure 1: Typical Horizontal Application 1/2 Threaded Rods (4) Power Disconnect Low Voltage Flexible Duct Collar P/T Plugs Isolation Grommets (Included) Condensate Drain Connection Hose Kits Insulate supply plenum anduse at least a 90 elbow to reduce noise Ball Valves Water Loop Layout the threaded rods per the dimensions in Figure 2. Assemble the hangers to the unit as shown in Figure 3. Securely tighten the brackets to the unit. When attaching the hanger rods to the bracket, a double nut is recommended since vibration could loosen a single nut. The unit should be pitched approximately 1/2-inch towards the drain in both directions, to facilitate condensate removal. Figure 2: Mounting Rod Layout Top View Figure 3: Mounting Hardware 1/2" Threaded Rod (not included) Vibration Isolator Washer (not included) 94.0 Hex Nuts (not included) 7

8 Installing Horizontal Units (cont.) Duct System A supply air duct fl ange is provided for fi eld installation to facilitate the secure duct connection at the job site. A fl exible connector is recommended for discharge and return air duct connections on metal duct systems to prevent vibration transmission. It is recommended that all ductwork be insulated with a minimum of 1/2-inch coated insulation. Installation of the units with uninsulated ductwork in an unconditioned space is not recommended, as the system s performance will be adversely affected. Condensate Drain The condensate disposal piping must be trapped a minimum of 1 1/2-inches and the piping must be pitched away from the unit not less than 1/8-inch per foot (see Figure 4). The condensate drain pan includes a drain tube, which is brazed to the drain pan. Horizontal units must be pitched 1/2-inch in both directions toward the drain tube for proper condensate drainage (see Figure 5). Figure 4: Suggested Layout of Condensate Drain Line Figure 5: Unit Pitch for Drain 1/2'' Pitch Vent (if needed) Copper Tube Stub 1.5" 1.5" 1/8" per foot 8

9 Installing Vertical Units Mounting Vertical Units Units are available with top discharge, left-hand or right-hand return air confi gurations. Vertical units are assembled on rails which facilitate moving and placement of the units. It is not necessarty to anchor the unit to the fl oor. Duct System A supply air duct fl ange is provided for fi eld installation to facilitate the secure duct connection at the job site. A fl exible connector is recommended for discharge and return air duct connections on metal duct systems to prevent vibration transmission. It is recommended that all ductwork be insulated with a minimum of 1/2-inch coated insulation. Installation of the units with uninsulated ductwork in an unconditioned space is not recommended, as the system s performance will be adversely affected. Condensate Drain In vertical units, the internal condensate drain assembly consists of a fl exible drain tube which is attached to the drain pan and a 3/4-inch (7-10 tons) or 1-inch (15, 20&23 tons) female pipe thread. An external water trap is not required as the drain tube serves as a trapping loop. The fi eld-installed piping and unit connection must be properly installed and sealed to prevent water leakage. Figure 6: Typical Vertical Application Flexible duct Collar Control Box Water Supply and Return Connections Condensate Drain ACCESS PANEL ACCESS PANEL ACCESS PANEL 9

10 Electrical Connections General 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 Code. Unit Power Connection Line voltage connection is made by connecting the incoming line voltage wires to the terminal bock as shown in Figure on the unit s wiring diagram attached to the inside front panel. Consult the Unit Electrical Data below for correct fuse size. 208 Volt Operation Note: All volt units are factory wired for 230 volt operation. For 208 volt operation, the red and the blue transformer wires must be switched between terminal strip PS and contactor RB. Unit Electrical Data - Horizontal SIZE RATED VOLTAGE VOLTAGE MIN/MAX COMPRESSOR* MCC RLA LRA FAN MOTOR FLA*** FAN HP TOTAL UNIT FLA MIN CIRC AMP MAX FUSE MAX HACR BREAKER ** ** /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ Notes: HACR circuit breaker in USA only. All fuses class RK-5. * Ratings per each compressor unit supplied with two. ** With optional motor. *** Ratings per each motor V180, V240 and V275 supplied with two. 10

11 Electrical Connections (cont.) Unit Electrical Data - Vertical SIZE RATED VOLTAGE VOLTAGE MIN/MAX COMPRESSOR* MCC RLA LRA FAN MOTOR FLA*** FAN HP TOTAL UNIT FLA MIN CIRC AMP MAX FUSE MAX HACR BREAKER ** ** ** ** /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ /60/3 414/ /60/3 518/ /60/3 197/ ** 460/60/3 414/ /60/3 518/ /60/3 414/ Notes: HACR circuit breaker in USA only. All fuses class RK-5. * Ratings per each compressor unit supplied with two. ** With optional motor. *** Ratings per each motor V180, V240 and V275 supplied with two. 11

12 Wiring Schematic V Series - Commercial /60/3, 460/60/3, 575/60/ Ton Johnson Control 97P /23/04 Compressor 1 Compressor 2 Unit Power Supply /60/3, 480/60/3, or 575/60/3 L1 L2 L3 G R C S Red Blue T3 T2 CC1 T1 R C S Red Blue T3 T2 CC2 T1 Green T3 Yellow Belt Drive Blower Motor T2 Brown T1 Gray RB Belt Drive Blower Motor Gray NOTE 2 Green L3 L2 L1 L3 L2 L1 L3 L2 L1 Note 4 TB 24VAC R 24V COM C Comp 1 Y1 Rev Valve O Fan G Alarm L Acc 2 X2 Acc 1 X1 Comp 2 Y2 Setpoint Shift SS AI Com AIC Room Sensor RS Sensor Com SC Temp Occ TO White Yellow Violet NOTE 6 NOTE 7 FP2 Gray T Gry/Wht Red White 23 11K Brown 24 CO Brown 25 FP1 T White 26 White 27 DA T /Red J8 Blue/Wht 34 Orange 35 Org/Wht J VD C - AI3 + - AI5 + - AI4 + - AI6 + - AI2 + 5VD C - AI1 + LED 5VD C PWM2 PWM2 Com PWM1 A12 A21 24VAC A24 A14 A25 A22 A11 A13 A23 24VAC Com A32 Green GROUND A34 A35 A31 A33 Yellow Red White Blk/Wht Yellow White Violet D09 D08 D07 D06 D05 D Red Orange Orange Pink Yellow Brown Gray Red RV2 HP2 Red L1 L2 Red Note 3 CPM1 Compressor Protection Module S1 S2 PB1 L1 L2 Blue 230V 460V 575V Note 1 Red 208V Tan T Tan L1 CPM2 S1 Tan Compressor L2 Protection S2 T Module Tan CC2 Transformer Blk/Wht Blk/Wht Yellow PB 2 L1 L2 White NOTE 5 ES OS White LP2 LP1 Gry/Wht Green Orange Blue Yellow Violet Red Gray Blue Pink Blk/Wht Orange J J VAC Com DI12 DI11 DI10 DI9 DI 8DI 7 DI 3/4/5/6/ Com DI6 DI5 DI4 DI 3 DI2 9VD C DI1 J7 A15 Johnson FX-10 D03 D02 D Red Orange Orange RV1 HP1 RB Red CC1 Blk/Wht Green Blk/Wht Gry/Wht Gry/Wht Legend L1 Factory low voltage wiring Factory line voltage wiring Field low voltage wiring Field line voltage wiring Optional block Internal junction Quick connect terminal Wire nut Field wire lug Ground T Relay Contacts- N.O., N.C. Thermistor - Johnson Control Relay coil P Switch - High pressure Switch - Low pressure Polarized connector Condensate Overflow CO - Condensate overflow HP1 - Stage 1 High Pressure FP1 - Freeze protection sensor 1 HP2 - Stage 2 High Pressure FP2 - Freeze protection sensor 2 LP1 - Stage 1 Low Pressure DA - Discharge Air Temperature LP2 - Stage 2 Low Pressure DF/AP- DirtyFilterorAirProving RB - Blower power relay CP/FP- Compressor Proving or Fan Proving RV1 - Reversing Valve coil 1 CC1 - Compressor contactor 1 RV2 - Reversing Valve coil 2 CC2 - Compressor contactor 2 OS - Occupied Switch CPM1 - Compressor Protection Module 1 ES - Emergency Shutdown CPM2 - Compressor Protection Module 2 Notes: 1 - Switch blue and red wires for 208V operation 2 - Second Blower used only on Ton units 3 - Compressor Protection Module is used only on 575/60/3, ton units 4-R,C,Y1,Y2,O,andGareforusewithawallmountedthermostat 5 - Disconnect for 15 degree freeze protection 6 - Acc 1 output is cycled with the compressor 7 - Acc 2 output is cycled with the fan 12

13 FX10 Microprocessor Control The Johnson Controls FX10 board is specifi cally designed for commercial heat pumps and provides control of the entire unit as well as input ports for Open N2, LonTalk, BacNet communication protocols as well as an input port for a user interface. The user interface is an accessory item that can be used to aid in diagnostics and unit setup. A 16 pin low voltage terminal board provides terminals for common fi eld connections. CAUTION: The FX10 control incorporates static sensitive CMOS devices. Touching the board or its componenets may result in damage as a result of static discharge. To prevent damage during service, it is recommended that the technician use a static discharge wrist strap, which is grounded to the heat pump chassis. When handling the circuit board, hold by the edges and avoid contact with electrical components. Circuit boards should always be stored in a static protected bag prior to installation. Installation Options Units using the FX10 have three different installation options. 1. Stand-alone unit controlled by an electronic room thermostat. 2. Stand-alone with a zone temperature sensor. A zone temperature sensor is a non-programmable temperature sensor that allows the user to adjust the zone temperature by +/- 5 F. A user interface (Kit # MUIK1) is required to change any zone temperature set points beyond 5 degrees. 3. Integrated into a building automation system by using a zone temperature sensor and adding a communication module for Open N2, LonTalk, or BacNet. Regardless of which installation option is chosen all low voltage wiring will be done through the 16-pin terminal board (see fi gure 7). Figure 7: 16-Pin Terminal Board Wiring COMMON C O REV. VALVE FAN G Y1 COMPRESSOR1 N/A LC1 LC2 N/A COMPRESSOR2 Y2 L LOCKOUT ACCESSORY 1 X1 X2 ACCESSORY 24VAC R SS SETPOINT SHIFT AI COMMON AIC RS ROOM SENSOR SENSOR COMMON SC TO TEMP OCCUPIED 13

14 FX10 Microprocessor Control Electronic Thermostat Connections If an electronic thermostat is being used, wire as shown in Figure 8. Figure 8: Electronic Thermostat Connections R 24VAC (HOT) Terminal Board Connections C Y1 Y2 O G 24VAC (COMMON) COMPRESSOR1 COMPRESSOR2 REVERSING VALVE BLOWER RELAY Thermostat Connections L SYSTEM MONITOR Zone Sensor Wiring Installation options 2 and 3 will use the wiring diagram for the zone temperature sensor, Figure 9. Figure 9: Zone Sensor Connections Terminal Board Connections SS RS AIC TO SC SETPOINT SHIFT ROOM SENSOR AI COMMON PUSH BUTTON DI COMMON Zone Sensor Connections 14

15 FX10 Operation Startup The unit will not operater until all the inputs and safety controls are checked for normal operating conditions. Fault Retry All faults are tested twice before fi nally locking the unit out to prevent nuisance service calls. Component Sequencing Delays Components are sequenced and delayed for optimum unit performance. See Table below. CONTROL TIMING Lead compressor ON delay 90 seconds Lag compressor ON delay 120 seconds Short cycle delay 4 minutes Minimum compressor ON time 2 minutes (except for fault condition) High pressure fault recognition Less than 1 second Low pressure fault recognition delay 30 seconds Freeze protection fault recognition delay 30 seconds Condensate overflow fault recognition delay 30 seconds Low pressure fault bypass delay 2 minutes Freeze protection fault bypass delay 2 minutes Random start delay seconds Short Cycle Protection The control allow a minimum compressor off time of 4 minutes and a minimum compresor run time of 2 minutes for short cycle protection. Random Start A random start delay of 1 to 120 seconds is generated after each power up to prevent simultaneous start-up of all units within a building after the release from an unoccupied cycle or power loss. Emergency Shutdown A normally open dry contact must be placed between DI2 and PB2-L2 (see unit schematic). Closing the contact will set the unit into emergency shutdown mode. All unit operation is suspended while in emergency shutdown mode. Condensate Overflow Protection The board incorporates an impedance liquid sensor at the top of the condensate drain pan. Upon a continuous 30 second sensing of the condensate, the operation of the unit is suspended. Safety Controls The FX10 board receives separate signals from a high pressure switch for safety, a low pressure switch to detect loss of refrigerant charge an a low suction temperature thermistor for freeze protection. Upon a continuous 30 second measurement of the fault (immediate for high pressure), compressor operation is stopped. Freeze Protection Notes: For applications using a closed loop antifreeze solution, remove the wire between DI5 and PB2-L1 (see unit schematic). On applications using an open loop/ground water system, make sure the wire is connected. For additional information on the FX10 Control, refer to Application Guide AGFX10 or Submittal Data SD

16 Duct System Duct System An air outlet collar is provided on all units to facilitate a duct connection. A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Any uninsulated duct should be insulated with a minimum of one-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 unit is connected to existing ductwork, a previous check should have been made to assure that the duct has the capacity to handle the air required for the unit s application. If ducting is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repairs. The duct system should be sized to handle the design airfl ow quietly. To maximize sound attenuation of the unit blower, the supply and return plenums should include internal duct liner of glass fi ber or be of ductboard construction for the fi rst few feet. If air noise or excessive air fl ow is a problem, the blower speed can be changed (minimum air fl ow must be maintained). See the Blower Sheave Adjustment section below and Blower Performance Data chart, page 16. Blower Drive Sheaves Blower Sheave Adjustment Follow the procedures listed below if airfl ow of heat pump is to be changed from factory setting. (Refer to Figure 10.) 1. Loosen the blower motor fastening nuts from the motor mount. 2. Turn the adjusting bolts until the tension is off the drive belt. 3. Remove belt from sheave and loosen allen heat set screw B. 4. Adjust sheave pitch diameter for desired speed by opening or closing moveable portion in or out in 1/2-turn increments. Do not open more than 5 full turns. 5. Sheave should be mounted with set screw A toward the motor. Be sure driven and drive sheaves are in alignment and parallel. 6. Retighten set screw B and replace drive belt on sheaves. 7. Turn motor mount adjusting bolts until belt has approximately 1/2-inch of defl ection midway between sheaves (4 lbs. tension if measured with gauge, see Figure 11). 8. Retighten motor mounting nuts. Belt tension of a new belt will drop rapidly during the fi rst few hours of operation. 9. Check and readjust as needed. Figure 10: Blower Motor Sheave Adjustments and Settings Figure 11: Checking Drive Belt Tension Keyway Set Screw A Moveable Portion Set Screw B MODEL DRIVE SHEAVE FACTORY SETTING Vertical Turns Open Turns Open Turns Open Turns Open Turns Open Turns Open Horizontal Turns Open Turns Open Turns Open Driven Sheave Deflection Drive Sheave 16

17 Blower Performance Data HORIZONTAL VERTICAL SIZE V080 V095 V120 V080 V095 V120 V180 V240 V275 DRIVE SHEAVE Airflow (CFM) at External Static Pressure (in. wg) Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Closed Turn Open Turns Open Turns Open Turns Open Turns Open Notes: Drive Sheave factory setting shown in bold. Shaded areas require larger blower motor and sheaves. 17

18 System Cleaning and Flushing Figure 12: Flushing Internal Piping Return Runout Supply Runout Rubber Hose Runouts Initially Connected Together Cleaning and Flushing Prior to startup of any heat pump, the water circulating system must be cleaned and fl ushed of all dirt and debris. If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location (This will prevent the introduction of dirt into the unit, see Figure 12). The system should be fi lled at the water make-up connection with all air vents open. After fi lling, vents should be closed. The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air and to verify circulation through all components of the system. As water circulates through the system, the contractor should check and repair any leaks found in the piping system. Drain(s) at the lowest point(s) in the system should be opened for initial fl ush and blowdown, making sure water fi ll valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the make-up water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, until drain water is clean and clear. The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections. Refi ll the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (ph 7.5 to 8.5). The specifi ed percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. WFI recommends Environol brand antifreeze. Once the system has been fi lled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, fl ow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure. In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full fl ow has been established through all components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the units will be ready for check, test and startup and for air and water balancing, Use forms when performing commercial check, test and startup. Obtain these forms from your commercial representative or Customer Service. Ground Source Loop System Checkout Once piping is completed between the unit pumping system and ground loop, fi nal purging and charging of the loop is needed. A high pressure pump is needed to achieve adequate fl ow 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 may decrease soon after initial installation, due to pipe expansion and loop temperature change. Running the unit for at least 30 minutes after the system has been completely purged of air will allow for the break-in period. It may be necessary to adjust static loop pressure (by adding water) after the unit has run for the fi rst time. Loop static pressure will also fl uctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fl uctuation is normal and should be considered when charging the system initially. Insure the pump provides adequate fl ow through the unit by checking pressure drop across the heat exchanger. Usually GPM of fl ow per ton of cooling capacity is recommended in earth loop applications. Mains 18

19 Unit Startup Before powering the unit, check the following: High voltage is correct and matches nameplate Fuses, breakers and wire size are correct Low voltage wiring is complete Piping has been completed and water system cleaned and fl ushed Air is purged from closed loop system Isolation valves are open and water control valves or loop pumps wired Condensate line is open and correctly pitched Transformer has been switched to lower voltage tap if needed Blower rotates freely Blower speed is correct Air fi lter is clean and in position Service/access panels are in place Return air temperature is between 60 F-80 F in heating and 70 F-95 F in cooling Air coil has been cleaned Startup Steps 1. Initiate a control signal to energize the blower motor. Check blower operation. 2. Initiate a control signal to place the unit in the cooling mode. Cooling set point must be set below room temperature. 3. First stage cooling will energize after a time delay. Check for correct rotation of scroll compressors in 120, 180, 240 units. Incorrect rotation will cause unusual noise and low refrigerant pressures. Switch any two power leads at the compressor or contractor to reverse rotation. 4. Be sure the compressor and water control valve or loop pumps are activated. 5. Initiate a control signal to energize second stage cooling. 6. Second stage cooling will energize after a time delay. Check for correct rotation as indicated in step Verify that the water fl ow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Water Pressure Drop Table on page Check the temperature of both the supply and discharge water. Refer to Unit Operating Pressures and Temperatures Table page Check for an air temperature drop of 15 to 25 F across the air coil, depending on fan speed and entering water temperature. 10. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or pumps deactivate. 11. Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set above room temperature. 12. First stage heating will energize after a time delay. 13. Initiate a control signal to energize second stage heating. 14. Second stage heating will energize after a time delay. 15. Check the temperature of both the supply and discharge water. Refer to Unit Operating Pressures and Temperatures Table on page Check for an air temperature rise of 20 F to 25 F across the air coil, depending on the fan speed and entering water temperature. 17. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate. 18. During all testing, check for excessive vibration, noise or water leaks. 19. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 20. Instruct the owner/operator in the proper operation of the thermostat and system maintenance. 21. Check belt tension and readjust as necessary after fi rst few hours. 19

20 Unit Operating Parameters Vertical Units EWT WATER FLOW/ TON (GPM) SUCTION DISCHARGE PRESSURE PRESSURE COOLING SUPER HEAT SUB COOLING WATER RISE F AIR DROP F SUCTION DISCHARGE PRESSURE PRESSURE HEATING SUPER HEAT SUB COOLING WATER DROP F AIR RISE F Horizontal Units EWT WATER FLOW/ TON (GPM) SUCTION DISCHARGE PRESSURE PRESSURE COOLING SUPER HEAT SUB COOLING WATER RISE F AIR DROP F SUCTION DISCHARGE PRESSURE PRESSURE SUPER HEAT HEATING SUB COOLING WATER DROP F AIR RISE F

21 Water Pressure Drop Vertical Units SIZE FLOW RATE GPM PRESSURE DROP (PSI) 30 F 50 F 90 F Horizontal Units SIZE FLOW RATE GPM PRESSURE DROP (PSI) 30 F 50 F 90 F

22 Preventive Maintenance Water Coil Maintenance 1. Keep all air out of the water. An open loop system should be checked to insure that the well head is not allowing air to infi ltrate the water line. Lines should always be airtight. 2. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure or air vents may draw air into the system. Notes: If the installation is performed in an area with a known high mineral content ( 125 P.P.M. or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water fl owing through the unit, the less chance for scaling. Other Maintenance Filters 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. Condensate Drain In areas where airborne bacteria produce a residual buildup in the drain pan, it may be necessary to chemically treat the pan 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. Air Coil The air coil must be clean to obtain maximum performance. Check once a year under normal operating conditions and brush, vacuum or chemically clean the air coil if necessary. Care must be taken not to damage or disturb the aluminum fi ns while cleaning. CAUTION: Fin edges are sharp. Drive Belts Check periodically for proper tension. (Refer to page 15.) 22

23 Replacement Procedures Obtaining Parts Contact your distributor for service or 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. 23

24 Manufactured by WFI 9000 Conservation Way Fort Wayne, IN Product: Type: Size: Versatec Water Source/Geothermal Heat Pumps 7 thru 23 Tons WFI has a policy of continuous product research and development and reserves the right to change design and specifi cations without notice WFI. Document Type: Installation Manual Part Number: IM2601 Release Date: 11/06 Supercedes: IM2601 (03/06)