versatec installation manual - waterfurnace · interior piping all units are recommended to be...

WF

I

IM2601 11/06

Installation Information

Water Piping Connections

Electrical Connections

Microprocessor Control

Startup Procedures

Preventive Maintenance

Ver

sate

c In

stal

latio

n M

anua

l

Water Source/Geothermal Heat Pumps7 thru 10 Ton Horizontal7 thru 23 Ton Vertical

••

2

VERSATEC 7 THRU 23 TON INSTALLATION MANUAL

Model Nomenclature

Model TypeVL = Versatec (Low Temp)VX = Versatec (Ext. Range)

Unit Capacity080 MBTUH095 MBTUH120 MBTUH180 MBTUH240 MBTUH275 MBTUH

Discharge Air ConfigurationT = Top Discharge VerticalE = End Discharge HorizontalS = Side Discharge Horizontal

Return Air ConfigurationL = LeftR= Right

Voltage3 = 208-230/60/34 = 460/60/35 = 575/60/3

Blower Options0 = Standard Blower1 = Oversized Blower Cabinet Options

0 = Painted1 = Nonpainted

Source Coax OptionsC = CopperN = Cupronickel

Sound KitA = NoneB = Blanket

Non-Standard Options Details

VintageC = All

Control Options4 = FX10 (standard - no communication)5 = FX10 w/ Open N2 Com Card6 = FX10 w/ Lonworks Com Card7 = FX10 w/ BacNet Com Card8 = FX10 std. no communication, w/User Interface9 = FX10 w/Open N2 Com Card, w/User Interface0 = FX10 w/Lonworks Com Card, w/User Interface3 = FX10 w/BacNet Com Card, w/User Interface

Non-Standard Options

VL 240 T L 4 0 0 C A 4 S S C

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 10-11

Wiring Schematic 12

FX10 Microprocessor Control & Operation 13-15

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

4


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 condi-tion. 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.

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 inspec-tion, 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.

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.

CAUTION: Duct connections should be made with 1/2-inch sheet metal screws to prevent damage to pip-ing and other internal components.

CAUTION: Be sure to remove the shipping material from the blower throat before connecting ductwork.

5


General In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be pres-ent, 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.

Iron, Fe2+ (Ferrous)Bacterial Iron Potential

Material Copper 90/10 Cupro-Nickel

pH Acidity/Alkalinity 7- 9 5 - 9

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

Hydrogen SulfideLess than .5 ppm

(rotten egg smell appears at 0.5 PPM) 10 - 50 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 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm

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

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

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

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

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

None None

Iron OxideLess than 1 ppm. Above this level

deposition will occur.Less than 1 ppm. Above this level

deposition will occur.

Suspended SolidsLess than 10 ppm and filtered for max

of 600 micron sizeLess than 10 ppm and filtered for max

of 600 micron size

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

Corrosion

Iron Fouling(Biological Growth)

Erosion

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

Water Quality

6


General Piping

Water ConnectionsAll supply and return water connections are female pipe thread of size specifi ed in physical dimensions. Never use fl ex-

ible hoses smaller than separate water connections on the unit and limit hose length to 10 ft. per connection. Check care-

fully for water leaks.

Interior PipingAll 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 dif-ferent 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 com-pletely. After the cleaning and fl ushing has taken place, the initial connection should have all valves wide open in prepara-tion for water system fi lling.

7


Installing Horizontal Units

Mounting Horizontal UnitsUnits 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 cor-ners 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.).

Top View

27.24

94.0

Figure 3: Mounting HardwareFigure 2: Mounting Rod Layout

Ball ValvesWater Loop

Flexible DuctCollar

1/2”Threaded Rods

(4)

P/T Plugs

Hose Kits

Insulate supplyplenumanduse atleast a 90° elbowto reduce noise

CondensateDrain

Connection

PowerDisconnect Low

Voltage

IsolationGrommets(Included)

Figure 1: Typical Horizontal Application

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.

1/2" Threaded Rod(not included)

VibrationIsolator

Washer(not included)

Hex Nuts(not included)

8


1.5" 1.5"

Vent (if needed)

1/8" per foot

Copper Tube Stub

1/2'' PitchFigure 5: Unit Pitch for DrainFigure 4: Suggested Layout of Condensate Drain Line

Duct SystemA supply air duct fl ange is provided for fi eld installation to facilitate the secure duct connection at the job site. A fl ex-

ible 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 DrainThe 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).

Installing Horizontal Units (cont.)

9


Control Box

CondensateDrain

Water Supplyand ReturnConnections

Flexible ductCollar

ACCESS

PANEL

ACCESS

PANEL

PANEL

ACCESS

Figure 6: Typical Vertical Application

Installing Vertical Units

Mounting Vertical UnitsUnits 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 SystemA supply air duct fl ange is provided for fi eld installation to facilitate the secure duct connection at the job site. A fl ex-

ible 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 DrainIn 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.

10


Electrical Connections

GeneralBe 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 ConnectionLine 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 OperationNote: All 208-230 volt units are factory wired for 230 volt operation. For 208 volt operation, the red and the blue transform-er wires must be switched between terminal strip PS and contactor RB.

SIZE RATEDVOLTAGEVOLTAGEMIN/MAX

COMPRESSOR* FANMOTORFLA***

FANHP

TOTALUNITFLA

MINCIRCAMP

MAXFUSE

MAXHACR

BREAKERMCC RLA LRA

080

208-230/60/3 197/253 14.0 9.0 70.0 5.6 1.5 23.6 25.9 30 30

460/60/3 414/506 7.1 4.6 33.0 2.8 1.5 12.0 13.2 15 15

575/60/3 518/633 5.3 3.4 27.0 2.0 1.5 8.8 9.6 10 10

080**

208-230/60/3 197/253 14.0 9.0 70.0 6.6 2.0 24.6 26.9 35 35

460/60/3 414/506 7.1 4.6 33.0 3.5 2.0 12.7 13.9 15 15

575/60/3 518/633 5.3 3.4 27.0 2.4 2.0 9.2 10.0 10 10

095

208-230/60/3 197/253 16.7 10.7 85.0 6.6 2.0 28.0 30.7 40 40

460/60/3 414/506 8.2 5.3 42.0 3.5 2.0 14.0 15.4 20 20

575/60/3 518/633 6.7 4.3 34.0 2.4 2.0 11.0 12.1 15 15

095**

208-230/60/3 197/253 16.7 10.7 85.0 9.2 3.0 30.6 33.3 40 40

40/60/3 414/506 8.2 5.3 42.0 4.3 3.0 14.9 16.2 20 20

575/60/3 518/633 6.7 4.3 34.0 3.6 3.0 12.2 13.3 15 15

120

208-230/60/3 197/253 27.0 17.3 123.0 9.2 3.0 43.8 48.1 60 60

460/60/3 414/506 14.0 9.0 62.0 4.3 3.0 22.3 24.6 30 30

575/60/3 518/633 11.0 7.1 50.0 3.6 3.0 17.8 19.6 25 25

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.

Unit Electrical Data - Horizontal

11


SIZE RATEDVOLTAGEVOLTAGEMIN/MAX

COMPRESSOR* FANMOTORFLA***

FANHP

TOTALUNITFLA

MINCIRCAMP

MAXFUSE

MAXHACR

BREAKERMCC RLA LRA

080

208-230/60/3 197/253 14.0 9.0 70.0 3.8 1.0 21.8 24.1 30 30

460/60/3 414/506 7.1 4.6 33.0 1.9 1.0 11.1 12.3 15 15

575/60/3 518/633 5.3 3.4 27.0 2.0 1.5 8.8 9.7 10 10

080**208-230/60/3 197/253 14.0 9.0 70.0 5.6 1.5 23.6 25.9 30 30

460/60/3 414/506 7.1 4.6 33.0 2.8 1.5 12.0 13.2 15 15

095

208-230/60/3 197/253 16.7 10.7 85.0 5.6 1.5 27.0 29.7 40 40

460/60/3 414/506 8.2 5.3 42.0 2.8 1.5 13.4 14.7 20 20

575/60/3 518/633 6.7 4.3 34.0 2.0 1.5 10.6 11.7 15 15

095**

208-230/60/3 197/253 16.7 10.7 85.0 6.6 2.0 28.0 30.7 40 40

460/60/3 414/506 8.2 5.3 42.0 3.5 2.0 14.1 15.4 20 20

575/60/3 518/633 6.7 4.3 34.0 2.4 2.0 11.0 12.1 15 15

120

208-230/60/3 197/253 27.0 17.3 123.0 6.6 2.0 41.2 45.5 60 60

460/60/3 414/506 14.0 9.0 62.0 3.5 2.0 21.5 23.8 30 30

575/60/3 518/633 11.0 7.1 50.0 2.4 2.0 16.6 18.4 25 25

120**

208-230/60/3 197/253 27.0 17.3 123.0 9.2 3.0 43.8 48.1 60 60

460/60/3 414/506 14.0 9.0 62.0 4.3 3.0 22.3 24.6 30 30

575/60/3 518/633 11.0 7.1 50.0 3.6 3.0 17.8 19.6 25 25

180

208-230/60/3 197/253 29.5 18.9 146.0 5.6 1.5 49.0 53.7 70 70

460/60/3 414/506 14.9 9.5 72.0 2.8 1.5 24.6 26.9 35 35

575/60/3 518/633 11.8 7.6 58.0 2.0 1.5 19.1 21.0 25 25

180**

208-230/60/3 197/253 29.5 18.9 146.0 6.6 2.0 51.0 55.7 70 70

460/60/3 414/506 14.8 9.5 72.0 3.5 2.0 26.0 28.3 35 35

575/60/3 518/633 11.8 7.6 58.0 2.4 2.0 19.9 21.8 25 25

240

208-230/60/3 197/253 47.0 30.1 225.0 6.6 2.0 73.5 81.0 110 110

460/60/3 414/506 24.2 15.5 114.0 3.5 2.0 38.0 41.9 50 50

575/60/3 518/633 18.9 12.1 80.0 2.4 2.0 29.0 32.1 40 40

240**

208-230/60/3 197/253 47.0 30.1 225.0 9.2 3.0 78.7 86.2 110 110

460/60/3 414/506 24.2 15.5 114.0 4.3 3.0 39.6 43.5 50 50

575/60/3 518/633 18.9 12.1 80.0 3.6 3.0 31.4 34.5 45 45

275 460/60/3 414/506 26.9 17.2 125.0 4.3 3.0 43.2 47.5 60 60

Unit Electrical Data - Vertical

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.

Electrical Connections (cont.)

12


Wiring SchematicV Series - Commercial 208-230/60/3, 460/60/3, 575/60/37-20 Ton Johnson Control 97P681-03 6/23/04

Transformer

Compressor 2

CC2T1

L1

T2

L2

T3

L3

CR

S

Blue BlackRed

Compressor 1

CC1T1

L1

T2

L2

T3

L3

CR

S

Blue BlackRedUnit Power Supply208-230/60/3, 480/60/3, or 575/60/3

L3L1 L2G

RedRed

YellowWhite

WhiteBrown

BlackBlack

Gray

RBT2 T1T3

L2 L1L3

Green

YellowBrown Gray

Gray

Belt DriveBlowerMotor

Belt DriveBlowerMotor Green

NOTE 2

Blue 230V460V575V

Red 208V

Black

Yellow

Blk/Wht

Note 1

Green

TDABlack

Black/Red

TFP1WhiteWhite

TFP2Gray

Gry/Wht

HP1Black Black

Black Black

Black Blk/WhtRB

HP2

RV1Red Red

RV2Red Red

BrownCO

LP1

Blk/Wht

Blk/Wht

L1

L2

S1

S2

Tan

TanT

CPM2CompressorProtection

Module

L1

L2

S1

S2

Tan

TanT

Black

Black

Note 3

Black

BlackRed

BlackLP2 VioletWhite

NOTE 5

White Blue

Blk/WhtOS

PB1

Red

L1

L2

Black

L1

L2

PB2

Yellow

OrangeGreen

Blue

VioletWhite

Yellow

Violet

White

Yellow

CC2

Black

Black

CC1

Gry/Wht

Blk/WhtYellow

NOTE 6

NOTE 7

ES

Brown 11K

Johnson FX-10

5VDCAI3

23242526272829303132333435363738

+-

AI5-+

AI4-+

AI6

AI2

AI1

5VDC

5VDC

LED

-

-

-

+

+

+

24VAC

24VACCom

GROUND

394041

PWM2PWM2 ComPWM1

42434445464748

24VAC ComDI12DI11DI10DI9DI8DI7

4950515253545556

DI 3/4/5/6/ ComDI6DI5DI4DI3DI2

DI1

9VDC

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

D09

D08

D07

D06

D05

D04

D03

D02

D01

J8

J2

J10

J9

J7

A23A13A11

A21A12

A25A22

A32

A31A35

A14A24

A34

A33

A15

Thermistor - Johnson Control

Relay coil

Switch - High pressure

Switch - Low pressure

Polarized connector

Condensate Overflow

Compressor contactor 1

Condensate overflow

132

P

Factory low voltage wiringFactory line voltage wiringField low voltage wiringField line voltage wiringOptional block

Internal junction

Quick connect terminal

Wire nut

Field wire lug

Ground

Notes:

CC1 -

CO - HP1 -

LP1 -

RB -RV1 -

Stage 1 High Pressure

Stage 1 Low Pressure

Blower power relayReversing Valve coil 1

L1

LegendRelay Contacts-

N.O., N.C. Freeze protection sensor 1FP1 -

T

1 - Switch blue and red wires for 208V operation

Discharge Air TemperatureDA -Dirty Filter or Air ProvingDF/AP-

CP/FP- Compressor Proving or Fan Proving

Freeze protection sensor 2FP2 -HP2 - Stage 2 High Pressure

LP2 - Stage 2 Low Pressure

RV2 - Reversing Valve coil 2CC2 - Compressor contactor 2

2 - Second Blower used only on 15 - 20 Ton units

CPM1 - Compressor Protection Module 1CPM2 - Compressor Protection Module 2

3 - Compressor Protection Module is used only on 575/60/3, 15-20 ton units4 - R, C, Y1, Y2, O, and G are for use with a wall mounted thermostat5 - Disconnect for 15 degree freeze protection

OS - Occupied SwitchES - Emergency Shutdown

6 - Acc 1 output is cycled with the compressor7 - Acc 2 output is cycled with the fan

Orange

Red

Blue/Wht

OrangeOrg/Wht

Gry/Wht

Gry/Wht

Black

TB

R

C

Y1

O

G

L

X1

X2

24VAC

24V COM

Alarm

Acc 1

Acc 2

Fan

Rev Valve

Comp 1

SS

AIC

RS

SC

TO

Setpoint Shift

AI Com

Room Sensor

Sensor Com

Temp Occ

Y2Comp 2

Green

Note 4

Gray

Pink

Orange

Orange

Pink

Orange

Orange

CPM1CompressorProtection

Module

13


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 inter-face. 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.

Installation OptionsUnits using the FX10 have three different installation options.

Stand-alone unit controlled by an electronic room thermostat.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.Integrated into a building automation system by using a zone temperature sensor and adding a communication mod-ule 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).

1.2.

3.

C

G

LC1

Y2

X1

R

AIC

SC

O

Y1

LC2

L

X2

SS

RS

TO

REV. VALVE

COMPRESSOR1

N/A

LOCKOUT

ACCESSORY

SETPOINT SHIFT

ROOM SENSOR

TEMP OCCUPIED

COMMON

FAN

N/A

COMPRESSOR2

ACCESSORY 1

24VAC

AI COMMON

SENSOR COMMON

Figure 7: 16-Pin Terminal Board Wiring

FX10 Microprocessor Control

CAUTION: The FX10 control incorporates static sensitive CMOS devices. Touching the board or its compo-nenets may result in damage as a result of static discharge. To prevent damage during service, it is recommend-ed 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.

14


FX10 Microprocessor Control

Electronic Thermostat Connections If an electronic thermostat is being used, wire as shown in Figure 8.

Zone Sensor Wiring Installation options 2 and 3 will use the wiring diagram for the zone temperature sensor, Figure 9.

R

C

Y1

Y2

O

G

L

24VAC(HOT)

24VAC(COMMON)

COMPRESSOR1

Term

inal

Boa

rdC

onne

ctio

ns ThermostatC

onnections

COMPRESSOR2

REVERSINGVALVE

BLOWERRELAY

SYSTEMMONITOR

Figure 8: Electronic Thermostat Connections

SS

RS

AIC

TO

SC

SETPOINTSHIFT

ROOMSENSOR

AICOMMON

Term

inal

Boa

rdC

onne

ctio

ns

ZoneS

ensorConnections

PUSHBUTTON

DICOMMON

Figure 9: Zone Sensor Connections

15


StartupThe unit will not operater until all the inputs and safety controls are checked for normal operating conditions.

Fault RetryAll faults are tested twice before fi nally locking the unit out to prevent nuisance service calls.

Component Sequencing DelaysComponents 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 overfl ow fault recognition delay 30 seconds

Low pressure fault bypass delay 2 minutes

Freeze protection fault bypass delay 2 minutes

Random start delay 0-120 seconds

Short Cycle ProtectionThe control allow a minimum compressor off time of 4 minutes and a minimum compresor run time of 2 minutes for short

cycle protection.

Random StartA 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 ShutdownA 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 Overfl ow ProtectionThe board incorporates an impedance liquid sensor at the top of the condensate drain pan. Upon a continuous 30 sec-

ond sensing of the condensate, the operation of the unit is suspended.

Safety ControlsThe 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 measure-ment 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 sche-matic). On applications using an open loop/ground water system, make sure the wire is connected. For additional informa-tion on the FX10 Control, refer to Application Guide AGFX10 or Submittal Data SD 1981.

FX10 Operation

16


Duct System

Duct SystemAn air outlet collar is provided on all units to facilitate a duct connection. A fl exible connector is recommended for dis-

charge 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 main-tained). 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.)

Loosen the blower motor fastening nuts from the motor mount. Turn the adjusting bolts until the tension is off the drive belt. Remove belt from sheave and loosen allen heat set screw “B”. Adjust sheave pitch diameter for desired speed by opening or closing moveable portion in or out in 1/2-turn incre-

ments. Do not open more than 5 full turns.Sheave should be mounted with set screw “A” toward the motor. Be sure driven and drive sheaves are in alignment

and parallel. Retighten set screw “B” and replace drive belt on sheaves. 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). Retighten motor mounting nuts. Belt tension of a new belt will drop rapidly during the fi rst few hours of operation. Check and readjust as needed.

1.2.3.4.

5.

6.7.

8.9.

Set Screw “A” Set Screw “B”

KeywayMoveablePortion MODEL DRIVE SHEAVE

FACTORY SETTING

Vertical080 3 Turns Open095 4 Turns Open120 5 Turns Open180 4 Turns Open240 4 Turns Open275 4 Turns Open

Horizontal080 2 Turns Open095 3 Turns Open120 2 Turns Open

Figure 10: Blower Motor Sheave Adjustments and Settings Figure 11: Checking Drive Belt Tension

DeflectionDriven Sheave

Drive Sheave

17


Blower Performance Data

Notes: Drive Sheave factory setting shown in bold. Shaded areas require larger blower motor and sheaves.

SIZE DRIVESHEAVEAirfl ow (CFM) at External Static Pressure (in. wg)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.4 1.6 1.8 2.0

HO

RIZ

ON

TAL

V080

Closed 3900 3800 3650 3500 3300 3100 2950 2750 2450 3050 26501 Turn Open 3700 3550 3400 3200 3000 2800 2550 3200 3000 2800

2 Turns Open 3400 3200 3050 2850 2650 2400 3200 2900 26503 Turns Open 3050 2900 3650 2400 3300 3150 2900 26504 Turns Open 2800 2550 3350 3850 2900 26505 Turns Open 2450 3250 3000 2750

V095

Closed 4450 4350 4200 4050 3900 3750 3600 3400 3250 3050 3800 3450 30001 Turn Open 4350 4200 4050 3990 3750 3600 3400 3200 3000 3900 3400 29502 Turns Open 4150 4000 3950 3650 3500 3400 3200 2900 3850 3600 32503 Turns Open 3900 3800 3650 3500 3300 3100 2900 3500 3300 30004 Turns Open 3700 3550 3350 3050 2900 3400 3200 3000 28005 Turns Open 3450 3250 3000 3500 3300 3100 2850

V120

Closed 4900 4800 4700 4600 4450 4300 4000 3700 4550 4400 41501 Turn Open 4900 4800 4700 4600 4450 4300 4200 4000 3700 4550 4300 4050

2 Turns Open 4800 4700 4550 4450 4300 4200 4050 3900 3750 3350 4300 40503 Turns Open 4600 4450 4350 4250 4100 3950 3750 3650 3500 3250 4200 39504 Turns Open 4400 4250 4100 4000 3850 3700 3550 3550 32005 Turns Open 4200 4050 3950 3750 3600 3450 3200

VE

RT

ICA

L

V080

Closed 4225 4100 3900 3700 3500 3250 3000 2700 3600 3400 2900 1 Turn Open 4000 3825 3600 3400 3100 2850 3550 3350 3100 28002 Turns Open 3725 3500 3300 3000 2700 3300 3200 2850 25003 Turns Open 3400 3150 2900 2800 2700 25504 Turns Open 3050 2800 3150 2900 26005 Turns Open 3150 2900 2600

V095

Closed 4400 4250 3950 3850 3600 3400 3100 4550 4150 3700 3000 1 Turn Open 4550 4400 4200 4000 3800 3550 3300 3000 4350 4150 3700 30002 Turns Open 4300 4100 3900 3700 3450 3200 2900 4250 4000 3700 31003 Turns Open 4100 3850 3600 3400 3150 2900 4000 3800 3500 3200 28504 Turns Open 3800 3600 3350 3150 2850 3800 3550 3300 29505 Turns Open 3550 3300 3050 2750 3600 3400 3150 2800

V120

Closed 5100 4900 4800 4550 4100 4900 4500 4150 36501 Turn Open 5200 5000 4800 4600 4400 4150 4950 4700 4360 38502 Turns Open 5000 4800 4650 4500 4400 4200 3950 3700 4850 4450 39003 Turns Open 4900 4700 4500 4350 4150 3900 3600 4800 4450 39504 Turns Open 4700 4600 4400 4200 4000 3700 4900 4700 4600 40505 Turns Open 4800 4600 4350 4100 3900 3600 4700 4500 4300 4050 3500

V180

Closed 9600 9200 8800 8500 8100 7600 7200 6600 6000 9200 8200 7000 54001 Turn Open 9600 8700 8400 7900 7400 7000 6400 5900 8500 8100 6900 54002 Turns Open 8600 8200 7800 7300 6800 6300 5800 8100 7700 7100 58003 Turns Open 8000 7600 7200 6700 6200 5800 8100 7600 7000 62004 Turns Open 7500 7000 6600 6000 7900 7700 7200 6500 5800 54005 Turns Open 7000 6500 5900 7800 7400 6800 6100 5200

V240

Closed 10400 10200 10000 9700 9400 9100 8300 9900 9000 8200 72001 Turn Open 10200 9900 9700 9400 9200 8900 8500 8100 9900 9200 8400 74002 Turns Open 9700 9400 9100 8900 8700 8400 8100 7700 7100 9200 8400 73003 Turns Open 10300 10000 9600 9200 8900 8500 8100 7600 7000 9600 8600 75004 Turns Open 9700 9300 9000 8500 8100 7700 7200 9500 9200 8700 76005 Turns Open 9000 8600 8200 7800 7400 6800 9200 8800 8400 7800

V275

Closed 10900 10400 9900 90001 Turn Open 11000 10700 10400 9900 92002 Turns Open 11200 10900 10600 10250 9900 92003 Turns Open 10600 10300 10000 9800 9600 86004 Turns Open 11200 10900 10600 10250 9900 9700 9500 9200 87005 Turns Open 10500 10200 9900 9500 9100 8900 8700

18


System Cleaning and Flushing

Cleaning and FlushingPrior 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 pres-sure 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 anti-freeze 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 (regard-less 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 CheckoutOnce 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 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 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 2.25-3.0 GPM of fl ow per ton of cooling capacity is recommended in earth loop applications.

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts InitiallyConnected Together

Figure 12: Flushing Internal Piping

19


Unit Startup

Before powering the unit, check the following:High voltage is correct and matches nameplateFuses, breakers and wire size are correctLow voltage wiring is completePiping has been completed and water system cleaned and fl ushedAir is purged from closed loop systemIsolation valves are open and water control valves or loop pumps wiredCondensate line is open and correctly pitchedTransformer has been switched to lower voltage tap if neededBlower rotates freelyBlower speed is correctAir fi lter is clean and in positionService/access panels are in placeReturn air temperature is between 60°F-80°F in heating and 70°F-95°F in coolingAir coil has been cleaned

Startup StepsInitiate a control signal to energize the blower motor. Check blower operation.Initiate a control signal to place the unit in the cooling mode. Cooling set point must be set below room temperature.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.Be sure the compressor and water control valve or loop pumps are activated.Initiate a control signal to energize second stage cooling.Second stage cooling will energize after a time delay. Check for correct rotation as indicated in step 3.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 20.Check the temperature of both the supply and discharge water. Refer to Unit Operating Pressures and Temperatures Table page 18.Check for an air temperature drop of 15° to 25°F across the air coil, depending on fan speed and entering water temperature.Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or pumps deactivate.Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set above room temperature.First stage heating will energize after a time delay.Initiate a control signal to energize second stage heating.Second stage heating will energize after a time delay.Check the temperature of both the supply and discharge water. Refer to Unit Operating Pressures and Temperatures Table on page 19.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.Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate.During all testing, check for excessive vibration, noise or water leaks.Set system to desired normal operating mode and set temperature to maintain desired comfort level.Instruct the owner/operator in the proper operation of the thermostat and system maintenance.Check belt tension and readjust as necessary after fi rst few hours.

••••••••••••••

1.2.3.

4.5.6.7.

8.

9.

10.

11.12.13.14.15.

16.

17.

18.19.20.21.

20


EWT

WATERFLOW/TON

(GPM)

COOLING HEATING

SUCTIONPRESSURE

DISCHARGEPRESSURE

SUPERHEAT

SUBCOOLING

WATERRISE° F

AIRDROP° F

SUCTIONPRESSURE

DISCHARGEPRESSURE

SUPERHEAT

SUBCOOLING

WATERDROP° F

AIRRISE° F

30

1.5 61-70 100-117 25-35 15-25 21-24 21-26 34-39 163-183 9-14 5-9 7-8 14-20

2.3 62-71 92-109 25-35 15-25 13-16 21-26 37-42 165-185 9-14 5-9 5-6 16-22

3.0 62-71 88-104 25-35 15-25 6-11 21-26 38-44 167-186 9-14 5-9 3-4 16-22

50

1.5 79-85 145-170 10-18 12-25 20-23 20-25 51-58 175-202 10-14 5-9 10-12 23-29

2.3 75-83 130-155 10-18 12-25 12-15 20-25 53-62 178-206 10-14 5-9 7-8 24-30

3.0 72-82 125-150 10-18 12-25 8-12 20-25 55-65 180-208 10-14 5-9 5-6 25-31

70

1.5 78-88 180-200 9-14 13-18 19-22 19-24 71-82 215-250 12-16 5-8 14-15 28-34

2.3 78-90 169-187 9-14 13-18 11-14 19-24 77-89 203-235 12-16 5-8 9-10 30-37

3.0 78-91 160-180 9-14 13-18 7-12 19-24 81-92 200-235 12-16 5-8 7-8 31-38

90

1.5 79-92 230-272 8-13 13-18 18-21 17-23 – – – – – –

2.3 80-93 215-248 8-13 13-18 10-14 17-23 – – – – – –

3.0 80-93 208-240 8-13 13-18 6-11 17-23 – – – – – –

Unit Operating Parameters

Vertical Units

EWT

WATERFLOW/TON

(GPM)

COOLING HEATING

SUCTIONPRESSURE

DISCHARGEPRESSURE

SUPERHEAT

SUBCOOLING

WATERRISE° F

AIRDROP° F

SUCTIONPRESSURE

DISCHARGEPRESSURE

SUPERHEAT

SUBCOOLING

WATERDROP° F

AIRRISE° F

30

1.5 61-70 100-117 25-35 15-25 21-24 21-26 34-39 163-183 9-14 5-9 7-8 14-20

2.25 62-71 92-109 25-35 15-25 13-16 21-26 37-42 165-185 9-14 5-9 5-6 16-22

3 62-71 88-104 25-35 15-25 6-11 21-26 38-44 167-186 9-14 5-9 3-4 16-22

50

1.5 79-85 145-170 10-18 12-25 20-23 20-25 51-58 175-202 10-14 5-9 10-12 23-29

2.25 75-83 130-155 10-18 12-25 12-15 20-25 53-62 178-206 10-14 5-9 7-8 24-30

3 72-82 125-150 10-18 12-25 8-12 20-25 55-65 180-208 10-14 5-9 5-6 25-31

70

1.5 78-88 180-200 9-14 13-18 19-22 19-24 71-82 215-250 12-16 5-8 14-15 28-34

2.25 78-90 169-187 9-14 13-18 11-14 19-24 77-89 203-235 12-16 5-8 9-10 30-37

3 78-91 160-180 9-14 13-18 7-12 19-24 81-92 200-235 12-16 5-8 7-8 31-38

90

1.5 79-92 230-272 8-13 13-18 18-21 17-23 – – – – – –

2.25 80-93 215-248 8-13 13-18 10-14 17-23 – – – – – –

3 80-93 208-240 8-13 13-18 6-11 17-23 – – – – – –

Horizontal Units

21


SIZE FLOW RATEGPMPRESSURE DROP (PSI)

30°F 50°F 90°F

08010 2.6 2.5 2.316 5.6 5.4 5.022 7.9 7.5 6.0

09512 2.4 2.2 2.318 5.5 5.0 5.024 9.5 8.8 7.7

12016 3.0 2.7 2.622 5.6 5.1 4.728 8.7 7.9 7.2

Water Pressure Drop

SIZE FLOW RATEGPMPRESSURE DROP (PSI)

30°F 50°F 90°F

08010 2.6 2.5 2.316 5.6 5.4 5.022 7.9 7.5 6.0

09512 2.4 2.2 2.118 5.5 5.0 4.824 9.5 8.6 7.7

12016 3.0 2.7 2.622 5.6 5.1 4.728 8.7 7.9 7.2

18020 1.8 1.7 1.432 4.4 4.2 3.644 8.2 7.8 7.1

24032 2.9 2.6 2.544 5.3 4.8 4.556 8.7 7.9 7.2

27534 3.1 2.8 2.652 8.2 7.4 6.970 11.7 10.9 10.1

Horizontal UnitsVertical Units

22


Preventive Maintenance

Water Coil MaintenanceKeep 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.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 MaintenanceFilters

Filters must be clean to obtain maximum performance. They should be inspected every two to three months under nor-mal operating conditions and be replaced when necessary. Units should never be operated without a fi lter.

Condensate DrainIn 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 CoilThe 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.

Drive BeltsCheck periodically for proper tension. (Refer to page 15.)

1.

2.

CAUTION: Fin edges are sharp.

23


Replacement Procedures

Obtaining PartsContact your distributor for service or replacement parts required.

In-warranty Material ReturnMaterial may not be returned except by permission of authorized service personnel. Contact your local distributor for

warranty return authorization and assistance.

Manufactured by WFI9000 Conservation WayFort Wayne, IN 46809

WFI has a policy of continuous product research and development and reserves the right to change design and specifi cations without notice. ©2006 WFI.

Product: Versatec Type: Water Source/Geothermal Heat PumpsSize: 7 thru 23 Tons

Document Type: Installation ManualPart Number: IM2601Release Date: 11/06Supercedes: IM2601 (03/06)

versatec installation manual - waterfurnace · interior piping all units are recommended to be...

Documents