Versatec Installation Manual

Geothermal/Water Source Heat Pumps 0.75-6 Ton Horizontal 0.75-5 Ton Vertical Installation Information Versatec Installation Manual Water Piping Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance IM2600 01/09

Model Nomenclature V L V 036 B 0 0 1 C L T 1 SSA Model Type Operational Range L = Low Temperature (50-110) X = Extended Range (30-110)* Cabinet Configuration V = Vertical H = Horizontal Unit Capacity MBTUH @ 85 F EWT Horizontal 009-070 Vertical 009-058 Vintage A = Multi-return verticals & horizontals except below B = Other verticals, horiz: 018, 030, 070 Voltage 0 = 208-230/60/1 (Commercial) 1 = 208-230/60/1 (Residential) 2 = 265-277/60/1 3 = 208-230/60/3 4 = 460/60/3 Hot Water Option 0 = None (all Horizontals) 1 = Hot Water Generation (Field installed external pump kit required) * ** *** Not available on Vertical 009 Commercial only Vertical Residential (009,070 & FX10 not available) Not available on Multi-Return Desuperheater only available on Vertical 024-058 models Non-Standard Options N = Sound Kit S = Standard Alpha Char. = Option Controls 1 = Electro-mechanical 2 = Microprocessor ** 4 = FX10 5 = FX10 w/open N2 Com Card 6 = FX10 w/lanworks Com Card 7 = FX10 w/bacnet Com Card Discharge Air T = Topflow (Vertical) E = End (Horizontal) S = Side (Horizontal) Return Air F = Front (Commercial Vertical only) L = Left R = Right M = Multi-Return *** Coax Options C = Copper N = Cupronickel Cabinet 0 = Painted 1 = Unpainted 2

Table of Contents General Installation Information 4 General Piping and Water Quality 5 Installing Horizontal Units 6-7 Setting Vertical Units 8 Electrical Connections 9 Thermostat Connections 9 Optional Microprocessor Control & Operation 10-12 Optional FX10 Microprocessor Control 13 Setting Blower Speed 14-15 System Cleaning and Flushing 16 Unit Startup 17 Unit Operating Parameters 18-21 Preventive Maintenance 22 Additional Product Notes 23 3

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 qualified service personnel should install, repair or service these systems. Untrained personnel can perform the basic maintenance functions of cleaning coils and replacing air filters. 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 fire 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. Unit Location Locate the unit in an indoor area that allows for easy removal of the air filter, service access panels and has enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connections. If the unit is located in a confined 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 airflow. If any defects or problems are identified 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 airflow 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 first 10 feet. If air noise or excessive airflow is a problem, the blower speed can be changed. See the Fan Performance Data tables for further details and blower motor speed selections. CAUTION: Be sure to remove the shipping material from the blower throat before connecting ductwork. 4

General Piping and Water Quality Water Piping Connections Units should not be connected to the supply and return piping until the water system has been cleaned and flushed completely (see page 16). Supply and return water connections are standard female pipe thread. Never use flexible hoses with an inside pipe diameter that is smaller than the water connections on the unit and limit the hose length to 10 feet or less per connection. -pressure flexible hoses provide sound attenuation for both normal unit operating noise and hydraulic pumping noise. Hard piping can also be brought directly to the unit although it is not recommended since no vibration or noise attenuation can be accomplished. Supply and return water connections must have swivel union fittings to facilitate unit removal. A manual shutoff valve should be installed on the water supply line to allow removal of the unit without disturbing the operation of the water system. A manual or motor driven shutoff valve should be installed on the return water piping. The manual return valve can be used for system balancing and should be adjusted for proper water flow, or a flow control device may be used to regulate water flow through the unit. Slow acting motorized valves are recommended to reduce the effects of water hammer. Pressure/ temperature ports (P/T Plugs) should be installed for serviceability. Sealant compound or Teflon tape should be applied to threaded fittings to assure a proper seal. Use backup wrench on unit fittings to prevent damage to water lines. Check carefully for water leaks. 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. 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 flushing. 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 Note: Grains = PPM divided by 17 mg/l is equivalent to PPM Copper 90/10 Cupro-Nickel 316 Stainless Steel ph Acidity/Alkalinity 7-9 7-9 7-9 Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm Hydrogen Sulfide (rotten egg smell appears at 0.5 PPM) 10-50 ppm Less than 1 ppm Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm Chlorine Chlorides Less than 20 ppm Less than125 ppm Less than 300 ppm Carbon Dioxide Less than 50 ppm 10-50 ppm 10-50 ppm Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm Corrosion Ammonia Chloride Ammonia Nitrate Ammonia Hydroxide Ammonia Sulfate Total Dissolved Solids (TDS) Less than 1000 ppm 1000-1500 ppm 1000-1500 ppm LSI Index + 0.5 to -.05 + 0.5 to -.05 + 0.5 to -.05 Iron Fouling Bacterial Iron Potential (Biological Growth) Iron Oxide Erosion Suspended Solids Threshold Velocity (Fresh Water) <.2ppm <.2 ppm Less than 1 ppm. Above this level Less than 1 ppm. Above this level deposition will occur. deposition will occur. Less than 10 ppm and filtered for max of Less than 10 ppm and filtered for max of 600 micron size 600 micron size < 6 ft/sec < 6 ft/sec <.2 ppm Less than 1 ppm. Above this level deposition will occur. Less than 10 ppm and filtered for max of 600 micron size <6 ft/sec 5

Installing Horizontal Units Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by four 3/8-inch diameter threaded rods. The rods are usually attached to the unit corner posts by hanger bracket kits furnished with each unit. Securely tighten the hanging brackets to the unit. The bracket design allows it to be positioned at the end or to the side of the unit as shown in Figure 1. Measure bracket hole location for threaded rod and transfer dimensions to supporting structure for proper threaded rod placement. In some installations hanger brackets should be positioned at the end of unit to allow air filter removal. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut, (refer to Figure 2). The unit should be pitched approximately 1/4-inch towards the drain in both directions to facilitate condensate removal (refer to Figure 4). CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling. Figure 1: Horizontal Unit Suspension Flexible Duct Collar Insulate supply plenum and use at least one 90 elbow to reduce noise 3/8 Threaded Rods To Line Power Hanging Brackets (Included) Hose Kits To Thermostat Disconnect Line Voltage Ball Valves Boiler/Cooling Tower Loop Some applications require an attic floor installation of horizontal units. In this case the unit is set in a full size secondary drain pan on top of vibration absorbing material. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material. 6

Installing Horizontal Units Horizontal Unit Hanger Location Figure 2: Hanger Location and Assembly 3/8î Threaded Rod (not supplied) Vibration Isolator Washer A C Bolt and Lockwasher Hex Nuts (not supplied) B D SIZE A B C D 009, 012 19.18 28.46 17.68 29.18 015-036 20.25 40.53 18.75 41.25 042, 048 27.18 46.33 25.68 47.18 058, 070 27.18 55.33 25.68 56.18 Condensate Drain Connect the drain through a trap to the condensate drain system in conformance with local plumbing codes. The condensate line must be trapped a minimum of 1 1/2-inches as shown in Figure 3. The condensate line should also be pitched away from the unit a minimum of 1/8-inch per foot. The top of the trap must be below the unit drain connection. Horizontal units should be pitched approximately 1/4-inch towards the drain in both directions to facilitate condensate removal (see Figure 4 below). Figure 3: Condensate Drain Connection 3/4" Male Adapter Vent Figure 4: Unit Pitch for Drain 1/4 Pitch 1-1/2" 1-1/2" 3/4" PVC or Copper 1/8" Per Foot Drain 7

Setting Vertical Units The entire base of the unit should be supported by a level, vibration-absorbing pad that is slightly larger than the unit cabinet. It is not necessary to anchor the unit to the floor (see Figure 5). Duct System A supply air duct flange is provided for field installation to facilitate the secure duct connection at the job site. An optional filter rack/return air duct collar is available. A flexible 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. Figure 5 - Versatec Series with Vibration Absorbing Pad (left-hand return shown) Flexible Duct Connection Condensate Drain On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a 3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensater piping. On vertical upflow units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary. The field installed PVC condensate piping and unit connection must be properly glued to prevent water leakage. Filter Rack Vibration Absorbing Pad Water Supply and Return Front Line Voltage Power Low Votage Power Field Conversion Residential Versatec vertical units are capable of being field converted from left return to front or right return by relocating the control box to the side (under the air coil) or to the back (respectively). To convert, remove four screws holding the control box in place. Relocate control box to desired location in compressor section. Replace screws. Ensure that wiring does not come in contact with water or refrigerant lines. Water connections on residential models are made inside the compressor compartment. Knockouts are provided in the units base to allow several field supplied piping connections. Figure 6 - Residential Versatec Series Base Pan Showing Water Piping Knockout Locations (left-hand return shown). Air Coil Side Front 8

Electrical Connections Be sure that the available power is the same voltage and phase as that shown on the unit serial plate(s). Line and Low voltage wiring must be done in accordance with local codes and/or the National Electric Code. Connecting the incoming line voltage wires to the L side of the compressor contactor makes the line voltage connection. Consult the unit data plate to determine the proper fuse size. Thermostat Connections Figure 7 - Electromechanical Thermostat Wiring Connections Field Connections 24 VAC COMMON REVERSING VALVE FAULT SIGNAL RUN SIGNAL COMPRESSOR FAN TB R C O L S Y G Unit Connections Yellow Red Green Orange Green Grd. Orange Brown Pink Yellow Violet Figure 8 - Microprocessor Thermostat Wiring Connections Requires common connection or 24 VAC for activation Used with TA32U02 thermostat only Field Connections 24 VAC COMMON COMPRESSOR REVERSING VALVE FAN LOCKOUT SIGNAL EMERGENCY SHUTDOWN NIGHT SETBACK LOAD SHED TB R C Y O G LO ES NS LS MICROPROCESSOR BOARD Figure 9 - Low Voltage Wiring for Auxiliary Heating EXTERNAL AUX HEATER R C GT G1 GU G W1 W2 R R C C G G W Y Y O O L L THERMOSTAT GEO UNIT (If the unit is equpiped with the Johnson Controls FX10 Controller, refer to page 13 and the Application Guide AGFX10 for installation instructions.) 9

Optional Microprocessor Control Note: The following applies to the standard microprocessor and NOT to the FX10 Controller. For FX10 instructions, refer to the Application Guide AGFX10. Startup The unit will not operate until all the inputs and safety controls are checked for normal operating conditions. Fault Retry All faults are tested twice before finally locking the unit out to prevent nuisance service calls. Component Sequencing Delays Components are sequenced and delayed for optimum unit performance. Short Cycle Protection and Random Start The control allows a minimum on or off time of 5 minutes for short cycle protection. A random time delay of 0 to 30 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. Night Setback A grounded signal to common or connecting 24 VAC to the NS Terminal will initiate the night setback mode on the TA32U02 thermostat. Load Shed A grounded signal to common or connecting 24 VAC to the LS Terminal places the controller into the load shed mode. The compressor will become disabled and the fan will start upon a thermostat call for heating or cooling. Emergency Shutdown A grounded signal to common or connecting 24 VAC to the ES Terminal places the controller into the emergency shut down mode. The compressor and fan operation are suspended while in the 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 microprocessor board recieves separate signals from a high pressure switch for safety, a low pressure switch for safety, a low pressure switch to detect loss of refrigerant charge and a low suction temperature thermistor for watercoil low temperature limit. Upon a continuous 30-second measuremnent of the fault (immediate for high pressure), compressor operation is stopped. Water Coil Low Temperature Limit Note: For applications using a closed loop antifreeze solution, set the freeze protecion switch SW1 #2 on the printed circuit boards to LOOP (off). On applications using an open loop/ground water system, set to WELL (on). 10

Optional Microprocessor Control Figure 10 - Versatec Logic Board Physical Layout CC CCG C C R R P3 Fan Relay FAN Versatec Microprocessor Logic Control 17P529A01 FAN COM CC RELAY SW1 6 1 7 2 8 3 9 4 10 5 R C Y O G LO ES NS LS P2 CAUTION: The printed circuit board incorporates static sensitive CMOS devices. Touching the board or its components may result in damage as a result of static discharge. To prevent damage during service, it is recommened 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 componenets. Circuit boards should always be stored in the manufacturer s static protected bag prior to installations. Operational Logic MODE INPUTS FAN COMP RV Htg Y ON ON OFF Clg Y,O ON ON ON Fan G ON OFF OFF Logic Board Operation NORMAL CONTROL TIMING Blower off delay 30 seconds Compressor on delay 10 seconds Short cycle delay 5 seconds Minimum compressor on time 60 seconds (except for fault condition) pressure fault recognition delay Less than 1 second Low pressure fault recognition delay 30 seconds Water coil low temperature limit fault recognition delay 30 seconds Condensate overflow fault recognition delay 30 seconds Low pressure fault bypass delay 2 minutes Water coil low temperature limit fault bypass delay 2 minutes Random start delay 0-30 seconds TEST CONTROL TIMING Blower off delay 5 seconds Compressor on delay 2 seconds Short cycle delay 15 seconds Minimum compressor on time 5 seconds (except for fault condition) pressure fault recognition delay Less than 1 second Low pressure fault recognition delay 30 seconds Water coil low temperature limit fault recognition delay 30 seconds Condensate overflow fault recognition delay 30 seconds Low pressure fault bypass delay 0 seconds Water coil low temperature limit fault bypass delay 0 seconds Random start delay 0 seconds 11

Optional Microprocessor Control Logic Board DIP Switch Setting SWITCH OFF ON SW1-1 SW1-2 SW1-3 SW1-4 (Versatec) SW1-4 (Split) SW1-5 SW2 Test - Selected timings sped up to facilitate troubleshooting Loop - Closed loop freeze protection Commercial - Enables NS features when TA32U02 thermostat is used IO Display* - Enables Input/Output display on external LED board Configures the board for Northern operation and disables the 2nd stage cooling Configures the board for Premier E Split operation and changes operation of SW1-4 to Split Mode OFF* - Normal or Input display mode activated Notes: * Refer to LED Display Mode for position of SW1-4 and SW2 Normal - Standard timings Well - Open loop Water coil low temperature limit setting (30F) Normal - Standard thermostat operation Normal* - Unit status display Configures the board for Split operation and enables the 2nd stage compressor Configures the board for Versatec operation and changes operation of SW1-4 to Versatec ON* - Current fault or Output display mode activated LED Normal Display Modes Drain LED Water Flow Pressure Low Pressure Airflow Status DHW Limit SW1 - #4 ON, SW2* OFF Drain Pan Overflow Lockout WCL Thermistor (loop<15 F, well<30 ) Lockout Pressure>380 PSI Lockout Low Pressure<15 PSI Lockout Not Used Microprocessor Malfunction** Not Used Notes: ** Flashing status light indicates microprocessor is functioning properly. Solid ON indicates microprocessor malfunction. LED Diagnostic Modes LED CURRENT FAULT STATUS INPUTS OUTPUTS SW1 - #4 ON, SW2* ON SW1 - #4 OFF, SW2* OFF SW1 - #4 OFF, SW2* ON Drain Drain Pan Overflow Lockout Y Compressor Water Flow WCL Thermistor (loop<15 F, well<30 ) Lockout G FAN Pressure Pressure>380 PSI Lockout O O Low Pressure Low Pressure<15 PSI Lockout ES ES Airflow Not Used NS NS Status Not Used LS LS DHW Limit Not Used Not Used Not Used Notes: * SW2 status (Down position = OFF ; Up position = ON ) Status board 17P503A01 needs to be purchased to show faults 12

FX10 Microprocessor Control The Johnson Controls FX10 board is specifically designed for commercial hat 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 field connections. FX10 Operation Startup The unit will not operate until all the inputs and safety controls are checked for normal operating conditions. Fault Retry All faults are tested twice before finally locking the unit out to prevent nuisance service calls. Component Sequencing Delays Components are sequenced and delayed for optimum unit performance. See table below. Lead compressor ON delay Lag compressor ON delay Short cycle delay Minimum compressor ON time pressure fault recognition Low pressure fault recognition delay CONTROL TIMING Water coil low temperature limit fault recognition delay Condensate overflow fault recognition delay Water coil low temperature limit fault bypass delay Freeze protection fault bypass delay Random start delay 30 seconds 60 seconds 4 minutes 2 minutes (except for fault condition) Less than 1 second 30 seconds 30 seconds 30 seconds 2 minutes 2 minutes 0-120 seconds Short Cycle Protection The control allow a minimum compressor off time of 4 minutes and a minimum compressor 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 startup 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. 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 and 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. Water Coil Low Temperature Limit Note: 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 AFGX10 or Submittal Data SD1981.) 13

Setting Blower Speed Fan Performance Data (Vertical Units) SIZE 009 012 015 018 024 030 036 042 048 058 FAN SPEED MOTOR HP AIR FLOW (CFM) AT EXTERNAL STATIC PRESSURE 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 425 415 400 385 375 355 340 320 300 - - Med 390 380 370 355 340 325 310 290 270 - - 1/10 Med Low 360 350 340 325 315 300 290 270 250 - - Low* 300 295 290 280 260 250 230 215 - - - 450 440 430 420 400 390 370 350 330 - - Med * 410 395 390 375 360 345 330 315 300 - - 1/10 Med Low 375 365 355 345 330 315 300 285 275 - - Low 320 310 300 285 275 265 250 235 220 - - 670 660 640 610 595 570 540 520 500 - - Medium 1/6 570 560 545 520 510 480 465 440 410 - - Low 460 450 430 410 405 375 360 340 310 - - 670 660 640 610 595 570 540 520 500 - - Medium 1/6 570 560 545 520 510 480 465 440 410 - - Low 460 450 430 410 405 375 360 340 310 - - 1020 1000 970 940 920 880 850 820 790 - - Medium 1/5 860 845 830 800 780 745 730 700 660 - - Low 780 770 755 725 720 680 660 630 600 - - 1215 1180 1140 1090 1060 990 950 900 830 - - Medium 1/3 1040 1020 990 940 920 860 830 780 720 - - Low 930 825 800 760 750 695 680 630 580 - - 1375 1350 1320 1280 1255 1210 1180 1150 1100 - - Medium 1/2 1175 1160 1140 1110 1100 1060 1040 1010 980 - - Low 1035 1030 1020 1010 1000 970 960 930 900 - - 1535 1530 1500 1470 1460 1420 1410 1370 1350 1280 1210 Medium 1/2 1360 1350 1340 1320 1310 1270 1245 1230 1220 1160 1080 Low 1085 1080 1075 1070 1060 1055 1040 1025 1010 960 900 1780 1760 1725 1690 1670 1620 1600 1550 1535 1450 1360 Medium 1/2 1530 1520 1510 1480 1470 1440 1430 1385 1375 1310 1240 Low 1180 1175 1170 1165 1160 1150 1140 1120 1110 1060 990 2240 2230 2215 2190 2185 2140 2130 2090 2080 2020 1950 Medium 3/4 2030 2025 2020 2010 2000 1985 1970 1940 1925 1870 1820 Low 1850 1830 1825 1815 1805 1800 1790 1775 1750 1715 1660 Notes: Factory settings are indicated in bold print. * Denotes 265V setting. 14

Setting Blower Speed Fan Performance Data (Horizontal Units) SIZE 009 012 015 018 024 030 036 042 048 058 070 FAN SPEED MOTOR HP AIR FLOW (CFM) AT EXTERNAL STATIC PRESSURE 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 385 373 360 345 330 315 300 285 270 - - Med 370 360 350 335 320 305 295 290 260 - - Med Low 1/10 340 327 315 303 290 277 265 250 235 - - Low 250 243 235 223 210 - - - - - - Low* 340 327 315 303 290 277 265 250 235 - - 385 375 360 345 330 315 300 285 270 - - Med 370 355 345 335 320 305 290 275 260 - - Med Low 1/10 340 327 315 300 285 270 260 250 235 - - Med Low* 377 365 353 340 325 300 297 280 265 - - Low 250 243 235 223 210 - - - - - - 890 880 870 855 840 820 800 770 740 700 - Medium 1/6 780 775 770 760 750 735 720 695 670 - - Low 650 645 640 630 620 605 590 560 530 - - 890 880 870 855 840 820 800 770 740 700 - Medium 1/6 780 775 770 760 750 735 720 695 670 - - Low 650 645 640 630 620 605 590 560 530 - - 1080 1050 1030 1005 980 950 915 880 840 800 - Medium 1/5 880 865 850 840 820 800 775 740 710 - - Low 800 790 775 760 745 725 700 670 630 - - 1250 1225 1200 1170 1145 1105 1070 1030 990 950 - Medium 1/3 1080 1070 1060 1040 1020 1000 970 930 900 - - Low 900 895 890 880 870 855 835 810 780 - - 1335 1300 1265 1230 1195 1160 1125 1090 1060 1010 - Medium 1/2 1185 1160 1140 1110 1080 1050 1020 980 940 - - Low 1065 1050 1035 1020 1000 980 950 920 890 - - 1620 1600 1580 1565 1545 1520 1500 1470 1445 1405 1355 Medium 1/2 1400 1390 1380 1360 1350 1340 1310 1290 1270 - - Low 1110 1100 1090 1080 1070 1055 1040 1030 1010 - - 1900 1870 1840 1810 1780 1750 1720 1685 1650 1580 1500 Medium 1/2 1600 1580 1560 1545 1530 1510 1480 1455 1430 - - Low 1220 1215 1210 1200 1195 1185 1170 1160 1140 - - 2200 2195 2190 2175 2160 2140 2120 2100 2075 2020 1950 Medium 3/4 1970 1960 1950 1940 1930 1915 1900 1880 1860 - - Low 1770 1765 1755 1745 1730 1715 1700 1680 1660 - - 2530 2510 2490 2470 2450 2430 2410 2380 2350 2280 2200 Medium 1 2290 2280 2270 2255 2240 2220 2200 2175 2150 - - Notes: * Denotes 265V setting. Factory settings are indicated in bold print. Low 2090 2080 2070 2060 2045 2020 2000 1980 1950 - - 15

System Cleaning and Flushing Cleaning and Flushing Prior to start up of any heat pump, the water circulating system must be cleaned and flushed 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 11). The system should be filled at the water make-up connection with all air vents open. After filling, 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 flush and blowdown, making sure water fill valves are set at the same rate. Figure 11: Flushing with Water Shutoff Valve Equipped Systems Return Runout Supply Runout Rubber Hose Runouts Initially Connected Together 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. Refill 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 specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Environol brand antifreeze is recommended.. Once the system has been filled 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, flow 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 flow 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 start up and for air and water balancing. Ground Source Loop System Checkout Once piping is completed between the unit pumping system and ground loop, final purging and charging of the loop is needed. A high pressure pump 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 40-50 PSI (summer) or 50-75 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 first time. Loop static pressure will also 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 charging the system initially. Insure the pump provides adequate flow through the unit by checking pressure drop across the heat exchanger. Usually 2.25-3.0 GPM of flow per ton of cooling capacity is recommended in earth loop applications. Mains 16

Unit Startup Connecting the incoming line voltage wires to the L side of the compressor contactor makes the line voltage connection. Consult the unit data plate to determine the proper fuse size. 208 Volt Operation All 208-230 volt units are factory wired for 230-volt operation. For 208-volt operation, the red and blue transformer wires must be switched. Before powering the unit, check the following. NOTE: Use check, test & start form available from your equipment representative. Verify the following: voltage is correct and matches nameplate Fuses, breakers and wire size are correct Low voltage wiring is complete Piping is complete and the water system has been cleaned and flushed Air is purged from closed loop system Isolation valves are open and water control valves or loop pumps are wired Condensate line is open, trapped and correctly pitched Transformer has been switched to lower voltage tap if needed Blower rotates freely and shipping support has been removed Blower speed tap is wired to desired fan speed (See Blower Performance Data tables, page 14-15) Air filter is clean and in position Service/access panels are in place Return air temperature is between 50-80 F in heating and 60-95 in cooling Air coil is clean with a clean filter If unit is equipped with the FX10 Controller, the FX10 Application Guide (AGFX10) has been referenced. 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. Cooling will energize after a time delay. 4. Be sure that the compressor and water control valve or loop pumps are activated. 5. Verify that the water flow rate is correct by measuring the water pressure drop through the heat exchanger using the P/T plugs and comparing to water pressure drop found in Startup Performance Tables on pages 18-21. 6. Check the temperature of both the supply and discharge water. Refer to Startup Performance Tables on pages 18-21. 7. Check for an air temperature drop of 15-25 F across the air coil, depending on the fan speed and entering water temperature. Refer to Startup Performance Tables on pages 18-21. 8. Adjust the cooling set point above the room temperature and verify that the compressor and water valve or loop pumps deactivate. 9. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. 10. First stage heating will energize after a time delay. 11. Check the temperature of both the supply and discharge water. Refer to Startup Performance Tables on pages 18-21. 12. Check for an air temperature rise of 20 F-35 F across the air coil, depending on the fan speed and entering water temperature. Refer to Startup Performance Tables on pages 18-21. 13. If auxiliary electric heaters are installed, adjust the heating set point until the electric heat banks are sequenced on. All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element. 14. Adjust the heating set point below room temperature and verify that the compressor and water valve or loop pumps deactivate. 15. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required. 16. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 17. Instruct the owner/operator of the proper operation of the thermostat and system maintenance. 17

Startup Perfomance for Vertical Units SIZE 009 012 015 018 024 WATER FLOW GPM 1.5 2.5 1.5 3 2.0 4.0 3 5 3 6 EWT, F WATER PRESSURE DROP, PSIG WATER TEMP. CHANGE, F AIR TEMP. CHANGE, F *HEATING **COOLING HEATING COOLING 40 1.6 7.6-25.2-50 1.5 9.3 16.8 29.4 22.1 70 1.4 12.2 16.1 36.9 16.1 90 1.4 15.1 15.4 43.8 15.3 40 4.1 4.9-26.8-50 4.0 5.9 10.2 30.8 22.6 70 3.8 7.8 9.8 38.8 16.4 90 3.7 9.6 9.3 46.0 15.4 40 1.8 9.8-23.7-50 1.7 11.3 21.0 26.8 21.6 70 1.6 15.4 20.2 34.4 20.4 90 1.5 19.0 19.2 41.3 19.5 40 6.2 5.4-25.6-50 6.1 6.3 10.6 29.1 21.8 70 5.8 8.4 10.1 37.2 20.7 90 5.4 10.5 9.8 45.0 19.5 40 0.8 9.7-24.6-50 0.8 11.4 19.5 28.1 22.4 70 0.7 15.1 20.1 35.6 21.5 90 0.7 18.7 19.1 42.4 20.2 40 2.2 5.2-26.1-50 2.1 6.2 10.5 29.8 22.6 70 2.0 8.2 10.0 37.8 21.7 90 1.9 10.1 9.6 45.2 21.3 40 1.3 7.6-22.1-50 1.2 9.0 16.4 25.5 22.0 70 1.2 12.3 15.5 32.7 20.4 90 1.1 15.3 14.4 39.4 18.0 40 3.2 4.9-23.4-50 3.0 5.8 9.8 26.9 22.0 70 2.9 7.9 9.3 34.7 20.9 90 2.8 9.9 8.7 42.0 18.4 40 1.6 8.6-20.6-50 1.5 10.5 21.6 24.4 22.6 70 1.2 14.1 21.5 31.5 23.1 90 1.1 17.3 19.4 37.1 20.6 40 4.2 4.8-22.6-50 4.1 5.8 11.0 26.4 23.1 70 4.0 7.7 10.5 33.4 22.3 90 3.8 9.3 10.0 39.6 20.9 Notes: * Water temperature changes for heating are based on 70 F entering air. ** Water temperature changes for cooling are based on 80/67 F entering air. Air temperature changes for heating are based on 70 F entering air and high speed fan. Air temperature changes for cooling are based on 80/67 F entering air and high speed fan. 18

Startup Perfomance for Vertical Units SIZE 030 036 042 048 058 WATER FLOW GPM 4 8 5 9 5 11 6 12 8 14 EWT, F WATER PRESSURE DROP, PSIG WATER TEMP. CHANGE, F AIR TEMP. CHANGE, F *HEATING **COOLING HEATING COOLING 40 2.7 7.6-19.8-50 2.6 9.2 20.1 23.0 23.0 70 2.5 13.4 19.1 31.6 21.4 90 2.3 16.9 17.8 38.9 20.3 40 10.2 4.3-21.6-50 10.1 5.1 10.2 25.3 23.2 70 10.0 7.3 9.7 33.9 21.7 90 9.8 9.1 9.0 41.6 20.4 40 1.8 7.8-22.0-50 1.7 9.2 19.2 25.4 21.7 70 1.6 12.6 18.2 33.2 20.5 90 1.5 16.4 17.0 41.5 19.6 40 5.2 4.6-23.3-50 5.2 5.5 10.6 27.1 22.6 70 5.1 7.6 10.3 35.5 20.9 90 5.0 9.7 9.4 44.1 19.8 40 1.9 8.4-20.6-50 1.8 9.4 22.6 13.0 22.3 70 1.7 13.8 21.1 31.1 21.3 90 1.5 17.8 20.2 38.6 18.7 40 8.1 4.2-22.4-50 8.0 5.0 10.4 25.8 22.8 70 7.9 7.0 9.9 34.2 21.8 90 7.7 9.2 9.2 43.2 19.3 40 2.2 8.9-22.7-50 2.2 10.5 21.5 25.9 24.6 70 2.0 14.2 20.5 33.3 23.8 90 1.9 18.0 19.1 41.1 22.4 40 8.1 4.8-24.1-50 7.7 5.7 10.7 27.7 24.3 70 7.3 7.8 10.3 36.2 23.7 90 6.8 9.9 9.8 44.9 22.9 40 3.5 8.3-21.7-50 3.4 10.0 20.5 25.3 22.0 70 3.3 13.7 20.1 32.9 21.2 90 3.1 16.6 18.2 39.0 19.8 40 7.8 5.2-23.2-50 7.7 6.2 11.8 26.9 22.3 70 7.3 8.1 11.4 34.1 21.5 90 6.9 10.2 10.4 41.8 19.9 Notes: * Water temperature changes for heating are based on 70 F entering air. ** Water temperature changes for cooling are based on 80/67 F entering air. Air temperature changes for heating are based on 70 F entering air and high speed fan. Air temperature changes for cooling are based on 80/67 F entering air and high speed fan. 19

Startup Perfomance for Horizontal Units SIZE 009 012 015 018 024 WATER FLOW GPM 2.0 2.5 2.3 3.0 2.0 4.0 3.0 5.0 3.0 6.0 EWT, F WATER PRESSURE DROP, PSIG WATER TEMP. CHANGE, F AIR TEMP. CHANGE, F *HEATING **COOLING HEATING COOLING 40 3.3 6.0-26.1-50 3.2 7.7 13.7 31.9 12.2 70 3.1 10.3 12.9 41.1 11.0 90 3.0 12.1 11.9 49.0 10.3 40 4.7 4.9-26.7-50 4.6 6.3 11.1 32.5 12.3 70 4.4 8.4 10.4 41.6 11.2 90 4.3 9.8 9.6 48.3 10.5 40 3.8 5.1-24.0-50 3.6 8.2 15.1 35.1 14.6 70 3.4 11.1 14.3 45.4 13.3 90 3.2 13.8 13.2 54.9 12.3 40 6.7 4.2-25.2-50 6.2 6.5 11.8 35.9 25.2 70 5.9 9.0 11.1 47.8 13.7 90 5.7 10.9 10.3 56.1 12.5 40 0.8 9.7-22.1-50 0.8 11.3 19.7 25.1 19.9 70 0.7 15.0 18.8 30.8 19.5 90 0.7 18.1 17.9 37.4 18.4 40 2.2 5.2-23.4-50 2.1 6.1 19.6 26.6 20.0 70 2.0 8.1 18.8 33.8 19.5 90 1.9 9.8 17.9 39.9 18.5 40 1.2 8.0-26.0-50 1.2 9.2 17.0 29.2 22.7 70 1.1 11.7 16.1 35.9 21.5 90 1.1 14.5 15.1 43.4 19.9 40 3.5 4.9-26.6-50 3.4 5.7 10.3 30.0 22.7 70 3.3 7.5 9.9 38.0 21.9 90 3.2 9.1 9.2 45.0 20.3 40 1.2 9.2-22.9-50 1.2 11.0 23.2 26.5 22.6 70 1.2 14.7 22.1 33.9 20.9 90 1.1 16.9 20.0 38.1 19.7 40 3.8 5.1-26.1-50 3.7 6.1 12.1 30.2 22.7 70 3.5 7.9 11.4 37.9 21.5 90 3.5 8.9 14.2 44.0 20.1 Notes: * Water temperature changes for heating are based on 70 F entering air. ** Water temperature changes for cooling are based on 80/67 F entering air. Air temperature changes for heating are based on 70 F entering air and high speed fan. Air temperature changes for cooling are based on 80/67 F entering air and high speed fan. 20

Startup Perfomance for Horizontal Units SIZE 030 036 042 048 058 070 WATER FLOW GPM 4.0 8.0 5.0 9.0 5.0 11.0 6.0 12.0 8.0 14.0 10 16 EWT, F WATER PRESSURE DROP, PSIG WATER TEMP. CHANGE, F AIR TEMP. CHANGE, F *HEATING **COOLING HEATING COOLING 40 3.1 8.1-21.6-50 3.0 9.8 20.9 25.2 22.0 70 2.9 13.1 19.7 32.3 21.0 90 2.7 15.8 18.6 38.2 19.7 40 10.3 4.3-22.6-50 10.1 5.2 10.5 26.3 22.1 70 9.9 6.9 10.0 33.9 21.1 90 9.7 8.4 9.5 40.5 20.0 40 1.8 7.7-21.9-50 1.7 9.2 18.4 25.4 20.7 70 1.6 12.2 17.4 32.7 20.0 90 1.5 14.6 16.4 38.3 18.8 40 5.0 4.5-22.8-50 4.9 5.4 10.3 26.8 21.3 70 4.7 7.3 9.7 35.0 20.1 90 4.5 8.7 9.2 40.9 19.3 40 2.0 7.9-19.6-50 1.9 9.5 22.2 22.6 21.1 70 1.8 13.5 20.9 30.1 19.8 90 1.7 17.7 19.6 38.0 18.3 40 8.6 4.1-22.0-50 8.6 5.0 10.2 25.7 21.7 70 8.3 6.9 9.9 33.4 20.2 90 8.0 8.8 9.0 41.4 19.4 40 2.2 8.6-22.3-50 2.1 10.1 22.3 25.3 40.0 70 2.0 14.2 21.0 33.7 20.2 90 1.8 18.1 19.7 41.7 18.6 40 7.4 4.8-24.4-50 7.3 5.7 11.4 28.0 21.8 70 6.9 7.8 10.7 36.5 20.3 90 6.7 9.9 10.0 45.2 19.0 40 2.9 8.4-21.8-50 2.8 9.8 20.1 24.7 20.2 70 2.6 12.7 19.1 30.7 18.9 90 2.4 15.6 18.1 36.8 18.0 40 7.4 5.1-22.9-50 7.2 5.9 11.6 25.8 20.5 70 6.8 7.6 10.9 32.1 19.0 90 6.3 9.3 10.4 38.3 18.3 40 3.6 7.9-23.8-50 3.5 8.7 16.5 26.1 21.5 70 3.4 12.7 16.4 35.2 20.7 90 3.3 15.2 16.6 41.5 20.2 40 9.1 5.1-24.3-50 8.9 5.7 10.4 26.9 21.5 70 8.6 8.4 10.3 37.1 21.2 90 8.3 10.2 10.5 44.7 20.9 Notes: * Water temperature changes for heating are based on 70 F entering air. ** Water temperature changes for cooling are based on 80/67 F entering air. Air temperature changes for heating are based on 70 F entering air and high speed fan. Air temperature changes for cooling are based on 80/67 F entering air and high speed fan. 21

Preventive Maintenance Water Coil/Desuperheater Coil Maintenance 1. 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 infiltrate the water line. Water 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; otherwise air vents may draw air into the system. Note: If the installation is in an area with a known high mineral content (125 PPM or greater) in the water, it is best to establish a periodic maintenance schedule so the coil can be checked regularly. Should coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water flowing through the unit, the less chance for scaling to occur. Other Maintenance Air 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 filter. 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 filters. Inspect twice a year to avoid the possibility of overflow. 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 fins while cleaning. CAUTION: Fin edges are sharp. Refrigerant System To maintain the factory sealed refrigerant circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the Startup Performance Tables on pages 18-21. Verify that air and water flow rates are at proper levels prior to servicing the refrigerant circuit. In-Warranty Material Return Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance. 22

Additional Product Notes Desuperheater If unit is equipped with desuperheater for hot water assist, DPK5 (desuperheater pump kit) is required. Kit includes pump, fittings, relay, and complete instructions. Ordered separately. Water Coil Low Temperature Limit Kits - Not needed on units with microprocessor FPK - Open Loop FPKCL - Closed Loop Auxiliary Heaters HEATER MODEL MIN USED WITH VERSATEC MODEL ELECTRICAL KW CFM 009 012 015 018 024 030 036 042 048 058 070 ECS4 240/1 4 280 ESC42 277/1 4 280 ECM4 240/1 4 280 ECM8 240/1 8 560 ECM12 240/1 12 840 ECM16 240/1 16 1120 ECM42 277/1 4 280 ECM82 277/1 8 560 ECM122 277/1 12 840 ECM162 277/1 16 1120 ECM83 240/3 8 560 ECM123 240/3 12 840 ECM163 240/3 16 1120 ECM84 480/3 8 560 ECM124 480/3 12 840 ECM164 480/3 16 1120 ECL10 240/1 10 700 ECL15 240/1 15 1050 ECL20 240/1 20 1400 ECL103 240/3 10 700 ECL153 240/3 15 1050 ECL203 240/3 20 1400 ECL104 480/3 10 700 ECL154 480/3 15 1050 ECL204 480/3 20 1400 Notes: fan tap setting must be above the minimum CFM for the heater selected. 4KW heaters are single stage. All others are two stage. For installation instructions, refer to instructions packaged with the heater. 23

Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com Product: Type: Size: Document: Versatec Geothermal/Water Source Heat Pumps 0.75-6 Ton Installation Manual IM2600 01/09 WaterFurnace International, Inc. has a policy of continuous product research and development and reserves the right to change design and specifications without notice. 2009 WaterFurnace International, Inc.